Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a door perimeter including a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates, it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate pivots it concentrates inflation force along a lower portion of the frangible door edge. This helps to predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.

Abstract: A vehicle passenger compartment console assembly including a console body having an outer shell and an access opening disposed in the console body outer shell. A positioning apparatus is movably supported within the console body outer shell. At least two storage modules are disposed within the shell and are movably supported on the positioning apparatus. The storage modules are sequentially movable between one or more concealed positions displaced from the access opening and a displayed position adjacent the access opening. The positioning apparatus is configured to support any one of the storage modules in the display position while simultaneously supporting at least one of the other storage modules in a concealed position. This arrangement allows passenger compartment occupants to gain physical access to a module and its contents through the access opening while leaving other modules concealed within the shell.

Abstract: A mold press includes an upper mold carrier mounted to slide up and down along an upright mold press frame and to rotate about a horizontal rotation axis. The mold press frame is supported on a mold press base to tip forward and aft about a horizontal upper mold pivot axis disposed parallel to and below the rotation axis. A lower mold carrier is supported on the mold press base below the upper mold carrier and above the upper mold pivot axis. The lower mold carrier includes a lower mold mounting plate that is pivotally supported on the mold press base for tipping motion along a hinged edge about a lower mold pivot axis that lies parallel to and below the rotation axis and above the upper mold pivot axis. An electronic motion controller may be programmed to coordinate the reciprocating, tipping and rotating motions to accommodate a variety of mold/retainer configurations.

Abstract: A method for manufacture an air bag cover includes providing a cover skin made of a polymeric material and weakening a seam region in the skin by selective exposure to ultraviolet light.

Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate rotates it concentrates inflation force along a lower portion of the frangible door edge. This helps predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.

Abstract: According to one aspect of the invention, a multi-layer automotive interior trim panel (10) comprises a decorative covering layer (12) and a supportive substrate layer (16). The substrate layer (16) is comprised of a rigid material formed into a predetermined shape for supporting the covering layer. The trim panel also includes an intermediate layer (18) disposed between the covering layer and the supportive substrate layer comprised of cushioning material. The intermediate layer includes a mat (20) of polymeric fibers, with the mat having a plurality of indentations (24) to provide a cushioning effect. A corresponding method for producing the interior trim panel having the three layers includes several steps. The first step is heating the cushion layer (18) to a predetermined temperature. The second step is melting a portion of the polymeric fibers in the cushion layer. The third step is stamping the cushion layer to form the plurality of indentations (24).

Abstract: An adjustable impact test fixture (10) for testing impact characteristics of interior trim panels (22). The fixture (10) comprises a support (12), a backing plate (14) attached to the support, and a movable floating plate (16) supported in spaced-apart relation to the backing plate. The fixture further includes one or more energy absorbing inserts (18) that are removably disposed between the backing plate (14) and the floating plate (16). Each insert (18) causes the fixture (10) to have a predetermined or known impact characteristic. The fixture (10) further includes a mounting assembly (20) adapted to fixedly secure a trim panel portion (22) to the floating plate (16).

Abstract: An exterior cladding attachment for a motor vehicle includes a main body portion and a plurality of carets integrally formed therewith which extend in an inboard direction. Each of the plurality of carets is adapted to engage an aperture provided in a body side panel of the motor vehicle and is formed to include a base portion and an engagement portion. The engagement portion passes through the associated aperture and has a stop surface for retaining the caret therein. The base portion includes first and second spaced apart sides having a thickness adjacent to the main body portion which is approximately 25% or less than the nominal thickness of the main body portion. To further secure the main body portion to the motor vehicle, the cladding attachment includes an adhesive strip disposed adjacent horizontally extending adjacent a lower edge of the main body portion.

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: A door latch assembly (10) for a glove box door (12) includes a pivot plate (16) mounted on the door and a latch handle (18) pivotally mounted on the pivot plate to move selectively between a latched position and an unlatched position. The handle (18) has a catch (20,22) to engage the glove box enclosure (14) when the latch handle is in a latched position, and disengage from the enclosure when the handle is in an unlatched position. A pair of specialized torsion springs (24) is molded to the pivot plate (16) to bias the latch handle (18) and the catch (20) into the engaged position.

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: An air bag cover (14) for use in a supplement inflatable restraint system includes an air bag cover skin made of a polymeric material. The cover skin includes a weakened tear seam region (16) for guiding the tearing of the air bag cover skin in response to air bag inflation. The tear seam region is weakened by photodegradation, i.e., selective exposure to ultraviolet light (20) which breaks polymer bonds within the polymeric material of the tear seam region. Photodegradation reduces the tensile strength and/or the percent elongation (measured at break) of the tear seam region (16) compared to the rest of the air bag cover skin (24).

Abstract: A method for deployably concealing an air bag behind an instrument panel which includes a decorative plastic skin that covers a structural panel and a door that covers an opening in the panel. The panel includes a retainer and an outer foam layer adhered to a retainer outer surface. The door pivots on a hinge at a rear margin of the door. The skin is adhered to outer surfaces of the door and the panel. When closed, the door outer surface lies flush with the panel outer surface forming a seam between the door and the panel. The skin extends across the seam to conceal the door and panel. When opened, a front edge of the door pivots away from the opening to provide an air bag deployment path through the panel. A portion of the skin surrounding the door separates from the outer foam layer of the panel. The skin peels back to form a skin "tent" when the door opens. A delaminated front edge of the skin forms a tent opening that serves as an exit for the deploying air bag.

Abstract: A lumbar support mechanism includes a flexible support member, a spring and a cable assembly. The flexible support member has oppositely disposed first and second ends. The spring has a first end and a second end. The first end of the spring is connected to one of the first end and second ends of the flexible support member. The cable assembly includes a sleeve and a cable slidably disposed therein. The sleeve has a first end connected to the second end of the spring. The cable has a first end connected an other of the first and second ends of the flexible support member.

Abstract: An air bag cover assembly comprises a flexible plastic air bag door closing an air bag deployment opening in a hard plastic retainer. A door outer edge abuts and is mechanically locked to an inner edge of the opening. The interlock comprises a protrusion in the door outer edge, which mates with a complementary recess in the inner edge of the opening. The interlock blocks outward and inward air bag door movement. The door and retainer are made of plastics, which generally do not adhere easily to one another. Silicone may be sprayed on the door outer edge to further reduce adhesion or where plastics, which generally adhere to one another, are used. Preferably, the exterior and interior surfaces of the door and retainer lie flush with one another. The door includes a flexible hinge flange that extends from an interior door surface and attaches the door to the vehicle structure. The hinge flange allows the door to swing outward upon air bag deployment while retaining the door to the vehicle structure.

Abstract: A vehicle interior trim member comprises trim panel configured to mount on a vehicle interior frame structure. The two ends of a hollow U-shaped handle integrally extend from an outer surface of the trim panel. A tubular interior cavity is disposed within and extends along the length of the handle. Cavity end walls are disposed across respective cavity ends adjacent the handle ends to Strengthen the handle. The handle and trim panel are integrally formed together as a single piece unitary member in a single operation from a single molten material. The cavity end walls may be configured to close off and seal the cavity. A panel aperture may be disposed in the trim panel between the handle ends and a panel plug disposed across the panel aperture, connected to a back surface of the panel by well known means. The cavity is formed in the handle by injecting a fluid such as nitrogen through gas injection nozzles into the molten handle material.

Abstract: A body side sill molding attachment for a motor vehicle includes a main body portion, first flange and a second flange. The first flange upwardly extends and includes a plurality of ribs adapted to frictionally engage an inboard side of a downwardly extending flange of a motor vehicle sill. The second flange longitudinally extends along an upper edge of the main body portion and includes a plurality of apertures adapted to align with a corresponding plurality of slots provided in the motor vehicle sill. Each of the apertures and associated slots are adapted to align and receive a mechanical fastener for securing an upper edge of the body side sill molding attachment to the vehicle.

Abstract: An air bag occupant restraint system (10) for a vehicle comprises an inflatable cushion (14) adapted to inflate in the event of a vehicle collision. A gas generating device (16) in communication with the cushion (14) inflates the cushion. The cushion (14) includes a transparent portion (18) disposed on at least a portion of the interior of the windshield (12) when in the collapsed state. With this arrangement, the transparent portion (18) can inflate to inhibit the occupant from colliding with the windshield (12) and other objects adjacent to the windshield in the event of a collision. Similarly, the inventive method for cushioning a vehicle occupant in the event of collision comprises the following steps. First, dispose an inflatable cushion (14) over the windshield (12) of the vehicle when the cushion is in an uninflated state. Next, communicate the cushion (14) with a gas generating device (16) adapted to inflate the cushion in the event of a collision. Then, sense when a collision occurs.

Abstract: A vehicle interior trim panel electrical switch assembly (10) includes a switch panel portion (16) with a continuous outer surface (18). Force sensitive resistor switches (20a-20g) are supported on the switch panel portion (16) and are secured to the inner surface of a skin cover having a continuous outer surface (18) and forming the outer layer of a soft feel composite. The force sensitive resistor switches are embedded in the soft feel composite either as being cast in a layer of flexible foam or being applied within preformed openings in a layer of flexible foam in certain embodiments in which case they are associated with a circuit module (34) that negates preloading effects due to thermal expansion caused by changes in ambient conditions. In a preferred embodiment the correction occurs due to a circuit configuration that corrects for such preloading effects on a deflection rate basis. The circuit module (34) for each switch (20a-20g) may also include a relay in high power applications.

Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate rotates it concentrates inflation force along a lower portion of the frangible door edge. This helps predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.