Abstract: An integrated structural system for a vehicle is provided. The integrated structural system having a molded duct system configured to guide airflow, the molded duct system having a first section and a second section, the molded duct system configured to provide a supporting surface; and a metal structure, the metal structure integrated with the molded duct system by a means for integrating the metal structure with the molded duct system forming an integrated structural load path assembly, the integrated structural load path assembly being configured as a load bearing area to distribute a load on the supporting surface over the integrated structural load path assembly, wherein the means for integrating the metal structure with the molded duct system includes one of sonic welding, heat staking, insert molding, and gluing.

Abstract: An integrated structural system for a vehicle is provided. The integrated structural system having a molded duct system configured to guide airflow, the molded duct system having a first section and a second section, the molded duct system configured to provide a supporting surface; and a metal structure, the metal structure integrated with the molded duct system by a means for integrating the metal structure with the molded duct system forming an integrated structural load path assembly, the integrated structural load path assembly being configured as a load bearing area to distribute a load on the supporting surface over the integrated structural load path assembly, wherein the means for integrating the metal structure with the molded duct system includes one of sonic welding, heat staking, insert molding, and gluing.

Abstract: An integrated structural system for a vehicle is provided. The integrated structural system includes a molded duct system configured to guide airflow having a first section and a second section and configured to operably attach a vehicle component thereto. The integrated structural system also includes a metal structure integrated with the molded duct system by means for integrating the metal structure with the molded duct system forming an integrated structural load path assembly. The integrated structural load path assembly is configured as a load bearing area to distribute a load of the vehicle component operably attached thereto. The means for integrating the metal structure with said molded duct system include, but not limited to, at least one of, sonic welding, heat staking, insert molding, and gluing.

Abstract: An integrated structural system for a vehicle is provided. The integrated structural system includes a molded duct system configured to guide airflow having a first section and a second section and configured to operably attach a vehicle component thereto. The integrated structural system also includes a metal structure integrated with the molded duct system by means for integrating the metal structure with the molded duct system forming an integrated structural load path assembly. The integrated structural load path assembly is configured as a load bearing area to distribute a load of the vehicle component operably attached thereto. The means for integrating the metal structure with said molded duct system include, but not limited to, at least one of, sonic welding, heat staking, insert molding, and gluing.

Abstract: An integrated structural system for a vehicle is provided. The integrated structural system includes a molded duct system configured to guide airflow having a first section and a second section and configured to operably attach a vehicle component thereto. The integrated structural system also includes a metal structure integrated with the molded duct system by means for integrating the metal structure with the molded duct system forming an integrated structural load path assembly. The integrated structural load path assembly is configured as a load bearing area to distribute a load of the vehicle component operably attached thereto. The means for integrating the metal structure with said molded duct system include, but not limited to, at least one of, sonic welding, heat staking, insert molding, and gluing.

Abstract: An instrument panel and method of making an instrument panel for use in a vehicle having a passenger side airbag module is disclosed. The instrument panel comprising: a first outer layer having a show surface and an inner surface; an intermediary layer disposed on the inner surface; an inner layer disposed on the intermediary layer; a plurality of cuts in the show surface, the plurality of cuts defining a deployable door in the instrument panel and the plurality of cuts in the show surface are not visually perceivable. The plurality of cuts being in the show surface of the first outer layer and the plurality of cuts do not extend all the way through the first outer layer.

Abstract: An integrated structural system for a vehicle is provided. The integrated structural system includes a molded duct system configured to guide airflow having a first section and a second section and configured to operably attach a vehicle component thereto. The integrated structural system also includes a metal structure integrated with the molded duct system by means for integrating the metal structure with the molded duct system forming an integrated structural load path assembly. The integrated structural load path assembly is configured as a load bearing area to distribute a load of the vehicle component operably attached thereto. The means for integrating the metal structure with said molded duct system include, but not limited to, at least one of, sonic welding, heat staking, insert molding, and gluing.

Abstract: An integrated structural system for a vehicle is provided. The integrated structural system includes a molded duct system configured to guide airflow having a first section and a second section and a vehicle component operably attached thereto. The integrated structural system also includes a metal structure integrated with the molded duct system by means for integrating the metal structure with the molded duct system forming an integrated structural load path assembly. The integrated structural load path assembly is configured as a load bearing area to distribute a load of the vehicle component operably attached thereto. The means for integrating the metal structure with said molded duct system include, but not limited to, at least one of, vibration welding, sonic welding, heat staking, insert molding, gluing, and mechanical fastening.

Abstract: A skin layer for covering a dash panel structure in overlying relation to an air bag cushion assembly. The skin layer is of a multi-layered construction including a top layer of virgin polymeric material forming a show surface of controlled predefined color across the vehicle dash panel and an underlying layer of regrind material formed from the scraps of material generated during molding and trimming of the dash panel covers. A tear seam may be scored across the underside of the skin extending into the underlying layer of recycled material in a desired break-out pattern for the air bag cushion. The skin layer may be disposed across an underlying layer of foam which in turn is disposed across a supporting panel structure.

Abstract: According to the present invention, an instrument panel having an instrument panel cover including a hidden deployment region integrally formed within an inner surface thereof by an ultrasonic embossing process is provided. More specifically, the deployment region comprises at least one and preferably a plurality of scores or cuts formed in the inner surface according to a predetermined pattern. The scores represent weakened portions of the instrument panel cover designed so that the force of an inflating air bag cushion causes the instrument panel cover to separate along the scores to thereby provide an opening for the inflating air bag cushion to deploy therethrough and be directed into the passenger compartment of a vehicle. The deployment region may be defined by any number of scores and therefore may have a variety of patterns, including but not limited to “H” pattern, “U” pattern, and “I” pattern.

Abstract: A skin layer for covering a dash panel structure in overlying relation to an air bag cushion assembly. The skin layer is of a multi-layered construction including a top layer of virgin polymeric material forming a show surface of controlled predefined color across the vehicle dash panel and an underlying layer of regrind material formed from the scraps of material generated during molding and trimming of the dash panel covers. A tear seam may be scored across the underside of the skin extending into the underlying layer of recycled material in a desired break-out pattern for the air bag cushion. The skin layer may be disposed across an underlying layer of foam which in turn is disposed across a supporting panel structure.

Abstract: A structural attachment system for a vehicle is provided. The structural attachment system includes a first structural member and a vehicle component. The structural attachment system also includes an attachment assembly arranged relative to the first structural member and the vehicle component. The attachment assembly is designed and positioned to reinforce a load bearing area and to distribute a load of the vehicle component over the first structural member.

Abstract: A storage unit is provided for selectively heating and/or cooling items placed therein. The storage unit has a first storage compartment and a second storage compartment. A thermoelectric module is positioned in between the first and second storage compartments. The thermoelectric module regulates and maintains various desired temperatures within the storage compartments. Particularly, the thermoelectric module is capable of heating the first storage compartment and cooling the second storage compartment.

Abstract: A storage unit is provided for selectively heating and/or cooling items placed therein. The storage unit has a first storage compartment and a second storage compartment. A thermoelectric module is positioned in between the first and second storage compartments. The thermoelectric module regulates and maintains various desired temperatures within the storage compartments. Particularly, the thermoelectric module is capable of heating the first storage compartment and cooling the second storage compartment.

Abstract: According to the present invention, an instrument panel having an instrument panel cover including a hidden deployment region integrally formed within an inner surface thereof by an ultrasonic embossing process is provided. More specifically, the deployment region comprises at least one and preferably a plurality of scores or cuts formed in the inner surface according to a predetermined pattern. The scores represent weakened portions of the instrument panel cover designed so that the force of an inflating air bag cushion causes the instrument panel cover to separate along the scores to thereby provide an opening for the inflating air bag cushion to deploy therethrough and be directed into the passenger compartment of a vehicle. The deployment region may be defined by any number of scores and therefore may have a variety of patterns, including but not limited to “H” pattern, “U” pattern, and “I” pattern.

Abstract: A structural attachment system for a vehicle is provided. The structural attachment system includes a first structural member and a vehicle component. The structural attachment system also includes an attachment assembly arranged relative to the first structural member and the vehicle component. The attachment assembly is designed and positioned to reinforce a load bearing area and to distribute a load of said vehicle component over said first structural member.

Abstract: A cross car support structure of an instrument panel assembly is provided for attachment to the vehicle side structure. The cross car support structure includes a one-piece, integrally molded beam preferably made entirely of plastic, the plastic beam having first and second opposing ends connected to the vehicle side structure. In addition, the beam includes a plurality of laterally extending, upwardly opening, U-shaped duct channels having upwardly facing edges. The cross car support further includes an instrument panel cover including a substrate layer having a bottom surface. The bottom surface of the substrate layer of the instrument panel cover is continuously secured to the upwardly facing edges of the beam so that the continuously secured instrument panel cover interconnects the upwardly facing edges and stiffens the beam such that the beam and the continuously secured instrument panel cover cooperatively provide the entire cross car support structure for the instrument panel assembly.