Abstract: A method of making a visor for a vehicle includes providing a mold having a three dimensional cavity, introducing a slide-on-rod pivot mechanism and a flow distributor into the cavity, simultaneously co-extruding a cover layer of material and a core layer of material into the cavity and around the hardware component, inflating the cover and core layers of material within the cavity; and removing the visor from the mold. A visor for a vehicle includes a visor body formed in a mold from a first layer and a second layer of co-extruded materials in a single blow molding operation. The first layer is a resilient material that forms a cover layer and the second material is a rigid material that forms a core portion of the visor. A decorative element integrally formed with the cover layer.

Abstract: A method of making a visor for a vehicle includes providing a mold having a three dimensional cavity, introducing at least one hardware component into the cavity, simultaneously co-extruding a cover layer of material and a core layer of material into the cavity and around the hardware component, inflating the cover and core layers of material within the cavity; and removing the visor from the mold. A visor for a vehicle includes a first panel and a second panel joined together along a common perimeter and having a hollow region therebetween, the first panel and the second panel integrally formed from an inner layer of a structural material and an outer layer of an upholstery material that are coextruded in a blow molding operation.

Abstract: An extrusion made from metal or plastic extends along the siderail of a vehicle and acts as a head impact countermeasure, and in the preferred embodiment as a platform for the attachment of any of a variety of siderail attachments, such as grab handles, coat hooks, visor tracks, etc. The components can be attached in a way which permits them to slide to the appropriate position and be locked into place. The hollow interior of the extrusion can be used to house additional safety components, such as a side air bag.

Abstract: An inflatable headliner system is mounted below a vehicle roof. It deforms upon an accident/impact toward vehicle occupants. In the preferred embodiment, inflatable portions surround a central section of an inflatable layer. Individual portions may be separated by passageways. If cross bows are employed in the vehicle roof structure, an embodiment utilizes inflatable portions beneath the cross bows.