Abstract: A modular vehicle headliner assembly includes a generally planar headliner substrate for mounting over an interior portion of a vehicle roof. An air duct is attached to one side of the substrate. An air-curtain assembly is attached to the air duct. The air duct supports the air-curtain assembly relative to the substrate.

Abstract: A method for forming an integrated trim plate in a single processing step. An appliqué section is reversibly securing to the lower section of a mold. A layer of thermoplastic covering is applied onto and over the appliqué section and lower section of the mold. A layer of foam is then injected between the thermoplastic covering and a substrate used to secure the integrated trim plate within a structure such as an automobile frame. The appliqué section may be magnetically secured to the lower section of the mold or may be physically secured within a forming section of the lower section.

Abstract: A method for forming an integrated trim plate in a single processing step. An appliqu é section is reversibly securing to the lower section of a mold. A layer of thermoplastic covering is applied onto and over the appliqu é section and lower section of the mold. A layer of foam is then injected between the thermoplastic covering and a substrate used to secure the integrated trim plate within a structure such as an automobile frame. The appliqu é section may be magnetically secured to the lower section of the mold or may be physically secured within a forming section of the lower section.

Abstract: A plastic cross car beam for a motor vehicle includes first and second members joined together at sealing points to form at least two ducts. The cross sectional shapes of the ducts are essentially constant along the length of the cross car beam and shaped to provide structural support for various types of loadings. Each duct is provided with at least one inlet, aligned with an HVAC assembly, and one outlet, aligned with a vent or register. Preferably a support member, which is integral with one of the members, extends downward from one of the ducts and supports an HVAC case. Also, preferably, the support member is provided with a pocket for receiving an energy absorbing bracket.

Abstract: A plastic cross car beam for a motor vehicle that includes first and second members joined together at sealing points to form at least two ducts. The cross sectional shapes of the ducts are essentially constant along the length of the cross car beam and shaped to provide structural support for various types of loadings. Each duct is provided with at least one inlet, aligned with an HVAC assembly, and one outlet, aligned with a vent or register. Preferably a support member, which is integral with one of the members, extends downward from one of the ducts and supports an HVAC case. Also, preferably, the support member is provided with a pocket for receiving an energy absorbing bracket.

Abstract: A selectively operable storage system incorporated within the passenger compartment of an automotive vehicle is described. The storage system is preferably deployed underneath the rear seat structure, for example, below the seat bottom structure. The storage system can include any number and combination of selectively operable sliding trays, pivoting trays, collapsible trays, pivoting lids, storage bins, and track systems.