Abstract: Doors for motor vehicles include door trim panel assemblies having multiple door trim panels held together at attachment points. A door trim panel includes a weakened perimeter formed from a series of apertures in the panel, creating a predetermined breakaway point where the assembly will rupture in the event a load is applied. Methods for tuning the durability of a trim panel assembly include a repeatable cycle in which pins are selected and inserted in a mold at varying positions. During injection molding, the pins form apertures to create a predetermined breakaway point. Changing the size, shape, and location of the pins allows tuning of the durability and properties of the breakaway point. Injection molds have variable pin placement capability to facilitate the method.

Abstract: A vehicle seat assembly includes a seat base, a seat back rotatably connected to the seat base, a seat bottom mounted on the seat base, and at least one of the following mounted to one of the seat base, seat back, and seat bottom: a resistance mechanism structured to exert a biasing force on at least one exercise arm operatively connected to the resistance mechanism; a bicycle seat receptacle structured for detachably mounting a bicycle seat to the seat base; and a docking mechanism structured for detachably mounting a pedal mechanism to the seat base.

Abstract: Doors for motor vehicles include door trim panel assemblies having multiple door trim panels held together at attachment points. A door trim panel includes a weakened perimeter formed from a series of apertures in the panel, creating a predetermined breakaway point where the assembly will rupture in the event a load is applied. Methods for tuning the durability of a trim panel assembly include a repeatable cycle in which pins are selected and inserted in a mold at varying positions. During injection molding, the pins form apertures to create a predetermined breakaway point. Changing the size, shape, and location of the pins allows tuning of the durability and properties of the breakaway point. Injection molds have variable pin placement capability to facilitate the method.

Abstract: A vehicle seat assembly includes a seat base, a seat back rotatably connected to the seat base, a seat bottom mounted on the seat base, and at least one of the following mounted to one of the seat base, seat back, and seat bottom: a resistance mechanism structured to exert a biasing force on at least one exercise arm operatively connected to the resistance mechanism; a bicycle seat receptacle structured for detachably mounting a bicycle seat to the seat base; and a docking mechanism structured for detachably mounting a pedal mechanism to the seat base.

Abstract: A vehicle includes a roof assembly including a roof outer panel having an outer facing surface and a sensor housing recess that extends below the outer facing surface. The sensor housing recess extends in a vehicle longitudinal direction between a front windshield and a rear windshield. A roof sensor housing assembly is mounted to the roof outer panel and extends along a length of the sensor housing recess. The roof sensor housing assembly includes a sensor housing structure that is mounted to the roof outer panel forming a sensor housing volume therebetween. The sensor housing structure extends at least partially above the outer facing surface of the outer roof panel. The sensor housing structure includes a transmission region that has increased transmittance therethrough compared to surrounding regions of the sensor housing structure.

Abstract: A vehicle roof structure for concealing one or more sensors therein includes a roof panel, a windshield extending up to the roof panel, and a spoiler. The spoiler extends across at least a portion of a width of the roof panel and includes a leading portion that is substantially parallel to a windshield-roof interface, an apex, wherein a height of the spoiler increases from a height of the roof panel to a height of the apex as the spoiler extends from the leading portion to the apex in a vehicle longitudinal direction, and a trailing portion extending from the apex to the roof panel. A sensor volume is formed between the spoiler and the roof panel. One or more sensors are at least partially positioned within the sensor volume, wherein the one or more sensors output a signal indicative of a characteristic of an environment of the vehicle.

Abstract: Embodiments of the present disclosure are directed to vehicles and vehicle roof structures for concealing one or more sensors. Vehicle roof structures according to the present disclosure include a roof panel and a window extending at least up to the roof panel. A headliner extends along an interior portion of the roof panel to the window and is at least partially spaced from the roof panel in a direction of an interior of the vehicle to provide a sensor mounting volume therebetween, wherein the window extends along at least a portion of the sensor mounting volume. One or more sensors are positioned behind the window within the sensor mounting volume to provide a signal indicative of a characteristic of an environment of the vehicle detected by the one or more sensors through the window.

Abstract: A vehicle includes a roof assembly including a roof outer panel having an outer facing surface and a sensor housing recess that extends below the outer facing surface. The sensor housing recess extends in a vehicle longitudinal direction between a front windshield and a rear windshield. A roof sensor housing assembly is mounted to the roof outer panel and extends along a length of the sensor housing recess. The roof sensor housing assembly includes a sensor housing structure that is mounted to the roof outer panel forming a sensor housing volume therebetween. The sensor housing structure extends at least partially above the outer facing surface of the outer roof panel. The sensor housing structure includes a transmission region that has increased transmittance therethrough compared to surrounding regions of the sensor housing structure.

Abstract: A vehicle roof structure for concealing one or more sensors therein includes a roof panel, a windshield extending up to the roof panel, and a spoiler. The spoiler extends across at least a portion of a width of the roof panel and includes a leading portion that is substantially parallel to a windshield-roof interface, an apex, wherein a height of the spoiler increases from a height of the roof panel to a height of the apex as the spoiler extends from the leading portion to the apex in a vehicle longitudinal direction, and a trailing portion extending from the apex to the roof panel. A sensor volume is formed between the spoiler and the roof panel. One or more sensors are at least partially positioned within the sensor volume, wherein the one or more sensors output a signal indicative of a characteristic of an environment of the vehicle.

Abstract: Embodiments of the present disclosure are directed to vehicles and vehicle roof structures for concealing one or more sensors. Vehicle roof structures according to the present disclosure include a roof panel and a window extending at least up to the roof panel. A headliner extends along an interior portion of the roof panel to the window and is at least partially spaced from the roof panel in a direction of an interior of the vehicle to provide a sensor mounting volume therebetween, wherein the window extends along at least a portion of the sensor mounting volume. One or more sensors are positioned behind the window within the sensor mounting volume to provide a signal indicative of a characteristic of an environment of the vehicle detected by the one or more sensors through the window.

Abstract: Methods and systems for vacuum forming to form a final plastic product defining a notch, including providing a plastic material; providing a mold for a preform plastic product from which to form the final plastic product having a sacrificial forming feature associated with forming an inline trimmable part defining a notch area from which to form the notch, the sacrificial forming feature positioned on the mold within the notch area to be trimmed via an inline trimming operation to form the notch and shaped to selectively reduce a material thickness at a selective remaining location of the preform plastic product; disposing the plastic material on the mold to form an assembly; applying vacuum forming to the assembly to form the preform plastic product; and reducing the material thickness at the selective remaining location of the preform plastic product during vacuum forming to affect a corresponding localized stiffness reduction.

Abstract: A vehicle includes a pillar garnish mounted at a side pillar assembly of the vehicle. The pillar garnish has an upper end portion, a roof head lining with an outer portion that extends along the upper end portion of the pillar garnish, and an airbag jump bracket fixedly located between a pillar body and the roof head lining. The airbag jump bracket includes a first portion extending in a vehicle height direction and a second portion extending outwardly from the first portion in a vehicle width direction. The second portion supports an airbag body that guides the airbag body toward an occupant compartment of the vehicle during an airbag deployment event. The airbag jump bracket further includes an outwardly turned flange portion that extends outwardly in the vehicle width direction to underhang the second portion of the airbag jump bracket. The outwardly turned flange portion has an underside and terminates at an end located beneath the second portion of the airbag jump bracket.

Abstract: Side pillar assemblies may include trim straps for structural rigidity during deployment of side airbag apparatuses. During deployment, the airbag can deploy from behind the roof head lining, above one or more pillar garnishes of the side pillar assembly and into the occupant compartment. A rib along the back surface of the pillar garnish may be placed in tension during a deployment event and inhibit fragmentation of the pillar garnish and limit movement of the pillar garnish into the occupant compartment. The rib may include one or more strap portions that may be placed in compression in the event of an impact on the interior facing portions of the pillar garnish. The strap portions may buckle under the compression force and provide a level of cushioning or energy dissipation due to the impact.

Abstract: A vehicle includes a pillar garnish mounted at a side pillar assembly of the vehicle. The pillar garnish has an upper end portion, a roof head lining with an outer portion that extends along the upper end portion of the pillar garnish, and an airbag jump bracket fixedly located between a pillar body and the roof head lining. The airbag jump bracket includes a first portion extending in a vehicle height direction and a second portion extending outwardly from the first portion in a vehicle width direction. The second portion supports an airbag body that guides the airbag body toward an occupant compartment of the vehicle during an airbag deployment event. The airbag jump bracket further includes an outwardly turned flange portion that extends outwardly in the vehicle width direction to underhang the second portion of the airbag jump bracket. The outwardly turned flange portion has an underside and terminates at an end located beneath the second portion of the airbag jump bracket.

Abstract: A vehicle includes a B-pillar garnish mounted at a side pillar assembly of the vehicle. The B-pillar garnish includes an airbag jump bracket engaging feature including a hook-shaped engaging portion extending upwardly beyond an end of an outwardly turned flange portion of the airbag jump bracket. The hook-shaped engaging portion includes a stem portion and an enlarged head portion that overhangs the end of the outwardly turned flange portion of the airbag jump bracket that engages the outwardly turned flange portion during an airbag deployment event. The stem portion is located adjacent the end of the outwardly turned flange portion of the airbag jump bracket. The stem portion is arranged to engage the end of the outwardly turned flange portion of the airbag jump bracket to limit movement of an upper end portion of the B-pillar garnish into the occupant compartment of the vehicle.

Abstract: A vehicle includes a pillar garnish mounted at a side pillar assembly of the vehicle. The pillar garnish has an upper end portion, a roof head lining with an outer portion that extends along the upper end portion of the pillar garnish, and an airbag jump bracket fixedly located between a pillar body and the roof head lining. The airbag jump bracket includes a first portion extending in a vehicle height direction and a second portion extending outwardly from the first portion in a vehicle width direction. The second portion supports an airbag body that guides the airbag body toward an occupant compartment of the vehicle during an airbag deployment event. The airbag jump bracket further includes an outwardly turned flange portion that extends outwardly in the vehicle width direction to underhang the second portion of the airbag jump bracket. The outwardly turned flange portion has an underside and terminates at an end located beneath the second portion of the airbag jump bracket.

Abstract: A load transfer structure in an A-pillar assembly for transferring force from a frontal impact to the vehicle rail, rocker and door reinforcement. The load transfer structure having a support wall, a pair of transverse walls, and a longitudinal wall and is disposed in a space within the A-pillar assembly. Accordingly, the load transfer structure reduces material required in conventional A-pillar assemblies while maintaining the same load transfer capabilities.

Abstract: A stamped metal panel used as part of a pillar of a motor vehicle includes a main wall, an outer side wall, an inner side wall and a transitional portion. The outer side wall extends from one side of the main wall. The inner side wall extends from an opposite side of the main wall and forms a generally U-shaped cross section with the main wall and the outer side wall. The inner side wall has a first wall that extends from the main wall and a second wall that extends from an end of the first wall opposite from the main wall. The transitional portion extends arcuately between the first wall and the second wall. The transitional portion is substantially tangential with at least the first wall of the first side wall to facilitate removal of the panel from between upper and lower halves of a stamping tool.