Abstract: A vehicle interior trim panel and method of making is provided where the vehicle interior trim panel comprises a skin, a substrate, a foam located between the skin and the substrate, and a flat wire at least partially surrounded by and embedded in the foam.

Abstract: A process for formation of a plastic composite includes providing a two part mold system wherein one of the parts is moveable and includes cavities and the other of the parts is stationary and includes cores each having less mass and sequentially moving the moveable mold part with respect to the stationary mold part to form an injection volume between each of said mold cavities of variable capacity.

Abstract: A method of forming a motor vehicle instrument panel with a flexibly tethered air bag deployment door includes the steps of molding an instrument panel with a first plastics material to a desired shape and with an integral air bag deployment door whose opening is defined by a tear seam formed by a groove molded in one side of the panel and with an integral mounting/hinge flange that extends from an inside surface of the door, and forming a bonded layer of second plastics material on one side of the flange and the inside surface of a potentially frangible portion of the door.

Abstract: An inflatable restraint apparatus for an automotive vehicle includes an air bag deployment door formed in a trim panel. The air bag deployment door outer surface has an area of 5 in2 to 35 in2, and at least a portion of the perimeter comprises a frangible marginal edge. The frangible marginal edge includes a frangible length, and at least 20% of the frangible length is non-linear. The apparatus also includes an air bag dispenser containing an air bag having a volume of at least 90 liters. The air bag dispenser includes an elongated container having an air bag receptacle containing an air bag and an inflator receptacle containing an inflator.

Abstract: Described is a metallized article, and a method for making the same, comprising a substrate having a polyurethane basecoat disposed thereon and with a layer of electrically discrete metallic islands of a corrosion prone metal disposed on the basecoat. A cross-linked polyurethane top coat, which is bound to an organosilane, preferably an epoxy silane, is disposed on and encapsulates the discrete metallic islands. The organsilane is also bound to the metallic islands.

Abstract: A method of forming a return flange on an automotive trim component is provided. The trim component has an inner surface, an outer surface, at least one rib extending from the inner surface, a flange and a hinge. The return flange is formed by contacting the rib with the inner surface of the flange by rotating the flange about the hinge and securing the flange to the rib.

Abstract: A motor vehicle comprising a lighting device disposed on a motor vehicle; the lighting device configured to emit light and aim at least a portion of the light in the direction of and illuminate a wheel well of the motor vehicle.

Abstract: A metallized article and method for making the article, including a substrate having a polyurethane basecoat disposed thereon, with a layer of electrically discrete metallic islands of a corrosion prone metal disposed on the basecoat. A cross-linked polyurethane topcoat, containing an aminosilane, is further disposed on an encapsulates the discrete metallic islands.

Abstract: An automotive headliner assembly includes a substrate that is configured to mount to a vehicle in a position generally covering a lower surface of a passenger compartment roof. Cavities are formed into the substrate between the upper substrate surface and the lower substrate surface to provide receptacles for electrical wiring, fiber optic cabling, EA foam and the like or to form a duct for directing air flow. Each of the cavities is integrally formed in the substrate. A foam layer is adhered to a lower surface of the substrate and the decorative cover is adhered to a lower surface of the foam layer. The headliner is constructed by first extruding molten parison into a blow mold shaped to complement the desired exterior contours of the headliner substrate to be formed. The cavities are then formed in the molten parison by inserting at least one blow pin into the parison and injecting pressurized gas.

Abstract: An apparatus for slush molding a thin shell having an outer layer and an inner layer. The apparatus includes two tubs alternately movable to a cast position for dispensing their respective material contents into a mold cavity. According to another embodiment of the invention, the apparatus includes a diverter valve configured to alternately open a passage from each of two tubs to the mold cavity to selectively dispense charge materials from the respective tubs into the mold cavity. In addition, a method is provided for forming a thin shell having an outer layer and an inner layer. A first polymer material is cast and allowed to melt on a heated mold surface to form an outer layer. A second polymer material is then cast and allowed to melt and form an inner layer on the inner surface of the outer layer. The shell is then removed from the mold.

Abstract: An airbag door system is provided comprising a substrate, an outer shell and a foam where all three layers possess a line of mechanical weakness with each line of mechanical weakness at least partially separating each layer into an airbag door portion and a trim member portion. The substrate line of mechanical weakness comprises at least one substrate aperture. The outer shell line of mechanical weakness comprises an outer shell reduced thickness portion defined by an outer shell sever extending partially through an outer shell thickness from an outer shell lower surface towards an outer shell upper surface. The foam line of mechanical weakness comprises a foam reduced thickness portion defined by a foam sever extending partially through a foam thickness from a foam lower surface towards a foam upper surface. The outer shell line of mechanical weakness is displaced relative to a foam line of mechanical weakness.

Abstract: An instrument panel of an automotive vehicle includes a rigid retainer preformed with an air bag opening and a recessed ledge extending about the opening. A separately formed door is installed on the opening and hinged to the retainer along one edge. The remaining three edges overlie the ledge to prevent inward movement of the door. The retainer and door are placed in a cavity of a mold tool in spaced relation to an outer skin and foam constituents are reacted therebetween to develop a foam layer. A foam seal is provided at the interface of the ledge and door to prevent the escape of foam past the ledge.

Abstract: A vehicle interior trim panel and method of making is provided where the vehicle interior trim panel comprises a skin, a substrate, a foam located between the skin and the substrate, and a flat wire at least partially surrounded by and embedded in the foam.

Abstract: A motor vehicle lighting device is provided comprising a ground illumination portion configured to direct a portion of the light emitted from a light source to illuminate a ground surface area rearward from the motor vehicle and a reverse signaling portion configured to direct a portion of the light emitted from the light source to an area different than the ground illumination portion. In this manner, a rearward vehicle lighting device designed for ground illumination and reverse signaling is provided from a single lamp and more preferably, using a single light source.

Abstract: An automotive trim panel is disclosed having an airbag door and at least one duct. The trim panel comprises a first retainer, having an aperture for deployment of an airbag, and a second retainer having an airbag door. When the first retainer and the second retainer are assembled, the airbag door of the second retainer is received in the aperture of the first retainer. Furthermore, at least one duct is formed when the first retainer and the second retainer are assembled.

Abstract: A skin for an automotive interior trim panel is provided comprising a first skin portion and a second skin portion. First skin portion comprises a receptacle and a second skin portion comprises a protrusion. When connected, a portion of the protrusion in mechanical engagement with a portion of the receptacle to join the first skin portion and the second skin portion.

Abstract: A tow bar for connecting a vehicle to an object to be towed which reduces impact related structural damage to the vehicle. The tow bar is positioned within the vehicle bumper wherein the bumper contains a section for concealing the tow bar and wherein the tow bar positioned within the bumper, when in a non-towing mode, is movable relative to the bumper, and wherein the tow bar can also be configured into a non-slidable towing configuration.

Abstract: An automotive interior trim panel has an outer flexible skin that overlies a rigid backing panel formed with a foam entry hole through which foam precursors are poured into a space between the skin and panel and they react and expand to generate a foam layer within the space. Tab projections are carried by the panel and extend into the foam space to at least partially cover the opening and provide rigid backing support for foam expanding in the region of the entry hole to control the density of the foam in this entry hole region such that it conforms more closely with the density of the immediate surrounding foam.

Abstract: A passenger protection apparatus for a motor vehicle is provided comprising a first interior trim member and a second interior trim member. The first interior trim member, preferably an instrument panel, is attached to the motor vehicle and the second interior trim member attached to the first interior trim member. The second trim member is attached to the first trim member such that the second interior trim member is removable from the first interior trim member without detaching the first interior tnm member from the motor vehicle The second interior trim member is located in the knee impact region of the motor vehicle and comprises a first energy management device in the form of an inflatable restraint apparatus having an airbag and an inflator.

Abstract: A method of molding a plastic shell having an outer pliable skin layer and a foam backing layer comprises casting a first skin layer portion from wear resistant material in a first casting sequence for those areas of the panel susceptible to high wear and in a second casting sequence casting self-skinning foamable material against the remaining portion of the mold surface and over the first-cast skin layer portion to develop, simultaneously, the remaining outer skin layer portion of the shell and a foam backing layer which extends across the entire skin layer.