Abstract: In at least one embodiment, the present invention relates to a trim panel for concealing an air bag. The panel comprises a substrate and a cover over the substrate. The cover includes a cover skin. The panel also comprises a tear seam having at least a portion comprising a pattern of alternating residual wall thicknesses in the panel. At least one embodiment of the present invention also relates to a method for making a trim panel for concealing an air bag.

Abstract: The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Abstract: The present invention provides for an improved trim part, such as an automotive handle, with a soft feel, for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, an automotive handle includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. A handle cover is molded to at least a portion of the substrate by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the handle with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the handle.

Abstract: The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Abstract: An automotive trim assembly adapted to have an airbag deploy through the trim assembly includes a substrate with a deployment door integrally molded with the substrate and having a front surface adapted to face the interior of the automobile and a back surface opposite the front surface. The airbag is adapted to be stored behind the deployment door, which is adapted to open when the airbag is deployed. A cover is molded onto at least a portion of the substrate and deployment door and includes an inner and outer layer of a polymer material having a substantially non-cellular structure and an inner core having a cellular structure positioned between the inner and outer layers. The cover is adapted to keep the door attached to the trim assembly when the airbag is deployed.

Abstract: In one advantageous embodiment of the claimed invention, an integral cushioned trim panel (14a-14c) for a vehicle passenger cabin (10) is provided. The integral cushioned trim panel (14a-14c) includes a substrate (22) for attachment to a predetermined portion (12a-12c) of the vehicle. The substrate (22) has a cover member (24) coupled thereto for substantially covering the substrate (22). In addition, the substrate (22) and the cover member (24) have a cushioning member (16) disposed therebetween. The cushioning member (16) is injection molded between the substrate (22) and the cover member (24) for forming an integral construction, minimizing the manufacturing cycle time, and decreasing the costs associated therewith.

Abstract: A method of manufacturing an airbag assembly and a trim component for vehicle including the step of providing a first mold structure having a first surface formed therein, a second mold structure having a second surface formed therein and a third mold structure having a third surface formed therein. The first mold structure and the second mold structure are positioned to define a first cavity. A first material is introduced into the first cavity to form a substrate. The substrate and the third mold structure are positioned to define a second cavity. A second material is introduced into the second cavity to form at least one of a portion of an airbag assembly and an outer layer overmolded onto the substrate. Additionally, a scrim material may be disposed within the second cavity to produce a hinge having an embedded layer of scrim material.

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 interior vehicle trim panel includes a substrate having a front face and an under face. The under face has a tear seam to allow an airbag to exit the substrate when the airbag is deployed. The tear seam defines an airbag door. The outer layer is bonded to the front face of the substrate. A portion of the outer layer defines a hinge member for the airbag door. The outer layer is preferably mechanically bonded to the substrate in a mold, thereby forming an overmolded interior vehicle trim panel. Preferably, the hinge member of the outer layer is thicker relative to a region of the outer layer adjacent the airbag door.

Abstract: An automotive assembly having an integrated spring mechanism. The assembly includes a first member and a second member pivotally coupled to the first member and moveable between a first and second position with respect to the first member. The assembly further includes a resilient element integrally molded with one of the first and second members. The resilient element includes an extension portion having a free end that is coupled to the other one of the first and second members. The extension portion imposes a force on the second member to bias the second member in at least one direction. A method of making the assembly includes a two shot molding process where the one of the first and second members is formed in a first shot of the molding operation and the resilient element is integrally molded thereto in the second shot of the molding operation.

Abstract: A cross beam assembly extends between side frame members of a vehicle and includes a beam having a hollow interior. The beam defines an opening formed therein. The assembly further includes an air bag inflator assembly having a source of pressurized gas for expelling gas to inflate an air bag. The inflator assembly is disposed within the hollow interior of the beam such that activation of the inflator assembly expels gas through said opening.

Abstract: A method of forming an airbag assembly for a vehicle including the steps of providing a sheet of hinge material, where the hinge material includes a sheet of scrim material encapsulated within a polymer. Next, a panel is provided that is formed of a substrate material. An under face of the panel may have a tear seam to allow an airbag to exit the panel body when the airbag is deployed, and the tear seam may define an airbag door. Next, a first portion of the sheet of hinge material is secured to the panel within the airbag door defined by the tear seam. Securing the hinge material to the panel may occur by vibration welding a portion of the hinge material to the panel. A second portion of the sheet of hinge material is secured to the airbag housing and an airbag housing is secured to the panel. The hinge material may be secured to the airbag housing such that a third portion of the sheet of hinge material forms a loop.

Abstract: The present invention provides for an improved trim part, e.g. a bolster or trim plate, with integrated appliqué for use in a trim assembly, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, the trim part, i.e. a bolster, includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An appliqué is provided in a second shot mold cavity then a cover is formed between the substrate and appliqué by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The formed cover is integrally molded to at least a portion of the substrate and the appliqué to form a trim part with integrated appliqué.

Abstract: An interior vehicle trim panel includes a panel body having a front face and an under face. The under face has a tear seam to allow an airbag to exit the panel body when the airbag is deployed. The tear seam defines an airbag door. A sheet of hinge material attached to the under face of the airbag door of the panel body. An airbag collar is attached to the under face of the panel body about the airbag door. An airbag housing is attached to the airbag collar, such that a portion of the sheet of hinge material is secured between the airbag collar and the airbag housing, thereby forming an interior vehicle trim panel.

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: In at least one embodiment, the present invention relates to a trim panel for concealing an air bag. The panel comprises a substrate and a cover over the substrate. The cover includes a cover skin. The panel also comprises a tear seam having at least a portion comprising a pattern of alternating residual wall thicknesses in the panel. At least one embodiment of the present invention also relates to a method for making a trim panel for concealing an air bag.

Abstract: A door trim panel for a door frame of a motor vehicle. The door trim panel includes a main body portion adapted to be removably secured to the door frame and a bolster removably secured to the main body portion. The bolster covers an access opening in the main body portion. The bolster includes a substrate having a bolster portion integrally formed with an armrest portion. A cover is integrally molded with the substrate and includes a first portion overlying the bolster portion and having a first thickness, and a second portion overlying the armrest portion and having a second thickness greater than the first thickness to provide a softer feel. The bolster may be made in a two shot molding process with the substrate being formed in the first shot of the molding process and the multi-feel cover being formed in the second shot of the molding process.

Abstract: An overmolded interior vehicle trim panel includes a substrate having a front face and an under face. The under face has a tear seam integrally molded therein to allow an airbag to exit the substrate when the airbag is deployed. The tear seam defines an airbag door. An outer layer is bonded to the front face of the substrate in a mold, thereby forming an overmolded interior vehicle trim panel. The trim panel can include a sheet of hinge material attached to one of the substrate and the outer layer of the overmolded interior trim panel. A portion of the sheet of hinge material defines a hinge member.

Abstract: An air delivery system (10) for a vehicle (12) includes an air plenum (42) and a coupling joint (14) that is coupled to the air plenum (42). The coupling joint (14) is configured to reside between and is hidden by overlapping sections (34,36) of a vehicle housing (16). An air transfer device (50) passes air through the air plenum (42) and the coupling joint (14).

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.