Abstract: A collapsible storage compartment includes an inner bin with an inner side wall and an inner base wall. The inner side wall is connected to a periphery of the inner base wall to define a cavity. The collapsible storage compartment further includes an outer bin connected to the inner bin. The outer bin includes an outer base wall and a flexible hinge. The flexible hinge is movably connected to the outer base wall and is configured to move the outer base wall between a stowed position and a deployed position, wherein at least a portion of the hinge flexes into the cavity to move the outer base wall toward the inner base wall when the outer base wall is moved from the deployed position to the stowed position.

Abstract: A collapsible storage compartment includes an inner bin with an inner side wall and an inner base wall. The inner side wall is connected to a periphery of the inner base wall to define a cavity. The collapsible storage compartment further includes an outer bin connected to the inner bin. The outer bin includes an outer base wall and a flexible hinge. The flexible hinge is movably connected to the outer base wall and is configured to move the outer base wall between a stowed position and a deployed position, wherein at least a portion of the hinge flexes into the cavity to move the outer base wall toward the inner base wall when the outer base wall is moved from the deployed position to the stowed position.

Abstract: A method and system of manufacturing are provided for using an open pour process with a single tool for a formation process of a component, the formation process including including using no more than a two-layer structure for the component of a first and a second layer wherein the first layer includes: a composite layer formed of a skin layer disposed on a foam layer, wherein the foam layer serves to support the skin layer and as an adhesive between the skin layer and the foam layer to combine both layers into the composite layer and additionally serves as another adhesive between a second layer which the composite layer is disposed thereon, wherein the second layer is a substrate layer formed of a substrate. Then, bonding using a first and a second half of the single tool, the first layer and second layer together.

Abstract: A method of manufacturing a trim component includes forming a skin layer of the trim component, and spraying a foam layer on the skin layer according to a first spray pattern that establishes a first gap in the foam layer arranged as a predetermined tear pattern. The skin layer extends across the first gap. A corresponding trim component has a skin layer with an outer surface and an inner surface opposite the outer surface, and a foam layer sprayed on the inner surface of the skin layer according to a predetermined spray pattern so that the foam layer has a first gap arranged as a predetermined tear pattern, with the skin layer extending across the first gap.

Abstract: A method for manufacturing a trim component includes the following steps: (a) forming an outer skin layer in the shape of a trim component; (b) applying an inner skin layer on the outer skin layer; (c) spraying a foam layer on the inner skin layer; (d) disposing a substrate on the foam layer; and (e) wrapping portions of the inner skin layer, the outer skin layer, and the foam layer around at least one edge of the substrate.

Abstract: A method of manufacturing a trim component includes forming a skin layer of the trim component, and spraying a foam layer on the skin layer according to a first spray pattern that establishes a first gap in the foam layer arranged as a predetermined tear pattern. The skin layer extends across the first gap. A corresponding trim component has a skin layer with an outer surface and an inner surface opposite the outer surface, and a foam layer sprayed on the inner surface of the skin layer according to a predetermined spray pattern so that the foam layer has a first gap arranged as a predetermined tear pattern, with the skin layer extending across the first gap.

Abstract: A method for manufacturing a trim component includes the following steps: (a) forming an outer skin layer in the shape of a trim component; (b) applying an inner skin layer on the outer skin layer; (c) spraying a foam layer on the inner skin layer; (d) disposing a substrate on the foam layer; and (e) wrapping portions of the inner skin layer, the outer skin layer, and the foam layer around at least one edge of the substrate.

Abstract: Interior soft trim components for a vehicle and methods for manufacturing the same are presented. Embodiments of the disclosed soft interior trim components may be manufactured using a spray application process. In some embodiments, the disclosed soft interior trim components may comprise a urethane skin layer and a urethane foam backer layer formed using a spray application process. The skin layer and foam backer layer may be bonded to a substrate material providing structure for the interior trim components. In certain embodiments, the skin layer and foam backer layer may be bonded to the substrate material prior to the foam backer layer curing, thereby allowing for bonding of the skin layer and foam backer layer to the substrate material without the use and/or with reduced use of adhesives.

Abstract: A lighted interior accessory assembly for a vehicle includes an interior accessory such as an armrest or console and a plurality of fasteners mounting the interior accessory on the interior panel. A mounting plate has a light pipe mounted thereon and emitting light along the length of the light pipe. The mounting plate is sandwiched between the armrest and the interior panel so that the mounting plate creates a gap between the armrest and the interior panel through which the light pipe emits light into the vehicle interior. Mounting the armrest directly to the door trim without inter-positioning the mounting plate between the armrest and the door trim eliminates the gap and eliminates the light pipe. Accordingly, a vehicle manufacturer can readily include a lighting feature in a luxury version of the vehicle and omit the lighting feature from a standard version of the vehicle.

Abstract: A fastener is configured to attach to a hole of a primary panel and to mate to a doghouse. The fastener includes a core having a doghouse end and a piercing end; a datum feature; a neck extending from the datum feature toward the doghouse end; a foot feature on the doghouse end; a cone on the piercing end; and at least three snap features, which are symmetric about the core. The cone is configured to pierce any rain paper covering the holes. The doghouse is configured to join a trim component to the fastener. The doghouse includes a fastener end configured to support the fastener and a trim end configured to attach to the trim panel. The doghouse also includes a cradle formed on the fastener end, and configured to hold the fastener, and a collar configured to allow the fastener access to the cradle.

Abstract: A lock indicator arm for a door having a latch mechanism includes a rod portion connectable on a first end to the latch mechanism, and a knob portion located on a second end of the rod portion opposite the first end and formed as a one-piece structure with the rod portion. The rod portion may include a spring region configured to bias the rod portion against either an interior panel, an exterior panel, or both panels. The knob portion and the rod portion of the lock indicator arm may be formed from a matrix material and a filler material. The filler material may include a plurality of fibers, and the plurality of fibers may be oriented substantially longitudinally along the rod portion. The rod portion of the lock indicator arm may have one of an H-shape cross section and a W-shape cross section.

Abstract: A lighted interior accessory assembly for a vehicle includes an interior accessory such as an armrest or console and a plurality of fasteners mounting the interior accessory on the interior panel. A mounting plate has a light pipe mounted thereon and emitting light along the length of the light pipe. The mounting plate is sandwiched between the armrest and the interior panel so that the mounting plate creates a gap between the armrest and the interior panel through which the light pipe emits light into the vehicle interior. Mounting the armrest directly to the door trim without inter-positioning the mounting plate between the armrest and the door trim eliminates the gap and eliminates the light pipe. Accordingly, a vehicle manufacturer can readily include a lighting feature in a luxury version of the vehicle and omit the lighting feature from a standard version of the vehicle.

Abstract: A composite material includes a first layer formed from a thermoformable reinforced thermoplastic composite consolidatable from an initial, lofted state having an initial thickness, to a substantially consolidated state having a final thickness that is less than the initial thickness. The material includes a second layer fused to the first and formed from an expanded polyolefin foam. The foam is compressible from an original form having an original average thickness to a compressed form having a final average thickness that is less than the original average thickness. The second layer has first and second regions in the compressed form. The first region has a first thickness that is less than the original average thickness. The second region has a second thickness that is greater than the first thickness and less than the original average thickness. The material is substantially free from an adhesive disposed between the first and second layers.

Abstract: A fastener for securing a trim panel to a substrate of a door includes a clip portion configured for slideable insertion over an edge of the substrate, and a latch configured for passing through a slot defined by the trim panel from a direction approximately perpendicular relative to a first wall plane. The latch includes at least one finger configured for biasing against the trim panel to limit movement of the trim panel relative to the fastener.

Abstract: A fastener is configured to attach to a hole of a primary panel and to mate to a doghouse. The fastener includes a core having a doghouse end and a piercing end; a datum feature; a neck extending from the datum feature toward the doghouse end; a foot feature on the doghouse end; a cone on the piercing end; and at least three snap features, which are symmetric about the core. The cone is configured to pierce any rain paper covering the holes. The doghouse is configured to join a trim component to the fastener. The doghouse includes a fastener end configured to support the fastener and a trim end configured to attach to the trim panel. The doghouse also includes a cradle formed on the fastener end, and configured to hold the fastener, and a collar configured to allow the fastener access to the cradle.

Abstract: A bracket nut for coupling a fastener to a sheet member is provided. The sheet member defines a first plane and the bracket nut defines a second plane, which is at an offset angle to the first plane. The sheet member defines a first hole substantially perpendicular to the first plane, and the bracket nut is configured to mate with the first hole. A second hole is defined in the bracket nut and is substantially perpendicular to the second plane. The second hole is configured to accept the fastener. The offset angle may be between approximately thirty to approximately sixty degrees. The bracket nut may include a first cantilevered arm and a second cantilevered arm. The first cantilevered arm and the second cantilevered arm are configured to prevent rotation about the first hole.

Abstract: A fastener for securing a trim panel to a substrate of a door includes a clip portion configured for slideable insertion over an edge of the substrate, and a latch configured for passing through a slot defined by the trim panel from a direction approximately perpendicular relative to a first wall plane. The latch includes at least one finger configured for biasing against the trim panel to limit movement of the trim panel relative to the fastener.

Abstract: A lock indicator arm for a door having a latch mechanism includes a rod portion connectable on a first end to the latch mechanism, and a knob portion located on a second end of the rod portion opposite the first end and formed as a one-piece structure with the rod portion. The rod portion may include a spring region configured to bias the rod portion against either an interior panel, an exterior panel, or both panels. The knob portion and the rod portion of the lock indicator arm may be formed from a matrix material and a filler material. The filler material may include a plurality of fibers, and the plurality of fibers may be oriented substantially longitudinally along the rod portion. The rod portion of the lock indicator arm may have one of an H-shape cross section and a W-shape cross section.

Abstract: A bracket nut for coupling a fastener to a sheet member is provided. The sheet member defines a first plane and the bracket nut defines a second plane, which is at an offset angle to the first plane. The sheet member defines a first hole substantially perpendicular to the first plane, and the bracket nut is configured to mate with the first hole. A second hole is defined in the bracket nut and is substantially perpendicular to the second plane. The second hole is configured to accept the fastener. The offset angle may be between approximately thirty to approximately sixty degrees. The bracket nut may include a first cantilevered arm and a second cantilevered arm. The first cantilevered arm and the second cantilevered arm are configured to prevent rotation about the first hole.

Abstract: A vehicle door assembly is provided that includes a retainer that secures to a door body panel, specifically, to the door inner panel, and is configured such that a door trim component or components may be secured to the retainer, rather than directly to the door trim panel. Door trim components of lightweight materials may be used, with the retainer providing the structural integrity required for securement to the door inner panel. Because it is not a visible component in the assembled door, the same retainer design may be used for doors of different models in a given vehicle platform, with different door trim components of different materials or styles consistent with the different models secured to identical retainers.