Abstract: A system is disclosed. The system includes a fluid reservoir containing a volume of fluid, a bell housing that forms a chamber, a workpiece having a first surface portion and a second surface portion, and a pressure manipulating sub-system in fluid communication with the chamber of the bell housing. The bell housing is arranged relative to the fluid reservoir such that a lower end of the bell housing is at least partially submerged in the fluid thereby sealing the chamber of the bell housing from atmosphere. The bell housing is arranged relative to the fluid reservoir such that the second surface portion of the workpiece is disposed within the chamber of the bell housing that is sealed from atmosphere. A method is also disclosed. An apparatus is also disclosed.

Abstract: A method is disclosed. The method includes the step of determining a spatial location of a match-mark region of each of a tire and a wheel, wherein at least one of the tire and the wheel does not include a physical match mark formed upon a surface or within a body portion of the tire and the wheel. A system is also disclosed. An apparatus is also disclosed.

Abstract: A system is disclosed. The system includes a fluid reservoir containing a volume of fluid, a bell housing that forms a chamber, a workpiece having a first surface portion and a second surface portion, and a pressure manipulating sub-system in fluid communication with the chamber of the bell housing. The bell housing is arranged relative to the fluid reservoir such that a lower end of the bell housing is at least partially submerged in the fluid thereby sealing the chamber of the bell housing from atmosphere. The bell housing is arranged relative to the fluid reservoir such that the second surface portion of the workpiece is disposed within the chamber of the bell housing that is sealed from atmosphere. A method is also disclosed. An apparatus is also disclosed.

Abstract: A method is disclosed. The method includes the step of determining a spatial location of a match-mark region of each of a tire and a wheel, wherein at least one of the tire and the wheel does not include a physical match mark formed upon a surface or within a body portion of the tire and the wheel. A system is also disclosed. An apparatus is also disclosed.

Abstract: A planar member connected to, and disposed behind, a vehicle seat assembly having a seat back and seat bottom, the planar member moveable between a first position adjacent the seat back and a second position adjacent a floor of a vehicle. The planar member has an upper and lower section connected to each other. The upper section is moveable between a first position and a second position. The upper section is adjacent the seat back when the planar member and upper section are in their respective first positions. The upper section forms a shelf when the planar member is in the first position and the upper section is in the second position. The upper section is perpendicular to, and forms a compartment within a cavity in the floor of the vehicle when the planar member and the upper section are in their respective second positions.

Abstract: An overhead console assembly mounted to a headliner in a passenger compartment of a vehicle. The overhead console assembly includes an overhead console housing configured for attachment adjacent to a lower surface of the headliner or frame of the vehicle roof. The console housing includes a lower surface, at least one channel in the lower surface and opposing pivotally mounted first and second doors at least partially covering the lower surface. At least one storage module is releasably securable and adjustably positionable within the channel in the overhead console housing. The at least one storage module includes a housing having a top surface, a bottom surface, a sidewall extending therebetween defining a receiving area therebetween accessible through an opening in the sidewall. An accessory module removably mountable within the receiving area of the storage module housing receives and stores items.

Abstract: The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the substrate.

Abstract: The present invention is directed toward providing a headliner for a motor vehicle comprising an interior layer adapted to present a surface that is exposed to the interior of the vehicle, a flexible film assembly that is supported by the interior layer opposite to the interior of the vehicle; and a fill layer adapted to be flowed over the flexible film and subsequently hardened to form a main supporting body of the headliner. The flexible film assembly has a first film layer adapted to establish a generally flat base surface that is mounted to the interior layer and a second film layer supported on the first film layer having a plurality of voids formed by portions of the second film layer that are spaced from said first film layer at predetermined intervals so as to establish an undulating upper surface of the film assembly. The plurality of voids are adapted to act as a plurality of resonating cavities to attenuate acoustical frequencies within the vehicle.

Abstract: This invention relates to a flexible headliner for an automotive vehicle. The headliner includes a flexible foam core layer having a nominal thickness of greater than 5 millimeters. A cover layer is bonded to a first side of the core layer. A backing layer is bonded to a second side of the core layer opposite the first side. The headliner is sized and shaped to conform to an interior roof of the vehicle. The invention also relates to particular methods of forming the headliner in a mold.

Abstract: A laminate for use as a headliner for an automobile comprises a core that is a mixture of basalt fibers and polypropylene binder. A scrim layer is provided adjacent a first side of the core. An adhesive layer and a covering are provided adjacent a second side of the core. The laminate can be manufactured by heating the core, providing a scrim layer adjacent the first side of the core and providing an adhesive layer and a covering adjacent the second side of the core to complete the laminate. A method for recycling a laminate comprises the steps of providing a laminate material formed of composite materials including reinforcement fibers that have a higher melting point than the incineration point of the other composite materials and heating the laminate to a temperature below the melting point of the basalt and above the incineration point of the other composite materials to reduce the other composite materials to ash without melting the basalt.

Abstract: A laminate for use as a headliner comprises a core having an adhesive layer provided adjacent opposing sides thereof. Basalt fiber structural reinforcement layers are provided adjacent each adhesive layer. A scrim layer is provided next to one reinforcement layer while a film barrier and covering are provided adjacent the other reinforcement layer. A method for manufacturing the laminate comprises the steps of providing a core, providing basalt fiber reinforcement layers adjacent opposing sides of the core, providing adhesive layers between opposing sides of the core and the reinforcement layers, applying a scrim layer to one reinforcement layer and a film barrier and covering to the other reinforcement layer to complete the laminate. According to a method for recycling a laminate, laminate material formed of composite materials including reinforcement fibers that have a melting point above the incineration point of the other composite materials is provided.

Abstract: A laminate for use as a headliner comprises a core having an inner layer of thermoplastic binder adjacent opposing sides thereof. A basalt structural reinforcement layer is provided adjacent each inner layer of thermoplastic binder. An outer layer of thermoplastic binder is applied adjacent each reinforcement layer. A scrim layer is applied adjacent one outer layer of thermoplastic binder and an adhesive layer and covering are provided adjacent the other outer layer of thermoplastic binder. A method of manufacturing the laminate comprises the steps of providing a scrim layer and a layer of thermoplastic binder. A basalt structural reinforcement layer is provided adjacent the layer of thermoplastic binder. Another layer of thermoplastic binder is provided adjacent the basalt structural reinforcement layer. A core is provided adjacent the layer of thermoplastic binder. Another basalt structural reinforcement layer is provided adjacent the core.

Abstract: A structural reinforcement layer for use in a laminate for a vehicle headliner comprises at least one of carbon fibers and natural fibers. A thermoplastic binder may adhere the fibers to one another. A method for manufacturing a laminate comprising a the structural reinforcement layer comprises the steps of providing a core, providing a first reinforcement layer containing carbon fibers adjacent one of opposing sides of the core, providing adhesive layers on each of the opposing sides of the core, applying a barrier film and covering to the first reinforcement layer to the first reinforcement layer. Applying a scrim mat comprising a reinforcement layer, a barrier film and a scrim layer to the other of the opposing sides of the core to complete the laminate. According to a method for recycling a laminate, laminate material formed of composite materials including carbon fibers that have a melting and/or degradation point above the incineration point of the other composite materials is provided.

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Abstract: The present invention is directed toward providing a headliner for a motor vehicle comprising an interior layer adapted to present a surface that is exposed to the interior of the vehicle, a flexible film assembly that is supported by the interior layer opposite to the interior of the vehicle; and a fill layer adapted to be flowed over the flexible film and subsequently hardened to form a main supporting body of the headliner. The flexible film assembly has a first film layer adapted to establish a generally flat base surface that is mounted to the interior layer and a second film layer supported on the first film layer having a plurality of voids formed by portions of the second film layer that are spaced from said first film layer at predetermined intervals so as to establish an undulating upper surface of the film assembly. The plurality of voids are adapted to act as a plurality of resonating cavities to attenuate acoustical frequencies within the vehicle.

Abstract: An impact absorbing member having a contact wall and base wall that are separated by first and second spacing walls. The spacing walls are oriented to be not aligned with the anticipated direction of an impact force. The spacing walls may be flat, curved, or formed in the shape of a bellows. The base wall may be provided with an adhesive or may include additional fastening features such as holes through which glue or fasteners may pass or may be formed as fastening rosettes.

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Abstract: A cushion structure having multiple indentation load deflection areas created by using inflatable preformed containers within a base cushion foam and method for making same. The invention can be utilized to make cushions for use with separately manufactured upholstery covers as well as for pour-in-place or foam-in-cover upholstered cushions. Such cushions are suitable for use in commercial and residential furniture as well as automobiles, buses, trains and aircraft.

Abstract: This invention relates to a flexible headliner for an automotive vehicle. The headliner includes a flexible foam core layer having a nominal thickness of greater than 5 millimeters. A cover layer is bonded to a first side of the core layer. A backing layer is bonded to a second side of the core layer opposite the first side. The headliner is sized and shaped to conform to an interior roof of the vehicle. The invention also relates to particular methods of forming the headliner in a mold.

Abstract: An impact absorbing and method for making the same. The impact absorbing assembly for vehicle interiors includes a body having tabs that are connected to the body by a bendable hinge. The body may be either secured to a structural member, a vehicle seat, a trim piece or may be formed integrally from part of a structural component making up part of the vehicle. The impact absorbing assembly may be disposed behind a covering layer or seat back shell.