Abstract: A method of forming an injection molding tool, the method includes milling at least one channel into a tool body. Each channel includes a bottom surface that is at a predefined distance from a top surface of the tool body, and two opposing walls extending from the bottom surface of the channel to the top surface of the tool body. A first wall of the two opposing walls is at a first angle relative to the bottom surface of the channel, and a second wall of the two opposing walls is at a second angle relative to the bottom surface of the channel. A distance between the first wall and the second wall increases from the bottom surface of the channel to the top surface of the tool body, and at least one wall of the two opposing walls has a curvature.

Abstract: A method of forming an injection molding tool, the method includes milling at least one channel into a tool body. Each channel includes a bottom surface that is at a predefined distance from a top surface of the tool body, and two opposing walls extending from the bottom surface of the channel to the top surface of the tool body. A first wall of the two opposing walls is at a first angle relative to the bottom surface of the channel, and a second wall of the two opposing walls is at a second angle relative to the bottom surface of the channel. A distance between the first wall and the second wall increases from the bottom surface of the channel to the top surface of the tool body, and at least one wall of the two opposing walls has a curvature.

Abstract: An instrument panel assembly for a vehicle includes an instrument panel body including a driver-side portion, a center stack portion, and a passenger-side portion. A cross-car beam assembly is configured to at least partially support the instrument panel body and includes a horizontal member extending across at least the passenger-side portion of the instrument panel body. A first lower reinforcement bracket is spaced apart from the horizontal member and extends across the passenger-side portion of the instrument panel body. A second lower reinforcement bracket is coupled with the first lower reinforcement bracket. A vertical reinforcement bracket extends between the horizontal member and the first and second lower reinforcement brackets. The vertical reinforcement bracket includes a curved portion proximate a first end and coupled with the horizontal member. A second end of the vertical reinforcement bracket is coupled with at least one of the first and second lower reinforcement brackets.

Abstract: An instrument panel assembly for a vehicle includes an instrument panel body including a driver-side portion, a center stack portion, and a passenger-side portion. A cross-car beam assembly is configured to at least partially support the instrument panel body and includes a horizontal member extending across at least the passenger-side portion of the instrument panel body. A first lower reinforcement bracket is spaced apart from the horizontal member and extends across the passenger-side portion of the instrument panel body. A second lower reinforcement bracket is coupled with the first lower reinforcement bracket. A vertical reinforcement bracket extends between the horizontal member and the first and second lower reinforcement brackets. The vertical reinforcement bracket includes a curved portion proximate a first end and coupled with the horizontal member. A second end of the vertical reinforcement bracket is coupled with at least one of the first and second lower reinforcement brackets.

Abstract: A coupling system includes a glovebox panel having inner and outer surfaces and a keyhole slot disposed therethrough having an enlarged portion leading to a narrowed portion. A ramped flange is disposed on the outer surface of the glovebox panel. A damper mechanism includes an abutment plate with a post and head member. The head member is received through an enlarged portion of the keyhole slot when the damper mechanism is in a pre-load position. The abutment plate engages the ramped flange to progressively drive the head member into engagement with the inner surface of the glovebox panel as the damper mechanism moves from the pre-load position to a seated position.

Abstract: A vehicle dashboard includes an air duct proximate an access aperture. The air duct selectively defines sealed and collapsed positions. A display module is positioned proximate the air duct. The display module is selectively accessible via the access aperture when the air duct is in the collapsed position. The collapsed position characterized by a nested portion of the air duct being removed from a duct receptacle.

Abstract: An active bolster includes a plastic trim wall that deploys toward a passenger compartment and a plastic-molded bladder member joined with the trim wall by a hot weld seam to form an inflatable bladder. The bladder member includes at least one substantially circumferential pleat for unfolding in response to an inflation gas. A reaction member is joined to a central region of the bladder member to provide a reaction surface. The pleat has a peak disposed proximate to the reaction member and an outer band between the peak and the weld seam at least a portion of which extends perpendicularly to the reaction member. A buffer zone is formed circumjacent the outer band between the trim wall and the reaction member. The pleat has a vent opening formed in the outer band providing an unobstructed path for inflation gas from the inflatable bladder to the buffer zone.

Abstract: A coupling system includes a glovebox panel having inner and outer surfaces and a keyhole slot disposed therethrough having an enlarged portion leading to a narrowed portion. A ramped flange is disposed on the outer surface of the glovebox panel. A damper mechanism includes an abutment plate with a post and head member. The head member is received through an enlarged portion of the keyhole slot when the damper mechanism is in a pre-load position. The abutment plate engages the ramped flange to progressively drive the head member into engagement with the inner surface of the glovebox panel as the damper mechanism moves from the pre-load position to a seated position.

Abstract: A cockpit system of interchangeable modules for a first vehicle having a left-hand-drive arrangement and for a second vehicle having a right-hand-drive arrangement, including a driver-side module, a passenger-side module, a center module fastenable between the driver-side module and the passenger-side module, a left-hand-drive top module, and right-hand-drive top module. Alternatively, a cockpit system of interchangeable modules for a first vehicle having a narrow cockpit width and for a second vehicle having a wide cockpit width including a driver-side module, a passenger-side module, a narrow center module, a wide center module, a narrow top module, and a wide top module.

Abstract: A cockpit system of interchangeable modules for a first vehicle having a left-hand-drive arrangement and for a second vehicle having a right-hand-drive arrangement, including a driver-side module, a passenger-side module, a center module fastenable between the driver-side module and the passenger-side module, a left-hand-drive top module, and right-hand-drive top module. Alternatively, a cockpit system of interchangeable modules for a first vehicle having a narrow cockpit width and for a second vehicle having a wide cockpit width including a driver-side module, a passenger-side module, a narrow center module, a wide center module, a narrow top module, and a wide top module.