Abstract: An antimicrobial, injection molded air duct for use in an air distribution system which delivers air to a passenger cabin of a vehicle or into an enclosed space within a residential structure is provided. The air duct includes a hollow, injection molded housing having an air passageway for communicating airflow therethrough. The housing includes a layer of molded material which at least partially defines the passageway and which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow. The molded material includes antimicrobial agents disbursed throughout the layer to reduce the number of pathogens contained within droplets absorbed by the layer.

Abstract: A low-profile, backlit panel assembly and a controller for displaying images and/or data within a passenger compartment of a vehicle are provided. The assembly includes a substrate panel perforated with a two-dimensional array of closely-spaced holes. The panel is configured to be attached to a support structure of the vehicle. The assembly further includes a plurality of semiconductor-based, lighting devices supported at a back surface of the panel. Each of the lighting devices includes at least one lighting element. Each of the lighting elements is individually addressable by the controller to control luminous intensity of the light emitted by the at least one lighting element. Each of the lighting devices is aligned with one of the holes so that light emitted by each of the lighting devices travels through its hole to the passenger compartment in the form of a pixel of a two-dimensional image.

Abstract: A sandwich-type, composite component having an injection molded backside protective covering including 3-D structures which provide at least one pattern at an outer surface of the component is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core bonded to and positioned between the outer layers and having a plurality of cavities. The covering is integrally formed from at least one elastomeric material and includes the 3-D structures bonded to the outer surface by injection molding. The 3-D structures are sized, shaped and arranged in one or more patterns at the outer surface. The one or more patterns may form a textured surface finish, a logo or indicia such as instructions at the outer surface. The component may be a vehicle interior component such as a vehicle load floor component.

Abstract: A sandwich-type, composite component having a sprayed backside protective coating is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core positioned between and bonded to the outer layers and having a plurality of cavities. The protective coating is integrally formed from an elastomeric material. The material is sprayed to form the coating and the coating is bonded to the outer surface by curing. The component may be a vehicle interior component such as a vehicle load floor component.

Abstract: A vibrating panel assembly configured to radiate sound into a passenger compartment of a vehicle having a support structure is provided. The assembly includes a substrate panel having front and back surfaces. The panel includes an inner portion, an outer boundary portion formed on the perimeter of the panel and an intermediate portion between the inner portion and the outer boundary portion. The vibrating panel has a frequency distribution of modes in a range of audible frequencies. The panel is configured to be attached to the support structure. An electroacoustic vibrator is mounted on the inner portion at the back surface at a predetermined location and is configured to vibrate the panel over the range of audible frequencies in response to an electrical signal. The intermediate portion is configured to increase modal density of the panel.

Abstract: A vibrating panel assembly configured to radiate sound into a passenger compartment of a vehicle having a support structure is provided. The assembly includes a substrate panel having front and back surfaces. The panel includes an inner portion, an outer boundary portion formed on the perimeter of the panel and an intermediate portion between the inner portion and the outer boundary portion. The vibrating panel has a frequency distribution of modes in a range of audible frequencies. The panel is configured to be attached to the support structure. An electroacoustic vibrator is mounted on the inner portion at the back surface at a predetermined location and is configured to vibrate the panel over the range of audible frequencies in response to an electrical signal. The intermediate portion is configured to increase modal density of the panel.

Abstract: A low-profile panel assembly configured to provide sound having at least one acoustic wavelength within a passenger compartment of a vehicle is provided. The vehicle has a support structure. The assembly includes a substrate panel perforated with at least one sub-wavelength hole which extends between front and back surfaces of the panel. The panel is configured to be attached to the support structure. A continuous membrane of facing material overlies and is in contact with the panel. The membrane is tightly stretched over and covers the at least one hole at the front surface of the panel. An electroacoustic sound source is configured to radiate acoustic waves against the back surface of the panel. The radiated acoustic waves travel through the at least one membrane-covered hole to vibrate at least one portion of the membrane which tightly covers the at least one hole. The at least one vibrating portion of the membrane radiates acoustic waves into the passenger compartment of the vehicle.

Abstract: An antimicrobial, injection molded air register for use in an air distribution system to direct airflow from ductwork into a passenger cabin of a vehicle or into an enclosed space within a residential structure is provided. The air register includes a perforated cover configured to cover an outlet end of the ductwork and a plurality of injection molded components supported by the cover to direct air flow into the passenger cabin. Each of the components includes a surface layer in fluid communication with the airflow and is made of a molded material which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow. The molded material includes antimicrobial agents disbursed throughout each of the surface layers to reduce the number of pathogens contained within droplets absorbed by the surface layers.

Abstract: An antimicrobial, injection molded air duct for use in an air distribution system which delivers air to a passenger cabin of a vehicle or into an enclosed space within a residential structure is provided. The air duct includes a hollow, injection molded housing having an air passageway for communicating airflow therethrough. The housing includes a layer of molded material which at least partially defines the passageway and which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow. The molded material includes antimicrobial agents disbursed throughout the layer to reduce the number of pathogens contained within droplets absorbed by the layer.

Abstract: An automated method and system for making painted vehicle body panel skins and vehicle body panels, such as instrument panels, are provided wherein throughput and equipment utilization are greatly improved at a relatively low cost. The method includes transferring a mold having a mold surface from an entrance station to a paint station within a dispensing area. The method further includes applying paint on the mold surface to form a layer of paint on the mold surface at the paint station. The method still further includes spraying curable polyurethane elastomer on the painted surface at a spray station within the dispensing area. The paint and spray stations may be coincident.

Abstract: A vehicle trim part having an injection molded, frontside protective covering is provided. The part includes a decorative layer having an outer surface which provides the appearance of a desirable material. An injection molded, light-transmissive protective layer is inter-bonded to the decorative layer and is integrally formed from a polymeric material which overlies and protects the decorative layer and provides a desired outer surface finish with little or no need for post-molding machining or polishing. The desired outer surface finish and the outer surface of the decorative layer at the interface between the layers form a reflected light pattern which is visible at the front of the part when lighting illuminates the outer surface finish and the outer surface of the decorative layer from the front of the part. The part may be a vehicle interior trim part.

Abstract: A vehicular window trim assembly includes a decorative outer trim member having upper and lower outer boundary mating portions formed on the perimeter of the trim member. The assembly also includes a channel-shaped window seal having a mouth to receive a panel-like member and upper and lower outer boundary mating portions formed on the perimeter of the seal mateable in sealed relationship with the upper and lower outer boundary mating portions, respectively, of the trim member to form an outer boundary. Mating portions of the trim member and the seal are joined together to form an outer boundary.

Abstract: A low-profile, backlit panel assembly and a controller for displaying images and/or data within a passenger compartment of a vehicle are provided. The assembly includes a substrate panel perforated with a two-dimensional array of closely-spaced holes. The panel is configured to be attached to a support structure of the vehicle. The assembly further includes a plurality of semiconductor-based, lighting devices supported at a back surface of the panel. Each of the lighting devices includes at least one lighting element. Each of the lighting elements is individually addressable by the controller to control luminous intensity of the light emitted by the at least one lighting element. Each of the lighting devices is aligned with one of the holes so that light emitted by each of the lighting devices travels through its hole to the passenger compartment in the form of a pixel of a two-dimensional image.

Abstract: A sandwich-type, composite component having a sprayed backside protective coating is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core positioned between and bonded to the outer layers and having a plurality of cavities. The protective coating is integrally formed from an elastomeric material. The material is sprayed to form the coating and the coating is bonded to the outer surface by curing. The component may be a vehicle interior component such as a vehicle load floor component.

Abstract: A sandwich-type, composite component having an injection molded backside protective covering including 3-D structures which provide at least one pattern at an outer surface of the component is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core bonded to and positioned between the outer layers and having a plurality of cavities. The covering is integrally formed from at least one elastomeric material and includes the 3-D structures bonded to the outer surface by injection molding. The 3-D structures are sized, shaped and arranged in one or more patterns at the outer surface. The one or more patterns may form a textured surface finish, a logo or indicia such as instructions at the outer surface. The component may be a vehicle interior component such as a vehicle load floor component.

Abstract: A vehicular window trim assembly includes a decorative outer trim member having upper and lower outer boundary mating portions formed on the perimeter of the trim member. The assembly also includes a channel-shaped window seal having a mouth to receive a panel-like member and upper and lower outer boundary mating portions formed on the perimeter of the seal mateable in sealed relationship with the upper and lower outer boundary mating portions, respectively, of the trim member to form an outer boundary. Mating portions of the trim member and the seal are joined together to form an outer boundary.

Abstract: An automated method and system for making painted vehicle body panel skins and vehicle body panels, such as instrument panels, are provided wherein throughput and equipment utilization are greatly improved at a relatively low cost. The method includes transferring a mold having a mold surface from an entrance station to a paint station within a dispensing area. The method further includes applying paint on the mold surface to form a layer of paint on the mold surface at the paint station. The method still further includes spraying curable polyurethane elastomer on the painted surface at a spray station within the dispensing area. The paint and spray stations may be coincident.

Abstract: A speaker system such as a sound bar assembly having a plurality of speaker units and improved sound quality is provided. Opposing mating portions of front and back panels of the assembly or system are fused or welded together to form outer boundary and interior joints where the front and back panels are welded together. The front and back panels are spaced apart at their first and second ends to define first and second speaker compartments, respectively, separated by a central compartment. A speaker unit is positioned in each of the speaker compartments. The speaker compartments are acoustically isolated from one another by the interior joints to improve the sound quality.

Abstract: A tackle box for charging electroluminescent lures comprises a container having an interior volume; a cover mateable with the container; one or more racks for receiving and retaining lures, where each rack has a substantially planar shape, is positionable in tracks formed in the interior of the container, and has an array of recesses formed in an upper end to hold lures; a light-transmissive shelf positionable in the container above the one or more racks; and an array of light sources carried on the shelf and energizeable to illuminate electroluminescent lures retained on the one or more racks. The racks can be arrayed in parallel tracks formed in the interior side walls of the container. Each rack is preferably formed with a scallop pattern of recesses on its upper end to hold lures for charging.

Abstract: A speaker system such as a sound bar assembly having a plurality of speaker units and improved sound quality is provided. Opposing mating portions of front and back panels of the assembly or system are fused or welded together to form outer boundary and interior joints where the front and back panels are welded together. The front and back panels are spaced apart at their first and second ends to define first and second speaker compartments, respectively, separated by a central compartment. A speaker unit is positioned in each of the speaker compartments. The speaker compartments are acoustically isolated from one another by the interior joints to improve the sound quality.