Abstract: A method for manufacturing an automotive interior component may include providing a cover, a substrate, a chute connected to the substrate, heating the cover, forming the cover via a negative vacuum forming tool, and supporting the substrate and chute via a buck. The method may include moving at least of the negative vacuum forming tool and the buck toward the other of the negative vacuum forming tool and the buck such that the cover and the substrate may be in contact with each other. The method may include bonding the substrate with the cover via providing pressurized fluid to a chamber of the buck to force the substrate toward the cover. The chamber may be defined by the buck and the substrate.

Abstract: An apparatus for manufacturing an automotive interior component and a method for manufacture thereof are provided. The method includes providing a first and second layer of the automotive interior component. The method includes providing an apparatus comprising a first press component and a second press component, the first press component including a pressure chamber configured to receive a protrusion of the first layer. The method includes inserting the first layer into the first press component, such that the protrusion is received by the pressure chamber of the first press component. The method includes coupling the first layer and the second layer, wherein coupling comprises moving at least one of the first press component and second press component toward the other and introducing a first fluid into the pressure chamber of the first press component such that the fluid applies a fluid pressure to the first layer.

Abstract: A method for manufacturing an automotive interior component may include providing a cover, a substrate, a chute connected to the substrate, heating the cover, forming the cover via a negative vacuum forming tool, and supporting the substrate and chute via a buck. The method may include moving at least of the negative vacuum forming tool and the buck toward the other of the negative vacuum forming tool and the buck such that the cover and the substrate may be in contact with each other. The method may include bonding the substrate with the cover via providing pressurized fluid to a chamber of the buck to force the substrate toward the cover. The chamber may be defined by the buck and the substrate.

Abstract: A stitching system is configured to stitch through decorative skins with a molded seam recess representing a seam and includes a sewing machine, an image acquisition mechanism, a controller, and a rotation mechanism. The sewing machine is rotatable with respect to a support table, and includes a sewing head to receive a sewing needle and a sewing foot to selectively engage the skin. The image acquisition mechanism produces an image of the seam recess with respect to the sewing head/needle(s). The controller determines the difference between the actual recess location and a predetermined desired recess location. Based on this difference, the controller determines a sewing machine rotation angle and orientation to reduce the difference to zero, and then produces a corresponding adjustment signal that drives the rotation mechanism. A robot can move either the sewing machine or the workpiece, and still use the herein-described real time steering control.

Abstract: An automotive interior component including an airbag chute having at least one weld bar, and a pre-stressed instrument panel having a substrate layer for bonding to the weld bar. The pre-stressing provides tensile stress at weld bar bonding areas to reduce any deformation visible on an exposed surface of the instrument panel.

Abstract: An apparatus for manufacturing an automotive interior component and a method for manufacture thereof are provided. The method includes providing a first and second layer of the automotive interior component. The method includes providing an apparatus comprising a first press component and a second press component, the first press component including a pressure chamber configured to receive a protrusion of the first layer. The method includes inserting the first layer into the first press component, such that the protrusion is received by the pressure chamber of the first press component. The method includes coupling the first layer and the second layer, wherein coupling comprises moving at least one of the first press component and second press component toward the other and introducing a first fluid into the pressure chamber of the first press component such that the fluid applies a fluid pressure to the first layer.

Abstract: A vehicle interior assembly includes a class A visible surface material having a first layer formed from a thermal plastic olefin and a second layer formed from a foam. The vehicle interior assembly also includes a substrate supporting the class A visible surface material. The substrate defines an opening for receiving a drop-in chute having an outer surface. In addition, the vehicle interior assembly includes a retention mechanism for securing the outer surface of the drop-in chute to the substrate.

Abstract: A method of manufacturing an automotive interior component includes the steps of: providing a mold apparatus comprising a first mold component and a second mold component; providing a substrate; applying a first layer of a soft-touch material to the substrate; applying a second layer of a fabric to one of the first mold component and the second mold component of the mold apparatus; forming a self-skinning foam layer, wherein a first surface of the self-skinning foam layer is configured for bonding to the first layer and a second surface of the self-skinning foam layer is configured for bonding to the second layer; and fastening the substrate, the first layer, the second layer together. Additional methods of manufacturing automotive interior components and automotive interior components are also provided.

Abstract: A stitching system is configured to stitch through decorative skins with a molded seam recess representing a seam and includes a sewing machine, an image acquisition mechanism, a controller, and a rotation mechanism. The sewing machine is rotatable with respect to a support table, and includes a sewing head to receive a sewing needle and a sewing foot to selectively engage the skin. The image acquisition mechanism produces an image of the seam recess with respect to the sewing head/needle(s). The controller determines the difference between the actual recess location and a predetermined desired recess location. Based on this difference, the controller determines a sewing machine rotation angle and orientation to reduce the difference to zero, and then produces a corresponding adjustment signal that drives the rotation mechanism. A robot can move either the sewing machine or the workpiece, and still use the herein-described real time steering control.

Abstract: A stitching system is configured to stitch through decorative skins with a molded seam recess representing a seam and includes a sewing machine, an image acquisition mechanism, a controller, and a rotation mechanism. The sewing machine is rotatable with respect to a support table, and includes a sewing head to receive a sewing needle and a sewing foot to selectively engage the skin. The image acquisition mechanism produces an image of the seam recess with respect to the sewing head/needle(s). The controller determines the difference between the actual recess location and a predetermined desired recess location. Based on this difference, the controller determines a sewing machine rotation angle and orientation to reduce the difference to zero, and then produces a corresponding adjustment signal that drives the rotation mechanism. A robot can move either the sewing machine or the workpiece, and still use the herein-described real time steering control.

Abstract: A vehicle trim panel is illuminated from behind to create an illuminated design (e.g., logo and/or lettering) includes a transparent layer and an opaque layer with an opening(s) in the shape of the design. An opaque or partially opaque design piece may be placed over the opening(s) in the opaque layer and be lit around its edges. The vehicle trim panel may be formed by forming a panel with a transparent layer and an opaque layer. An opening in the opaque layer may be formed by removing opaque material (e.g., by machining or laser etching) or by masking (the mask is placed between the opaque layer and transparent layer and removed taking a portion of the opaque layer with it). A design piece may be placed over the location of the opening in the opaque layer.

Abstract: An automotive interior component including an airbag chute having at least one weld bar, and a pre-stressed instrument panel having a substrate layer for bonding to the weld bar. The pre-stressing provides tensile stress at weld bar bonding areas to reduce any deformation visible on an exposed surface of the instrument panel.

Abstract: A vehicle interior assembly that includes airbags and a method of forming thereof.

Abstract: An automotive interior component including an airbag chute having at least one weld bar, and a pre-stressed instrument panel having a substrate layer for bonding to the weld bar. The pre-stressing provides tensile stress at weld bar bonding areas to reduce any deformation visible on an exposed surface of the instrument panel.

Abstract: A method of manufacturing an automotive interior component includes the steps of: providing a mold apparatus comprising a first mold component and a second mold component; providing a substrate; applying a first layer of a soft-touch material to the substrate; applying a second layer of a fabric to one of the first mold component and the second mold component of the mold apparatus; forming a self-skinning foam layer, wherein a first surface of the self-skinning foam layer is configured for bonding to the first layer and a second surface of the self-skinning foam layer is configured for bonding to the second layer; and fastening the substrate, the first layer, the second layer together. Additional methods of manufacturing automotive interior components and automotive interior components are also provided.

Abstract: A method of manufacturing an automotive instrument panel for eliminating distortion in an area of vibration welded air bags comprises: providing a weld fixture including at least one pre-stressor protrusion; placing the at least one pre-stressor protrusion against an instrument panel; generating a force to press the weld fixture against the instrument panel to create compression in a first surface of the instrument panel where the weld fixture contacts the instrument panel and to create tension in a second surface of the instrument panel, the second surface opposite to the first surface; and vibration welding an air bag chute to the instrument panel such that a weld bar of the air bag chute is welded to the second surface of the instrument panel.

Abstract: An injection molded plastic instrument panel P.S.I.R. hidden door milling method including applying a stiff tape, having a hardness greater than a hardness of the plastic instrument panel, to a plastic instrument panel surface to be milled to prevent flexing of the surface during milling. The method may further include milling the surface along a generally width-wise central location of the tape, and removing the tape upon completion of the milling, with the method thereby minimizing burrs along edges of the milled surface. The invention also provides an injection molded plastic instrument panel P.S.I.R. hidden door, and a plastic automotive panel made by method described herein.

Abstract: An automotive Passenger Side Inflatable Restraint (PSIR) hidden door system contained in an automotive instrument panel and a method of scoring the PSIR door system. The system includes forward and rearward doors hingedly connected at first and second hinges, respectively, to a PSIR airbag chute. The system further includes a common tear line of reduced material thickness integrally joining the forward and rearward doors. The common tear line has a substantially non-linear shape with first and second linear ends.

Abstract: A multi-door automotive Passenger Side Inflatable Restraint system includes an instrument panel including a substrate, a plurality of doors, and a cover attached to the instrument panel. The plurality of doors includes a forward door that is substantially trapezoidal in shape, a rearward door that is substantially trapezoidal in shape, a left lateral door that is substantially triangular in shape, and a right lateral door that is substantially triangular in shape.

Abstract: An automotive PSIR hidden chute assembly contained behind an automotive instrument panel. The PSIR may include chute forward and rearward doors, first and second chute flanges, and an instrument panel, each constructed of a first hard material, and first and second chute hinges, first and second chute sidewalls and a chute end wall, each constructed of a second tough ductile material, such that the first material and the second material have different thermal expansion properties and different elastic modulus properties.