Abstract: An expanded laminate and method of forming an expanded laminate are disclosed. In at least one embodiment, the method includes selectively applying a relatively high temperature-resistant material to a surface of a first metal sheet to form a covered portion and an uncovered portion and diffusion bonding the first metal sheet to a second metal sheet at the uncovered portion to form a bonded region and an unbonded region. Pressurized gas may be introduced between the first and second metal sheets to expand the first and second metal sheets in the unbonded region. The metal sheets may be aluminum sheets. The sheets may be positioned in a die having a plurality of cavities such that when the pressurized gas is introduced the sheets expand into the cavities. The diffusion bonding may be performed by applying pressure, for example, using rollers.

Abstract: A seat assembly for a vehicle includes a seat, and a first seatbelt having a first end and a second end. The first end of the first seatbelt is coupled to the seat. The seat assembly includes a latch plate and a second seatbelt. The latch plate is fixed to the second end of the first seatbelt, and the second seatbelt is slideably coupled to the latch plate. The first seatbelt and the second seatbelt increase lateral support of the occupant during, e.g., a rollover event, oblique or side impacts.

Abstract: A seat belt buckle assembly includes a buckle housing; a plate extending from the buckle housing and defining a slot; and a bracket including a rivet engaged in the slot. The plate and rivet are configured such that, in response to an impact force that exceeds a threshold acting to pull the buckle housing away from the bracket, the slot plastically deforms, permitting the buckle housing and plate to translate relative to the bracket.

Abstract: An impact absorbing system includes a vehicle floor, a rocker, and a reinforcement member. The rocker is disposed below the vehicle floor. The reinforcement member is supported on the rocker. The reinforcement member is deployable from an undeployed position beneath the vehicle floor to a deployed position above the vehicle floor.

Abstract: A method of adjusting a stamping die is provided. The method includes providing a two-sided stamping die configured to form parts from sheet metal blanks according to a desired geometry upon closing the die, adjusting the desired geometry of the part, and repeatedly depositing layer upon layer of material onto a first side of the die in a stacked configuration to modify the geometry of the first side of the die such that the die forms parts from sheet metal blanks according to the adjusted desired geometry.

Abstract: An energy absorber including a cover defining a cavity and a lattice core. The lattice core includes rod-shaped links having first and second ends connected at spaced nodes to form a three-dimensional structure disposed inside the cavity. The lattice core includes a first portion and a second portion that has a higher density than the first portion. The second portion is arranged behind the first portion relative to an expected direction of an impact with an object that initially contacts the cover in front of the first portion. A third portion may be arranged behind the second portion relative to the expected direction of an impact that has a higher density than the second portion. The first core may be a three-dimensional body having a negative Poisson's Ratio. The lattice core may be formed by an additive printing process.

Abstract: A method of constructing a vehicle component includes depositing a layer of a first metal, extruding a filament of a second metal onto the layer, and depositing a second layer of the first metal on the filament.

Abstract: A seatbelt retractor includes a base, a spool, a cylinder and a cylinder lock. The spool is rotatably coupled to the base and has a piston portion. The cylinder is engaged with the piston portion and therewith defines a first chamber. The piston portion is movable from a first position yielding a first chamber volume to a second position yielding a second chamber volume. The cylinder lock in a first condition rotatably fixes the cylinder to the base. Damping fluid is disposed in the chamber.

Abstract: An automotive armrest includes an elastic core defining a patterned array of channels extending therethrough such that the elastic core exhibits a predetermined target vertical stiffness and a predetermined target lateral stiffness different than the predetermined target vertical stiffness. The automotive armrest also includes a skin arranged with the elastic core.

Abstract: A seatbelt retractor includes a base, a spool, a cylinder, a transfer plate, and a cylinder lock. The spool is rotatably coupled to the base and has a piston portion. The cylinder is engaged with the piston portion and therewith defines a chamber. The piston portion is movable from a first position to a second position. The transfer plate is translateably disposed in the first chamber. The cylinder lock in a first condition rotatably fixes the cylinder to the base. Damping fluid is in the chamber.

Abstract: A vehicle includes a seatback having a rear-mounted and rotationally operable tray table selectively operable between a plurality of rotational positions. An actuator is coupled to the seatback and the tray table, wherein in response to a decelerating impact, the actuator applies a generally downward force that biases the tray table toward a safety position against a back surface of the seatback.

Abstract: The present disclosure is directed to a table that may be selectively stored in a portion of a vehicle console. An outer housing member having a storage cavity therein attaches to a side of the vehicle console. A support shaft supporting a table is mounted for sliding and rotational movement with respect to the vehicle console. The support shaft is slidable in a first direction from a storage position wherein the table is positioned in a vertical orientation in the cavity of the outer housing member. The support shaft is also rotatable 270 degrees from the storage position to move the table into a horizontal use position after removal from the storage position.

Abstract: An airbag assembly includes a base, an airbag supported by the base and defining an inflation chamber, an external tether, and an internal tether. The airbag includes a panel and an extension extending transverse to the panel. The panel includes an internal surface facing the inflation chamber and an external surface facing away from the inflation chamber. The external tether extends from the extension to the external surface of the panel. The internal tether extends from the base to the internal surface of the panel. During a vehicle impact, the momentum of the occupant may move the occupant towards the extension. The extension may absorb energy from the occupant and reduce or prevent the head of the occupant from sliding across the panel and/or rotating.

Abstract: A seat assembly includes a seat back and a headrest adjustably coupled to the seat back. The headrest defines a first guide passage and a second guide passage, each extending through the headrest. The seat assembly includes a retractor and a belt. The belt extends continuously from a first end to a second end. The first end is engaged with the retractor. The belt has a looped portion from the first guide passage to the second guide passage. The belt extends from the looped portion through the first guide passage to the first end, and extends from the looped portion through the second guide passage to the second end.

Abstract: A plus-two belt system is provided. The plus-two belt system is a supplement to a traditional three-point belt system. The plus-two belt system has a longitudinal webbing anchored at a first end and coiled on a retractor at a second end. When an occupant is sensed and the vehicle engine is on, a reminder chime can sound when a magnetic strip in the webbing of the plus-two belt system is detected. The magnetic strip can be detected with a Hall effect sensor and the Hall effect sensor can be located adjacent the retractor.

Abstract: A restraint system includes a housing, a spool rotatably coupled to the housing, and an actuator fixed relative to the housing. The spool has a base plate with holes. The holes are spaced from each other circumferentially about the spool. The actuator has a pin movable between an engaged position extending into one of the holes and a disengaged position spaced from the holes.

Abstract: An inflatable tunnel reinforcement for reinforcing a vehicle tunnel structure includes a first wall, a second wall, and at least one fold connecting the first and second walls. The inflatable tunnel reinforcement further includes an inflator adapted to increase a gas pressure between the first and second walls. In an inflated configuration, the inflatable tunnel reinforcement forms a continuous load path between interior walls of the tunnel structure generally orthogonal to a longitudinal axis of the tunnel structure.

Abstract: A vehicle glove box assembly may include a glove box defining a compartment, a door arranged on the glove box moveable between open and closed positions, and a tray assembly arranged on and hinged to the door and pivotable with respect to the door to provide a flat surface in a deployed position.

Abstract: A retractor assembly includes a housing; a spool rotatably coupled to the housing and defining an axis; a webbing coiled about the spool; a disc in contact with the webbing and movable parallel to the axis; and a linear variable differential transformer including a core movable parallel to the axis with the disc.

Abstract: A vehicle includes seats having both a primary three-point seatbelt and a supplemental two-point seatbelt. Occupation of a first seat is determined. The three-point seatbelt is determined as being one of buckled and unbuckled. The two-point seatbelt is determined as being one of buckled and unbuckled. A warning signal is initiated upon determining that one of the seatbelts is unbuckled and the seat is occupied. The warning signal is terminated upon determining that both of the seatbelts are buckled and that the signal has been initiated.