Abstract: A radar system transmits an environment-sensing pulse and processing circuitry time-reverses an order of radar return samples and generates a convolution matrix from the radar return samples resulting from a transmission of the environment-sensing pulse. The processing circuitry may also generate a plurality of return energy-ranked vectors from a decomposition of the convolution matrix. The processing circuitry may select one of the return energy-ranked vectors for generation of a clutter-orthogonal transmit waveform. In some embodiments, the processing circuitry may select a clutter-orthogonal vector from the plurality of return energy-ranked vectors and may quantize the clutter-orthogonal vector for application to the phase modulator for generation of the clutter-orthogonal transmit waveform. The radar system may perform multiple correlations on sampled radar returns from the clutter orthogonal transmit waveform using a family of pseudo-orthogonal waveforms to detect a slow-moving target.

Abstract: A method of making an integrated inner trim panel for a vehicle door and an inner trim panel made thereby are disclosed. The method includes sequentially spraying a skin layer, a padding layer, and applying a structural layer in an open mold that defines the facing surface of the inner panel of a door. The integrated inner trim panel may be provided with areas of greater and lesser padding. The skin layer may be formed from a reactant mixture of polyurethane. The padding layer may be a foam polyurethane composition. The structural layer may be a glass-reinforced polyurethane reactant mixture. The inner door panel is an integrated layered structure including a skin layer, a padding layer, and a structural layer. The padding layer may be varied in thickness to provide selectively variable padding in predetermined areas.

Abstract: A cross beam assembly extends between side frame members of a vehicle and includes a beam having a hollow interior. The beam defines an opening formed therein. The assembly further includes an air bag inflator assembly having a source of pressurized gas for expelling gas to inflate an air bag. The inflator assembly is disposed within the hollow interior of the beam such that activation of the inflator assembly expels gas through said opening.

Abstract: A center console for an automobile includes an armrest that is selectively adjustable by vehicle occupants to and between a first position wherein the armrest is in a substantially horizontal orientation, and a second position wherein the armrest extends angularly away from the console. The console further includes a controllable damper coupled to the armrest and actuable between high and low damping states. In the low damping state, the armrest may be selectively placed at any position desired by the vehicle occupants. When the damper is actuated to the high damping state, the damper maintains the selected position of the armrest.

Abstract: A method of making a vehicle part includes spraying material proximate a surface of a tool to form a skin layer, and spraying material onto the skin layer to form a resilient layer. The method further includes removing the skin layer and the resilient layer from the tool and positioning the layers in a mold. Next, the method involves applying material onto the resilient layer to form a rigid substrate on the resilient layer.

Abstract: An in-mold degating device that includes a base having mounting ears for removable attachment to a mold system. The base is removably attached to the die half such that the uppermost surface of the base is flush with the surface of the die half. The insert further includes a body fixed to the base including a pair of opposed surfaces that define predetermined relief angles relative to the base. The body further includes a gate flow passage having an inlet within one of the opposed surfaces and an outlet within the other of the opposed surfaces. The gate flow passage tapers inwardly from the inlet to the outlet. The outlet includes an edge surface that forms an acute angle relative to the gate flow passage. The edge surface defines a shearing edge point that separates the finished molded part from cooled excess material.

Abstract: An automotive interior trim component includes a rigid substrate member that forms the structural support for the trim component. A portion of the substrate member has a thickness that is reduced relative to surrounding portions of the substrate member to define a target area for providing a soft feel to the trim component. The trim component may further include a flexible cover layer and a backing member disposed on a side of the substrate member opposite the cover layer. The substrate member and cover layer may be formed in a two-shot molding operation.

Abstract: A method of manufacturing an overmolded trim component includes providing a first mold portion and a movable mold element. The movable mold element includes first and second mold surfaces positioned at a first angle with respect to one another. The movable mold element is then positioned into the first position to define a first cavity. A first material is then introduced into the first cavity, thereby forming a substrate. The substrate includes a first substrate surface is at a second angle with respect to a second substrate surface. The movable mold element is then positioned into the second position to define a second cavity. A second material is then introduced into the second cavity, thereby forming an overmolded trim component. The movable mold element is oriented at a third angle with respect to the first substrate surface and at a fourth angle with respect to the second substrate surface.

Abstract: An injection molding system for forming a molded plastic part including a die having a pair of die halves which mate along their joining surfaces to form a parting line and define a mold cavity, a plurality of ejection pins within at least one of the die halves and operable to move the finished molded part in a direction away from at least one of the die halves, a gate removably mounted to one of the die halves, and a runner. The gate includes an inlet and an outlet having an edge surface extending in a direction generally opposite to the movement of the molded part upon ejection from the mold cavity. Upon separation of the two die halves, the ejection pins are then further operable to remove excess cooled plastic material from the gate and the runner.

Abstract: An overmolded interior vehicle trim panel includes a substrate having a front face and an under face. The under face has a tear seam integrally molded therein to allow an airbag to exit the substrate when the airbag is deployed. The tear seam defines an airbag door. An outer layer is bonded to the front face of the substrate in a mold, thereby forming an overmolded interior vehicle trim panel. The trim panel can include a sheet of hinge material attached to one of the substrate and the outer layer of the overmolded interior trim panel. A portion of the sheet of hinge material defines a hinge member.

Abstract: A cross beam assembly extends between side frame members of a vehicle and includes a beam having a hollow interior. The beam defines an opening formed therein. The assembly further includes an air bag inflator assembly having a source of pressurized gas for expelling gas to inflate an air bag. The inflator assembly is disposed within the hollow interior of the beam such that activation of the inflator assembly expels gas through said opening.

Abstract: A system and method of making polyurethane skins for interior components is provided wherein a colorant/polyol mixture is injected into a polyurethane layer to provide color in the polyurethane layer. An in-mold coating may be applied to the mold over which the polyurethane layer is sprayed. The colorant/polyol mixture is combined to match the color of the in-mold coating. The colorant/polyol mixture is injected into the same spray applicator that dispenses polyol and isocyanate of a two part polyurethane forming mixture. The colorant may be selectively injected into the spray applicator to selectively provide color in the polyol and isocyanate composition that matches the color of the in-mold coating.

Abstract: An injection molding system for forming a molded plastic part including a die having a pair of die halves which mate along their joining surfaces to form a parting line and define a mold cavity, a plurality of ejection pins within at least one of the die halves and operable to move the finished molded part in a direction away from at least one of the die halves, a gate removably mounted to one of the die halves, and a runner. The gate includes an inlet and an outlet having an edge surface extending in a direction generally opposite to the movement of the molded part upon ejection from the mold cavity. Upon separation of the two die halves, the ejection pins are then further operable to remove excess cooled plastic material from the gate and the runner.

Abstract: An overmolded interior vehicle trim panel includes a substrate having a front face and an under face. The under face has a tear seam integrally molded therein to allow an airbag to exit the substrate when the airbag is deployed. The tear seam defines an airbag door. An outer layer is bonded to the front face of the substrate in a mold, thereby forming an overmolded interior vehicle trim panel. The trim panel can include a sheet of hinge material attached to one of the substrate and the outer layer of the overmolded interior trim panel. A portion of the sheet of hinge material defines a hinge member.

Abstract: A method for reducing vibration in an instrument panel structure is achieved by introducing one or more piezoelectric actuator and sensor assemblies between various structures contained within the instrument panel structure. The assembly has a sensor component that senses vibrations between the structures and an actuator component that is activated to produce a reverse sine pulse that dampens the vibrations. The assembly also has an electronic control module, located integrally or as a separate component, electrically to the sensor and actuator for precisely controlling the actuation of the actuator. In alternative embodiments, multiple assemblies may be coupled to a single electronic control module for achieving total system vibration control.

Abstract: A method of forming an instrument panel for a vehicle includes first providing a first mold structure having a first surface formed therein, a second mold structure having a second surface formed therein, and a third mold structure having a third surface formed therein. The first mold structure is positioned relative to the second mold structure such that the first and second surfaces are in a spaced relationship with one another to define a first cavity. A first material is introduced into the first cavity to form a substrate. The second mold structure is positioned away from the substrate. The third mold structure is positioned relative to the first mold structure such that the third surface and the substrate are in a spaced relationship with one another to define a second cavity. A second material is introduced into the second cavity to form an outer layer overmolded onto the substrate. The first material is different from the second material.

Abstract: A method of manufacturing an overmolded trim component includes providing a first mold portion and a movable mold element. The movable mold element includes first and second mold surfaces positioned at a first angle with respect to one another. The movable mold element is then positioned into the first position to define a first cavity. A first material is then introduced into the first cavity, thereby forming a substrate. The substrate includes a first substrate surface is at a second angle with respect to a second substrate surface. The movable mold element is then positioned into the second position to define a second cavity. A second material is then introduced into the second cavity, thereby forming an overmolded trim component. The movable mold element is oriented at a third angle with respect to the first substrate surface and at a fourth angle with respect to the second substrate surface.

Abstract: A spin-stabilized missile includes two or more spin nozzles along a perimeter of the missile, the nozzles being operatively coupled to a pressurized gas source. The pressurized gas source provides pressurized gas which passes through the nozzles and external to the missile, thereby providing circumferential thrust which causes a torque on the missile that results in the missile rolling or spinning. The pressurized gas source may be a pressure container containing solid rocket fuel. The pressurized gas source for spinning the missile may be the same as that for the missile's main propulsion system.

Abstract: A spray nozzle of a fire protection system is provided for discharging a hollow cone spray pattern. The nozzle generally includes a hollow, elongated body and an integral core subassembly which may be preassembled. The integral subassembly configuration simplifies the subsequent assembly, disassembly or service of the overall nozzle in the field. In an exemplary embodiment, the subassembly includes a unitary core holder having a plate portion and an annular wall portion, with a discharge orifice disposed centrally in the plate portion. Additionally, the subassembly includes a disc-shaped core having a plurality of sloped passages. The core and core holder are cooperatively shaped to define generally cylindrical a whirl chamber in a space between a downstream surface of the core and the plate portion of the core holder.