Abstract: An opening switch for a vehicle having a decorative cover assembly, a sensor housing region, and a microelectromechanical (MEMS) sensor mounted in the sensor housing region. The decorative cover assembly has an inner surface, an outer surface, an anchor portion, and a deflection portion. When contact from a vehicle user occurs at the deflection portion in the decorative cover assembly, a microdeflection occurs. The microdeflection has a microdeflection apex, and the microdeflection apex is spaced from other surfaces in the sensor housing region when the contact from the user occurs at the deflection portion in the decorative cover assembly. The MEMS sensor is configured to generate an output signal that is indicative of a force of the contact from the user. The force integrated switch can include haptic feedback and/or backlighting.

Abstract: An opening switch for a vehicle having a decorative cover assembly, a sensor housing region, and a microelectromechanical (MEMS) sensor mounted in the sensor housing region. The decorative cover assembly has an inner surface, an outer surface, an anchor portion, and a deflection portion. When contact from a vehicle user occurs at the deflection portion in the decorative cover assembly, a microdeflection occurs. The microdeflection has a microdeflection apex, and the microdeflection apex is spaced from other surfaces in the sensor housing region when the contact from the user occurs at the deflection portion in the decorative cover assembly. The MEMS sensor is configured to generate an output signal that is indicative of a force of the contact from the user. The force integrated switch can include haptic feedback and/or backlighting.

Abstract: A vehicle interior panel can be constructed to include accent lighting in the form of an electroluminescent element that includes a thin multi-layer film disposed over a substrate. The multi-layer film is sufficiently thin to conform to the shape of the substrate surface over which it is disposed, making it possible to integrate accent lighting with the panel in a manner that gives the impression that the light is produced at the visible outer surface of the panel. The substrate plays a dual role, providing both the overall shape, contour, and structure for the panel while additionally functioning as one of the electrodes of the electroluminescent element. The substrate includes an electrically active material that is integrated into a plastic material either by blending an additive with the plastic material prior to molding the substrate, or by insert molding and embedding electrically conductive material into the plastic material.

Abstract: A vehicle interior panel can be constructed to include accent lighting in the form of an electroluminescent element that includes a thin multi-layer film disposed over a substrate. The multi-layer film is sufficiently thin to conform to the shape of the substrate surface over which it is disposed, making it possible to integrate accent lighting with the panel in a manner that gives the impression that the light is produced at the visible outer surface of the panel. The substrate plays a dual role, providing both the overall shape, contour, and structure for the panel while additionally functioning as one of the electrodes of the electroluminescent element. The substrate includes an electrically active material that is integrated into a plastic material either by blending an additive with the plastic material prior to molding the substrate, or by insert molding and embedding electrically conductive material into the plastic material.

Abstract: A vehicle interior panel includes an adjustable locator. The adjustable locator is operable to move a panel body after the panel body is mounted to a vehicle body and enables alignment of an aesthetic feature line with a complimentary feature line of an adjacent vehicle interior panel. A post of the adjustable locator can engage a receiver of the vehicle body at a fixed location while a working surface of the adjustable locator exerts a force on a reaction surface of the panel body to move the panel body. The adjustable locator can include gear teeth, a cam surface, ratcheting features, an adjustment rotor, or any combination thereof.

Abstract: A vehicle interior panel includes an adjustable locator. The adjustable locator is operable to move a panel body after the panel body is mounted to a vehicle body and enables alignment of an aesthetic feature line with a complimentary feature line of an adjacent vehicle interior panel. A post of the adjustable locator can engage a receiver of the vehicle body at a fixed location while a working surface of the adjustable locator exerts a force on a reaction surface of the panel body to move the panel body. The adjustable locator can include gear teeth, a cam surface, ratcheting features, an adjustment rotor, or any combination thereof.

Abstract: Plastic panels for motor vehicles and methods for making plastic panels are provided herein. In one example, a plastic panel for a motor vehicle comprises a first molded microcellular polymeric substrate and a second polymeric substrate. The first molded microcellular polymeric substrate has a first outer skin, a second outer skin, a microcellular structured core that is disposed between the first and second outer skins, and a wall that extends between the first and second outer skins to define a support structure in the microcellular structured core. The second polymeric substrate comprises a weld feature that is aligned with the support structure and that is coupled to the second outer skin of the first molded microcellular polymeric substrate.

Abstract: A non-visible tear seam can be formed in a vehicle interior panel in a mechanical piercing process with a piercing tool that radially supports a needle during the process. The radial support enables the use of higher gauge needles and the formation of non-visible microholes through a visible surface of the panel. The piercing tool is capable of forming each of the microholes of the tear seam individually and may be disposable and/or may be configured with a replaceable needle.

Abstract: Plastic panels for motor vehicles and methods for making plastic panels are provided herein. In one example, a plastic panel for a motor vehicle comprises a first molded microcellular polymeric substrate and a second polymeric substrate. The first molded microcellular polymeric substrate has a first outer skin, a second outer skin, a microcellular structured core that is disposed between the first and second outer skins, and a wall that extends between the first and second outer skins to define a support structure in the microcellular structured core. The second polymeric substrate comprises a weld feature that is aligned with the support structure and that is coupled to the second outer skin of the first molded microcellular polymeric substrate.

Abstract: Interior panels having integrated airbag deployment doors for motor vehicles, and methods for making such interior panels are provided herein. In one example, an interior panel comprises a substrate that comprises a first PP/TPO material. An airbag chute-door assembly comprises a chute portion that has a chute wall. The chute wall at least partially surrounds an interior space that is sized to permit passage of an airbag during deployment. A first door flap portion is disposed adjacent to the interior space. The first door flap portion comprises a first door flap section and at least one first weld feature. The at least one first weld feature comprises a second PP/TPO material and attaches the first door flap section to the substrate. A first hinge pivotally connects the first door flap section to the chute portion. The first hinge comprises a TPE material.

Abstract: A door module of a vehicle includes: a panel of door glass including an upper peripheral edge and a lower peripheral edge; a lift plate coupled to the lower peripheral edge of the door glass such that a regulator may move the door glass between a full-up position and a full-down position within the door module via the lift plate; and a position block movable within the door module to: (i) a first position below the lift plate such that the lift plate rests on the position block and the door glass is at a position above the full-down position when the door glass is inserted into the lift plate during manufacture, and (ii) after such insertion, a second position that permits the lift plate to move further downward such that the door glass is at the full-down position.

Abstract: A door module of a vehicle includes: a panel of door glass including an upper peripheral edge and a lower peripheral edge; a lift plate coupled to the lower peripheral edge of the door glass such that a regulator may move the door glass between a full-up position and a full-down position within the door module via the lift plate; and a position block movable within the door module to: (i) a first position below the lift plate such that the lift plate rests on the position block and the door glass is at a position above the full-down position when the door glass is inserted into the lift plate during manufacture, and (ii) after such insertion, a second position that permits the lift plate to move further downward such that the door glass is at the full-down position.

Abstract: A lift plate for holding a window pane is disclosed which may include a clamp operable to grasp a window pane with a grasping force responsive to a force of insertion of the window pane into the clamp; and a reinforcement system operable to follow a movement of at least a portion of the clamp and to prevent retraction of the clamp from a grasping position with respect to the window pane.

Abstract: An apparatus for locking a door trim panel to a door module includes: at least one hook depending from an inwardly directed surface of said door trim panel; an elongate locking element having a first end and a second end, the first end being connected to an end of the hook by way of a hinge; at least one receiver depending from an opposing surface of said door module and being operable to engage said hook, the receiver including an edge directed toward the opposing surface of the door module; and a cleat depending from the surface of the door trim panel and operable to engage the second end of the locking element when the locking element is a locking position, wherein the edge of the receiver engages the locking element and prevents the hook from disengaging from the receiver once the second end of the locking element engages the cleat.

Abstract: An apparatus for locking a door trim panel to a door module includes: at least one hook depending from an inwardly directed surface of said door trim panel; an elongate locking element having a first end and a second end, the first end being connected to an end of the hook by way of a hinge; at least one receiver depending from an opposing surface of said door module and being operable to engage said hook, the receiver including an edge directed toward the opposing surface of the door module; and a cleat depending from the surface of the door trim panel and operable to engage the second end of the locking element when the locking element is a locking position, wherein the edge of the receiver engages the locking element and prevents the hook from disengaging from the receiver once the second end of the locking element engages the cleat.