Abstract: An active bolster for an automotive vehicle has a outer trim panel with a welding track. An expandable bladder member has a central section configured to attach to a support structure of a vehicle, a welding flange along a peripheral edge, and a pleated region between the central section and the welding flange. The welding track and the welding flange are joined by a hot weld to form a sealed chamber. The welding track includes a plurality of radially-spaced stepped pits. Each pit has an upper section defining a first opening with a respective first cross-sectional area and a lower section defining a second opening with a respective second cross-sectional area smaller than the respective first area. A perimeter of each upper section is melted by the hot weld and a perimeter of each lower section is not melted by the hot weld.

Abstract: An active glove box bolster system for an automotive vehicle comprises an instrument panel housing defining a door space. A glove box door comprises a longitudinally-movable latch rod having a sloped end. A striker is provided on the housing for receiving the latch rod in a pocket between a front wall and a rear wall. The front wall slidably engages the sloped end during closing of the door to retract the latch rod until it enters the pocket. The latch rod includes a first interlock element adjacent to the sloped end, and the rear wall includes a second interlock element aligned with the first interlock element. The interlock elements engage to resist movement in response to a force against the door in a direction to push the door through the door space.

Abstract: An inflatable heel blocker is provided for protecting an operator of a motor vehicle in the event of an accident. The heel blocker includes an inflatable bladder having a first portion secured to the floor plan pan adjacent the toe pan and underneath the vehicle control pedals. Significantly, when deployed, the rearmost and lowermost portion of the bladder is secured to the floor pan thereby maximizing the effectiveness of the device.

Abstract: An airbag assembly includes inner and outer panels that are coupled to define a cavity therebetween, an inflatable member disposed within the cavity and at least one reinforcing band disposed within at least the inner panel. The reinforcing band includes a plurality of glass fibers, and each of the plurality of glass fibers includes a coating layer.

Abstract: An active bolster for an interior trim surface of an automotive vehicle has a plastic-molded outer trim panel with a closed-loop bonding section on an inside surface. A plastic-molded expandable bladder member has a central attachment section configured to attach to a support structure of the vehicle, a bonding flange along an peripheral edge, and a baffle section between the central attachment section and the bonding flange. The closed-loop bonding section and the bonding flange are configured to define a substantially closed toroidal region therebetween. An attachment body is molded in-situ to substantially fill the toroidal region. As a result of the in-situ molding of the attachment body in the toroidal region, the trim panel and bladder member become bonded via the attachment body resulting in a high bonding strength.

Abstract: An active glove box system comprises an instrument panel and a glove box door. The instrument panel housing defines a door space bordered by a curb flange along top and lateral sides of the door space. The glove box door comprises a trim wall providing an outside trim surface of the door, a bladder wall sealed along an outer edge to the trim wall defining an inflatable cavity, and a reaction wall. The reaction wall defines a back surface of the door, is attached to the bladder wall, and has an outer fringe surface abutting the curb flange when the door is closed. The fringe surface and the curb flange comprise interlocking features configured to engage and disengage in a door opening direction and to provide interference against movement of the reaction wall along an inward perpendicular direction when engaged.

Abstract: An active bolster mounts at an interior trim surface of a passenger compartment in an automotive vehicle. A plastic-molded front wall deploys in a deployment direction toward a passenger in the passenger compartment. A plastic-molded back wall is joined around a substantially sealed perimeter with the front wall to form an inflatable bladder. The back wall includes at least one substantially circumferential pleated baffle and a plurality of attachment towers projecting from a central region disposed within the baffle to join with a reaction surface. An inflator couples an inflation gas into the inflatable bladder in response to a crash event of the vehicle. At least one of the attachment towers includes an elongated notch sunk partially into a surface of the attachment tower to provide a thinned wall section configured to tear open at a predetermined pressure during inflation.

Abstract: An active bolster protects a passenger in an automotive vehicle during a crash event. An interior trim panel has a front wall with a front surface facing the passenger and a back surface including a plurality of closed bonding tracks spaced laterally across the panel. A plurality of bladder walls each has an outer flange bonded to a respective bonding track, a plurality of pleats disposed annularly adjacent the respective outer flange and defining a respective extension length, and central mounting towers attaching the respective bladder wall to a reaction structure. A plurality of micro gas generators are each mounted to a respective bladder wall for inflating the respective bladder walls. Inflation causes unfolding of the respective pleats while the trim panel deploys away from the reaction structure by a non-uniform distance resulting from a bladder wall having a pleat extension length not equal to another laterally-spaced bladder wall.

Abstract: An active bolster for an interior trim surface of a vehicle has a trim panel with a closed-loop bonding section on an inside surface. A first stud extending from an inside trim panel surface at the closed-loop bonding section, and a second stud extends from the panel inside surface radially outward of the bonding section. A thermoplastic expandable bladder member has a welding flange along an peripheral edge which is hot-welded with the bonding section. The welding flange has a stud aperture receiving the first stud. A stepped bracket comprises a first plate overlying the welding flange and a second plate overlying the trim panel. The first plate has a first aperture receiving the first stud. The second plate has a second aperture receiving the second stud. The studs have respective re-melted heads clamping the bracket in place.

Abstract: A vehicle instrument panel has a pedestrian protection zone along a forward side. The instrument panel generally has a low stiffness that avoids impact forces in the pedestrian protection zone greater than a predetermined force. An accessory component mounted on the instrument panel within the protection zone has a stiffness that could generate an impact force above the predetermined force. A cover providing a trim surface of the instrument panel has an annular wall region between inner and outer tear seams which encompass the accessory component. An annular bladder wall joined to the annular wall region forms a substantially toroidal expandable chamber. An inflator is arranged to supply an inflation gas into the expandable chamber during an impact of a pedestrian to tear the tear seams and expand the expandable chamber above the instrument panel body to intercept the pedestrian prior to impacting the accessory component.

Abstract: An active bolster for an automotive vehicle has a plastic-molded outer trim panel with a closed-loop welding section. A plastic-molded expandable bladder member has a central attachment section, a welding flange along a peripheral edge, and a pleated region between the central attachment section and the welding flange. The welding section and the welding flange are joined by a hot weld. An inflator couples an inflation gas into a space between the trim panel and bladder member to expand the bladder member in response to a crash event. The bladder member includes a first blocking rib projecting toward the trim panel between the welding flange and the pleated region. The trim panel includes a second blocking rib projecting toward the bladder member. The blocking ribs mechanically interlock to resist separation of the bladder member and trim panel during expansion and to shield the hot weld from the inflation gas.

Abstract: An active bolster for an interior trim surface of an automotive vehicle has a plastic-molded outer trim panel with a closed-loop bonding section on an inside surface. A plastic-molded expandable bladder member has a central attachment section configured to attach to a support structure of the vehicle, a bonding flange along an peripheral edge, and a baffle section between the central attachment section and the bonding flange. The closed-loop bonding section and the bonding flange are configured to define a substantially closed toroidal region therebetween. An attachment body is molded in-situ to substantially fill the toroidal region. As a result of the in-situ molding of the attachment body in the toroidal region, the trim panel and bladder member become bonded via the attachment body resulting in a high bonding strength.

Abstract: An active bolster mounts at an interior trim surface of a passenger compartment in an automotive vehicle. A plastic-molded, expandable front wall deploys toward a passenger in the passenger compartment. A plastic-molded back wall is joined around a substantially sealed perimeter with the front wall to form an inflatable bladder. The back wall includes an inflator receptacle defined by a raised recess wall having an inflator aperture. An inflator with a gas outlet end and an electrical connector end is received in the inflator aperture with the gas outlet end inside the inflatable bladder. The recess wall has a predetermined thickness for substantially retaining shape during inflation of the bladder. The inflator receptacle includes a flexible seal disposed around an inner edge of the inflator aperture comprised of a flashing edge bearing against the inflator and having a thickness less than the predetermined thickness of the recess wall.

Abstract: An active bolster mounts at an interior trim surface of a passenger compartment in an automotive vehicle. A plastic-molded, expandable front wall deploys toward a passenger in the passenger compartment. A plastic-molded back wall is joined around a substantially sealed perimeter with the front wall to form an inflatable bladder. The back wall includes an inflator receptacle defined by a raised recess wall having an inflator aperture. An inflator with a gas outlet end and an electrical connector end is received in the inflator aperture with the gas outlet end inside the inflatable bladder. The recess wall has a predetermined thickness for substantially retaining shape during inflation of the bladder. The inflator receptacle includes a flexible seal disposed around an inner edge of the inflator aperture comprised of a flashing edge bearing against the inflator and having a thickness less than the predetermined thickness of the recess wall.

Abstract: An active bolster at an interior trim surface of an automotive vehicle has a plastic-molded outer trim panel and a plastic-molded expandable bladder member. The bladder member has a central attachment section configured to attach to a support structure of the vehicle, a welding flange welded to the trim panel, and a baffle section between the attachment section and the welding flange. An inflator couples an inflation gas into a space between the trim panel and bladder member to expand the bladder member in response to a crash event of the vehicle. The welding flange has a generally-rectangular profile with a pair of long edges and a pair of short edges. The baffle section includes circumferential pleats providing an expansion length of the bladder member that is greater at the long edges than at the short edges to reduce stress on the weld along its weakest point.

Abstract: An active bolster for mounting at an interior trim surface of an automotive vehicle has a plastic-molded, expandable inner wall having a welding flange disposed at an outer perimeter and a pleated region bending inward from the welding flange. A plastic-molded outer wall overlies the inner wall, wherein the welding flange is hot welded to the outer wall to form an inflatable bladder for receiving an inflation gas. The inner wall further includes a blocking rib extending from between the welding flange and the pleated region into abutment with the outer wall to restrict flow of the inflation gas against the welding flange.

Abstract: An active bolster for mounting at an interior trim surface of an automotive vehicle has a plastic-molded, expandable inner wall having a welding flange disposed at an outer perimeter and a pleated region bending inward from the welding flange. A plastic-molded outer wall overlies the inner wall, wherein the welding flange is hot welded to the outer wall to form an inflatable bladder for receiving an inflation gas. The inner wall further includes a blocking rib extending from between the welding flange and the pleated region into abutment with the outer wall to restrict flow of the inflation gas against the welding flange.

Abstract: An active bolster for an automotive vehicle has an inner wall and an outer wall joined around a substantially closed perimeter to form an inflatable bladder. An inflator couples an inflation gas into the inflatable bladder in response to a crash event of the vehicle. The inner wall has an inner vessel region with a substantially-planar portion and an outer pleated region with a plurality of circumferential pleats, wherein each pleat has an inward edge and an outward edge. Adjacent pleats are continuous so that the inward edge of an outer pleat is shared as the outward edge of an inner pleat. The pleat edges have a stepped spacing from the outer wall that progressively decreases from an innermost edge to an outermost outward edge, whereby adjacent pleats unfold during inflation such that an inner pleat is unfolding with a substantially uniform pressure when an outer pleat begins to unfold.

Abstract: An active bolster has a plastic-molded, expandable inner wall and a plastic-molded outer wall overlying the inner wall are joined around a closed perimeter region to form an inflatable bladder. One wall surface includes a plurality of upstanding, concentric ribs within the closed perimeter region for providing attachment between the inner and outer walls which is preserved during inflation of the inflatable bladder. The concentric ribs include an innermost rib and an outermost rib. Each concentric rib has a respective window, wherein the windows are respectively offset to provide a to serpentine path through the concentric ribs from the central volume to atmosphere outside the outermost rib. At least one of the windows is closed by a breakaway seal configured to prevent flow of the inflation gas through the serpentine path until it ruptures at a predetermined pressure during inflation of the inflatable bladder.

Abstract: A latch mechanism is provided for securing a storage compartment door within a vehicle. The latch mechanism includes a mounting bracket, a handle, and an undivided, one piece latching member. The latching member includes a main body portion, a first pliable leg portion, a second pliable leg portion, a first post portion, and a second post portion. The latching member is in a relaxed position when the handle is in the latched position and a flexed position when the handle is in the unlatched position. The handle includes at least one abutment member for displacing the main body portion of the latching member as the handle is pivoted from the latched position to the unlatched position. Displacement of the main body portion causes the first and second pliable leg portions to resiliently retract which retracts the first post member and the second post member from extended post positions to retracted post positions.