Abstract: An air bag assembly, for use with a vehicle having a panel with a breakaway door, includes an air bag housing having first and second housing portions. Each housing portion has a connection flange, and the connection flanges are positioned adjacent each other and secured together. An air bag and inflator are disposed within the air bag housing, and the inflator is operable to inflate the air bag. The assembly further includes a tether having a first end adapted to be secured to the breakaway door of the panel and a second end that is secured between the connection flanges.

Abstract: An in-mold degating device that includes a base having mounting ears for removable attachment to a mold system. The base is removably attached to the die half such that the uppermost surface of the base is flush with the surface of the die half. The insert further includes a body fixed to the base including a pair of opposed surfaces that define predetermined relief angles relative to the base. The body further includes a gate flow passage having an inlet within one of the opposed surfaces and an outlet within the other of the opposed surfaces. The gate flow passage tapers inwardly from the inlet to the outlet. The outlet includes an edge surface that forms an acute angle relative to the gate flow passage. The edge surface defines a shearing edge point that separates the finished molded part from cooled excess material.

Abstract: A vibration dampener for a vehicle to militate against vibration which results in undesirable noise. In an embodiment, the dampener is used in a steering column in the vehicle to militate against the vibration being transmitted to the hands of a driver during operation of the vehicle.

Abstract: Disclosed is a device and method of attaching a housing unit, particularly an instrument cluster housing, to an IP retainer without the necessity of attaching the bottom edge of said housing with fasteners such as screws and the incumbent requirement for fastener driver and driver operator access. This achieved by providing at least one snap-in attachment member on the bottom edge of the housing. The attachment member terminating in a mounting pin mounted in corresponding pin mounts provided in the receiving IP retainer.

Abstract: A thermally controlled storage space system (10), such as for the dashboard (40) of a vehicle (12). The system (10) has a housing (22), which is configured to couple a portion of the vehicles air control system (48), such as a heating system, a ventilation system, or an air-conditioning system. A heat exchanger (26) is coupled to the housing (22) and to a thermoelectric device (28). A temperature sensor (62) generates a temperature signal indicative of the temperature within the housing (22). A controller (18), which is coupled to the thermoelectric device (28), adjusts the temperature within the housing (22) in response to the temperature signal.

Abstract: An injection molding system for forming a molded plastic part including a die having a pair of die halves which mate along their joining surfaces to form a parting line and define a mold cavity, a plurality of ejection pins within at least one of the die halves and operable to move the finished molded part in a direction away from at least one of the die halves, a gate removably mounted to one of the die halves, and a runner. The gate includes an inlet and an outlet having an edge surface extending in a direction generally opposite to the movement of the molded part upon ejection from the mold cavity. Upon separation of the two die halves, the ejection pins are then further operable to remove excess cooled plastic material from the gate and the runner.

Abstract: An air bag deployment door mechanism for the instrument panel of an automotive vehicle. A deployment door is molded integral with the instrument panel retainer and defined by a plurality of closely spaced holes about its perimeter. The spacing between the holes define the physical connection between the deployment door and the instrument panel retainer. A tear initiator is molded into the deployment door which is activated by the inflating air bag. The tear initiator pierces the foam and decorative layers prior the severing of the physical connection between the deployment door and the instrument panel retainer.

Abstract: A method and apparatus for mounting knee and glove box surface configurations on a support structure utilizing a universal energy-absorbing bracket capable of being mounted on cross-car beams of a number of different car lines for supporting the different knee and glove box surface configurations.

Abstract: An air bag assembly, for mounting on a panel having a recess, includes an air bag adapted to be positioned in the recess, and an inflator associated with the air bag for inflating the air bag. The inflator is further adapted to be positioned in the recess and mounted to the panel. The assembly also includes a cover configured to cover the air bag and to release the air bag when the air bag is inflated. The cover has a side wall with an enlarged end, and the enlarged end is configured to be trapped between the inflator and the panel when the inflator is mounted to the panel, so as to secure the cover to the panel.

Abstract: An emergency locking console assembly (10) for automatically locking in a closed position during a vehicular collision is provided. The assembly (10) includes an open-topped container (18) that is coupled to a vehicle (12). This container (18) has a lid (20) couple thereto for enclosing various items within the assembly (10). In addition, the assembly (10) includes an inertia actuated locking mechanism (34) coupled to the container (18) for the purpose of automatically engaging the lid (20) and locking the assembly (10) in a closed position during a vehicular collision.

Abstract: A glove box damper device is disclosed having a cam rotationally moving against a spring to slow the descent of glove box lid during opening. The glove box damper device is easy to install, has reduced costs over many previous damper devices and reduces breakage. The glove box damper is suitable for use with glove box lids having a sheet metal insert to meet automotive safety requirements.

Abstract: A method of manufacturing a vehicle pull handle assembly includes injection molding a pull strap portion in the first shot of a multi-shot molding process. The pull strap portion includes a first pivot joint member. A base is over-molded onto the pull strap portion in the second shot of the multi-shot molding process. The base includes a second pivot joint member which pivotally mates with the first pivot joint member but does not chemically bond with the first pivot joint member in the final molded pull handle assembly.

Abstract: A method for manufacturing a modular plate for a cockpit-type instruments panel includes molding a modular plate having an outer peripheral rim and a plurality of apertures in a first shot of an two-shot injection molding process, and then overmolding a plurality of seals about the outer rim and at least one aperture during a second shot of the two-shot process.

Abstract: A vehicle cup holder assembly comprising a vehicle component including a cup holder opening therein and an aperture formed adjacent the cup holder opening. A base injection molded from a first material and including an attachment feature which extends into the aperture and is selectively movable between extended and collapsed positions with respect to the aperture. An arm cup injection molded from a second material at least partially around the base and including an arm, wherein the second material is overmolded onto the base but not chemically bonded to the first material so that the arm cup and arm are rotatable with respect to the base for adjustably securing a cup in the cup holder opening.

Abstract: A vehicle instrument panel assembly includes a substrate having a recess formed therein with a deployable air bag assembly positioned within the recess. The air bag assembly is attached to the substrate by an attachment bolt. An air bag cover is secured to the substrate by a snap-in attachment feature to enclose the air bag assembly within the recess. The air bag cover includes an integrally molded tether which is connected to the attachment bolt such that deployment of the air bag assembly causes detachment of the snap-in attachment feature to allow air bag deployment outside the recess while the tether maintains its connection with the attachment bolt.

Abstract: An outlet for a climate control system includes a support member and multiple vanes pivotally connected to the support member. The outlet also includes a link attached to the vanes such that the vanes are pivotable in unison. Furthermore, the link comprises a soft, rubbery material having a Shore A hardness in the range of 40 to 80.

Abstract: The present invention provides a method of manufacturing a vehicle cup holder arm, and a vehicle cup holder assembly produced thereby. The method includes injection molding a first material to form a base including an attachment feature adapted for engagement within an aperture adjacent a cup holder opening in a vehicle. A second material is injection molded to form an arm cup around the base and includes an arm. The second material does not chemically bond to the first material so that the arm cup and arm are rotatable with respect to the base for adjustably securing a cup in the cup holder opening. A third material is injection molded onto the arm to form a soft rubber grip for engaging a cup. The cup holder arm may be movable vertically for adjustment with respect to differently-sized cups.

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 method for supporting an electrical component in a vehicle includes providing an electrical component, selecting a vehicle component to be made at least in part of a flexible foam material, and producing the vehicle component such that the electrical component is embedded in the foam material of the vehicle component, thereby providing support for the electrical component.

Abstract: A wire harness comprises a plurality of wires routed along a surface of a trim panel. The wires are encased and secured to the trim panel by a foam polymer. The wires are first routed on a surface of the trim panel. A foam gun including a wire guide and a nozzle is moved along the length of the wires, simultaneously gathering and aligning the wires and spraying a foamable liquid onto the wires. The liquid polymer foams and cures, thereby securing the wires to the trim panel and encasing the wires.