Abstract: The present invention involves a molded seamless vehicle interior panel having a seamless airbag door for concealing an airbag. The panel includes a retainer portion and a door portion circumscribed by the retainer portion. The retainer portion is disposed adjacent the airbag of the vehicle and has an opening to define a void over the airbag. The retainer portion has an appearance finish of an aesthetic look. The door portion disposed within the void integrally circumscribed by the retainer portion to define the seamless airbag door through which the airbag may deploy. The door portion has an appearance finish compatible to the appearance of the retainer portion such that no seam is visible. The door portion is molded together with the retainer portion and formed of a material different than the material of the retainer portion.

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: 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: 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: 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 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: 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: 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 vehicle airbag system includes a panel having a breakaway door, and an airbag housing that extends behind the breakaway door. An inflatable airbag cushion and an inflator are disposed within the airbag housing, and the inflator is operable to inflate the airbag cushion. The system also includes a tether having a first portion attached to the breakaway door of the panel and a second portion attached to at least one of the panel and the airbag housing. Furthermore, the tether comprises natural fibers.

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 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: A molded energy absorber includes two sections connected by a plurality of hinge elements. One section has a plurality of telescopically crushable tubular cylinders integrally molded thereon. The two sections are folded together and the energy absorber attaches to a structural vehicle pillar on the inside of the vehicle. Upon impact, the tubular cylinders are fractured and crush telescopically, thereby dissipating much of the impact energy.

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: 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 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: 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: The present invention involves a molded seamless vehicle interior panel having a seamless airbag door for concealing an airbag. The panel includes a retainer portion and a door portion circumscribed by the retainer portion. The retainer portion is disposed adjacent the airbag of the vehicle and has an opening to define a void over the airbag. The retainer portion has an appearance finish of an aesthetic look. The door portion disposed within the void integrally circumscribed by the retainer portion to define the seamless airbag door through which the airbag may deploy. The door portion has an appearance finish compatible to the appearance of the retainer portion such that no seam is visible. The door portion is molded together with the retainer portion and formed of a material different than the material of the retainer portion.

Abstract: The present invention involves a molded seamless vehicle interior panel having a seamless airbag door for concealing an airbag. The panel includes a retainer portion and a door portion circumscribed by the retainer portion. The retainer portion is disposed adjacent the airbag of the vehicle and has an opening to define a void over the airbag. The retainer portion has an appearance finish of an aesthetic look. The door portion disposed within the void integrally circumscribed by the retainer portion to define the seamless airbag door through which the airbag may deploy. The door portion has an appearance finish compatible to the appearance of the retainer portion such that no seam is visible. The door portion is molded together with the retainer portion and formed of a material different than the material of the retainer portion.

Abstract: A configurable instrument panel design is provided that integrates component designs so that an instrument panel can be configured for a specific vehicle content as late in the vehicle assembly process as possible. An electrical system is provided that utilizes a flat flexible cable that is the same for every vehicle independent of vehicle content. Electronic modules are provided with connectors that only connect to the specific wires required for a particular module. A plurality of different multiplexing links are built-in to the electrical system and wiring arrangement allowing the system to be universal across all possible instrument panel configurations. This allows the system to accommodate lower option vehicles at a lower cost than conventional technology. Thin smart switch units can be installed at a final stage in the instrument panel assembly process to configure the feature content of the instrument panel.

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.