Abstract: An interior vehicle component comprises a base and a panel coupled to the base. The panel is moveable between a first position and a second position. The panel has a first side and an opposite second side. The first side is configured to be visible to a vehicle occupant when the panel is in the first position. The second side cooperates with the base to define a cavity. The panel has an aperture extending through the first side and the second side. The panel also comprises at least one of a solid state switch and a light source supported at the first side of the panel, and a flexible circuit coupled to a backside of the at least one of the solid state switch and the light source through the aperture.

Abstract: A user interface assembly (100, 104, 200) for operating a system within a vehicle (10) is disclosed that comprises a base (110, 210) and a user interface (100, 104, 200) supported at the base (110, 210) and configured to be selectively actuated for operating the system. The user interface includes a first portion and a second portion. The interface assembly also comprises a light source (140, 240) configured to provide light into the first portion of user interface (100, 104, 200). The user interface (100, 104, 200) is configured to function as a conduit for the light directed into the first portion so that the light can be emitted from the second portion of the user interface (100, 104, 200).

Abstract: A lithium battery for use in a vehicle includes a container, a plurality of positive terminals extending from a first end of the lithium battery, and a plurality of negative terminals extending from a second end of the lithium battery. The plurality of positive terminals are provided in a first configuration and the plurality of negative terminals are provided in a second configuration, the first configuration differing from the second configuration. A battery system for use in a vehicle may include a plurality of electrically connected lithium cells or batteries.

Abstract: A trim panel and method of forming a trim panel for a vehicle. The trim panel can include a localized cushioned portion of softness (150) at pre-selected locations on the panel.

Abstract: The invention is also directed to a method for forming a component for a vehicle. The method comprises forming a substrate in a mold by injecting a first resin into a first cavity, reconfiguring a portion of the mold to form a second cavity, and injecting a second resin into a second cavity; providing a flexible member adjacent at least a portion of the substrate to form a cavity between the substrate and the flexible member; coupling at least a portion of the flexible member to the substrate; and introducing a material into the cavity after securing at least a portion of the flexible member to the substrate.

Abstract: An apparatus and method for making a trim panel. The method includes providing a preform laminate including a compressible material sandwiched between a flexible skin and a back skin. Positioning the preform laminate in the mold. Placing an insert with the preform laminate in the mold to created a step to establish a seam location and define a secondary area on the preform laminate. Compressing the compressible material by introducing a molten polymeric material to the mold forming a substrate and bonding the substrate to the preform laminate forming the trim component. The preform laminate folds onto itself and creates a crease along the step to simulate the seam and provide a contour change with the appearance of cushioning in the secondary area, and removing the trim panel component from the mold.

Abstract: A panel for use in a vehicle interior is disclosed. The panel includes a unitary integral one-piece flexible member (e.g., coverstock) having a first portion with a first ornamental appearance and a second portion with a second ornamental appearance, and a substrate at least partially molded behind the flexible member. A border between the first portion and the second portion is located in a recess formed when the substrate is molded. A method of forming a panel also is disclosed. The method includes moving a first mold section toward a second mold section so that a projection of the mold pushes a portion of the flexible member at least partially into a recess of the mold, and injecting a polymer resin between the flexible member and the first mold section so that the border is located in the recess.

Abstract: An interior vehicle component comprises a base and a panel coupled to the base. The panel is moveable between a first position and a second position. The panel has a first side and an opposite second side. The first side is configured to be visible to a vehicle occupant when the panel is in the first position. The second side cooperates with the base to define a cavity. The panel has an aperture extending through the first side and the second side. The panel also comprises at least one of a solid state switch and a light source supported at the first side of the panel, and a flexible circuit coupled to a backside of the at least one of the solid state switch and the light source through the aperture.

Abstract: A molded article with multi-material or color and soft portions and a method of making the same is disclosed. The molded article comprises a multi injection substrate, and a coverstock or skin. The article is formed by a process wherein the coverstock or skin is secured within the mold, a first material is injected into a first cavity, a retractor member is moved to define a second cavity, and a second material is injected into the second cavity. The first and second materials may be different types of plastic, different colors, or combinations thereof. The first cavity is defined by two mold sections (e.g., a cavity and a core) and the retractor member. The second cavity is also defined by the two mold sections, the retractor member, and the (at least partially) hardened first material. The first material may be configured to couple to the second material by a locking interface provided by recesses and/or projections on the mold sections.

Abstract: A roof system for a vehicle includes a panel assembly having a transparent roof panel (14), a privacy panel (18), and a transparent display panel (16). An image generator (40) is configured to display an image on the display panel (16) and a control system operates the image generator (40) and actuates the privacy panel (18) between a transparent mode and an opaque mode. The system may also includes a perimeter trim member (20) having a perimeter ventilation system surrounding the panels. The transparent display panel (16) may also be provided with a user interface region having instruments, displays and touch-activated switches (52). The system may also include ambient lighting bands (60) adjacent to the perimeter of the panels.

Abstract: A method of forming a panel is disclosed. The method includes forming a flexible skin (22); coupling a compressible material (24) to the skin (22); positioning the skin (22) and compressible material (24) in a mold; and forming a rigid substrate (20) around the skin (22) and compressible material (24) providing a first soft region (12) wherein the compressible material (24) is disposed between the skin (22) and the substrate (20) so that a first soft region (12) is defined by the compressible material (24).

Abstract: A user interface assembly (100, 104, 200) for operating a system within a vehicle (10) is disclosed that comprises a base (110, 210) and a user interface (100, 104, 200) supported at the base (110, 210) and configured to be selectively actuated for operating the system. The user interface includes a first portion and a second portion. The interface assembly also comprises a light source (140, 240) configured to provide light into the first portion of user interface (100, 104, 200). The user interface (100, 104, 200) is configured to function as a conduit for the light directed into the first portion so that the light can be emitted from the second portion of the user interface (100,104, 200).

Abstract: An apparatus and method for making a trim panel. The method includes providing a preform laminate including a compressible material sandwiched between a flexible skin and a back skin. Positioning the preform laminate in the mold. Placing an insert with the preform laminate in the mold to created a step to establish a seam location and define a secondary area on the preform laminate. Compressing the compressible material by introducing a molten polymeric material to the mold forming a substrate and bonding the substrate to the preform laminate forming the trim component. The preform laminate folds onto itself and creates a crease along the step to simulate the seam and provide a contour change with the appearance of cushioning in the secondary area, and removing the trim panel component from the mold.

Abstract: A trim panel and method of forming a trim panel for a vehicle. The trim panel can include a localized cushioned portion of softness (150) at pre-selected locations on the panel.

Abstract: The invention is also directed to a method for forming a component for a vehicle. The method comprises forming a substrate in a mold by injecting a first resin into a first cavity, reconfiguring a portion of the mold to form a second cavity, and injecting a second resin into a second cavity; providing a flexible member adjacent at least a portion of the substrate to form a cavity between the substrate and the flexible member; coupling at least a portion of the flexible member to the substrate; and introducing a material into the cavity after securing at least a portion of the flexible member to the substrate.

Abstract: A molded article, such as a door trim panel, for a vehicle interior comprises a coverstock configured to provide at least a portion of an A-side of the molded article; a decorative element coupled to the coverstock by an adhesive; and a substrate molded behind the coverstock and configured to provide structural support to the coverstock. The decorative element may be an injection molded plastic material. The adhesive may comprise a pressure sensitive adhesive. The coverstock and substrate may comprise a recess for the decorative element to be located at least partially within.

Abstract: A molded article with multi-material or color and soft portions and a method of making the same is disclosed. The molded article comprises a multi injection substrate, and a coverstock or skin. The article is formed by a process wherein the coverstock or skin is secured within the mold, a first material is injected into a first cavity, a retractor member is moved to define a second cavity, and a second material is injected into the second cavity. The first and second materials may be different types of plastic, different colors, or combinations thereof. The first cavity is defined by two mold sections (e.g., a cavity and a core) and the retractor member. The second cavity is also defined by the two mold sections, the retractor member, and the (at least partially) hardened first material. The first material may be configured to couple to the second material by a locking interface provided by recesses and/or projections on the mold sections.

Abstract: A battery system includes a plurality of sleeves modularly coupled together by members provided on an exterior surface of the sleeves. Each of the sleeves is configured to contain an electrochemical cell and comprises an inner surface. A plurality of features extend from the inner surface to define a space between the inner surface and an electrochemical cell provided within the sleeve. An end has a plurality of apertures that are aligned with the space to allow a cooling fluid to enter the sleeve through the apertures and pass adjacent the cell via the spaces to cool the cell.

Abstract: A roof system for a vehicle includes a panel assembly having a transparent roof panel (14), a privacy panel (18), and a transparent display panel (16). An image generator (40) is configured to display an image on the display panel (16) and a control system operates the image generator (40) and actuates the privacy panel (18) between a transparent mode and an opaque mode. The system may also includes a perimeter trim member (20) having a perimeter ventilation system surrounding the panels. The transparent display panel (16) may also be provided with a user interface region having instruments, displays and touch-activated switches (52). The system may also include ambient lighting bands (60) adjacent to the perimeter of the panels.

Abstract: A battery system for a vehicle includes a battery module having a plurality of cells electrically coupled together and a first conductive element for electrically coupling the battery module to other elements in the battery system. The battery system also has a base configured for securing the battery module in place in the vehicle. The base includes a second conductive element for electrically coupling the base to the first conductive element, and a rotatable arm for securing the battery module in place relative to the base. The first conductive element is configured to contact the second conductive element when the rotatable arm is positioned to secure the battery module in place relative to the base.