Patents by Inventor Todd DePue

Todd DePue has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20060154028
    Abstract: In one advantageous embodiment of the claimed invention, an integral cushioned trim panel (14a-14c) for a vehicle passenger cabin (10) is provided. The integral cushioned trim panel (14a-14c) includes a substrate (22) for attachment to a predetermined portion (12a-12c) of the vehicle. The substrate (22) has a cover member (24) coupled thereto for substantially covering the substrate (22). In addition, the substrate (22) and the cover member (24) have a cushioning member (16) disposed therebetween. The cushioning member (16) is injection molded between the substrate (22) and the cover member (24) for forming an integral construction, minimizing the manufacturing cycle time, and decreasing the costs associated therewith.
    Type: Application
    Filed: January 12, 2005
    Publication date: July 13, 2006
    Applicant: LEAR CORPORATION
    Inventors: David Dooley, Randy Reed, Glenn Cowelchuk, Michael Hier, Todd DePue
  • Publication number: 20060138183
    Abstract: A foldable sheet for making a storage box for a vehicle. The foldable sheet has multiple portions foldably connected together along at least one fold line. The portions are foldable to at least a partially define a storage box. A hinge may be configured to allow the storage box to pivot with respect to the vehicle.
    Type: Application
    Filed: February 16, 2006
    Publication date: June 29, 2006
    Applicant: LEAR CORPORATION
    Inventors: David Hein, Todd DePue, John Slaven, Michael Schoemann, Doug Lyons
  • Publication number: 20060131910
    Abstract: A method and system for storage comprising a console and base. The console being slidable within the base so as to permit it to be easily re-positionable. The method and system relating to re-positioning the base, such as to facilitate folding a second row load floor, to facilitate removing the console, and/or to optimize positioning of the console relative to passengers.
    Type: Application
    Filed: December 17, 2004
    Publication date: June 22, 2006
    Applicant: LEAR CORPORATION
    Inventors: Glenn Cowelchuk, Todd DePue, Jerry Yatros
  • Publication number: 20060097532
    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.
    Type: Application
    Filed: November 8, 2004
    Publication date: May 11, 2006
    Inventors: Robert Adams, Michael Cass, Todd DePue, Kenneth Shaner
  • Publication number: 20060097536
    Abstract: An automotive assembly having an integrated spring mechanism. The assembly includes a first member and a second member pivotally coupled to the first member and moveable between a first and second position with respect to the first member. The assembly further includes a resilient element integrally molded with one of the first and second members. The resilient element includes an extension portion having a free end that is coupled to the other one of the first and second members. The extension portion imposes a force on the second member to bias the second member in at least one direction. A method of making the assembly includes a two shot molding process where the one of the first and second members is formed in a first shot of the molding operation and the resilient element is integrally molded thereto in the second shot of the molding operation.
    Type: Application
    Filed: November 10, 2004
    Publication date: May 11, 2006
    Inventors: Todd DePue, David Dooley, Randy Reed, Glenn Cowelchuk, Michael Hier
  • Publication number: 20060100764
    Abstract: An automotive center console is adjustable in fore and aft directions. In one embodiment, the console includes a console housing slidably mounted within the vehicle interior and a controllable damper having high and low damping states. In the high damping state, the controllable damper maintains the console housing in a selected position. When it is desired to relocate the console housing to a new position, the controllable damper is actuated to the low damping state, whereby the console housing may be freely moved to the desired position. The controllable damper is actuated back to the high damping state to maintain the console housing in the new position.
    Type: Application
    Filed: November 8, 2004
    Publication date: May 11, 2006
    Inventors: Robert Adams, Michael Cass, Todd DePue, Kenneth Shaner
  • Publication number: 20060097545
    Abstract: A door trim panel for a door frame of a motor vehicle. The door trim panel includes a main body portion adapted to be removably secured to the door frame and a bolster removably secured to the main body portion. The bolster covers an access opening in the main body portion. The bolster includes a substrate having a bolster portion integrally formed with an armrest portion. A cover is integrally molded with the substrate and includes a first portion overlying the bolster portion and having a first thickness, and a second portion overlying the armrest portion and having a second thickness greater than the first thickness to provide a softer feel. The bolster may be made in a two shot molding process with the substrate being formed in the first shot of the molding process and the multi-feel cover being formed in the second shot of the molding process.
    Type: Application
    Filed: November 9, 2004
    Publication date: May 11, 2006
    Inventors: Glenn Cowelchuk, David Dooley, Michael Hier, Todd DePue, Randy Reed
  • Publication number: 20060097534
    Abstract: A vehicle storage assembly includes a storage compartment having an opening to permit access to the compartment. A door adjacent the opening is moveable between a closed position that covers the opening and an open position that permits access to the compartment through the opening. The storage assembly further includes a controllable damper coupled to the door and actuable between high and low damping states, such that the door is maintained in one of the closed position, the open position, or any position therebetween when the controllable damper is in the high damping state. To move the door to a new position, the controllable damper is actuated from the high damping state to the low damping state whereby the door can then be freely moved to the desired position. The controllable damper may then be actuated from the low damping state to the high damping state to retain the door in the selected position.
    Type: Application
    Filed: November 8, 2004
    Publication date: May 11, 2006
    Inventors: Robert Adams, Michael Cass, Todd DePue, Kenneth Shaner
  • Publication number: 20060097544
    Abstract: An automotive interior trim assembly has at least one area which provides an enhanced tactile feel that is soft to the touch. The interior trim assembly includes a substrate member forming at least part of a structural support of a trim assembly and a cover member formed of thermoplastic elastic foam supported on the substrate member. In one embodiment, the interior trim assembly is formed in a two-shot molding operation wherein a first material is molding during a first shot to form the substrate member. The cover member is molded onto the substrate member during a second shot of the molding operation to form the interior trim assembly.
    Type: Application
    Filed: November 9, 2004
    Publication date: May 11, 2006
    Inventors: Glenn Cowelchuk, David Dooley, Michael Hier, Todd DePue, Randy Reed
  • Publication number: 20060099395
    Abstract: An automotive interior trim assembly has at least one area which provides an enhanced tactile feel that is soft to the touch. The interior trim assembly includes a first substrate member forming at least part of a structural support of a trim assembly and a cover member formed of thermoplastic elastic foam supported on the first substrate member. A second substrate member is connected to the first substrate member. In one embodiment, a portion of the interior trim assembly is formed in a two-shot molding operation wherein a first material is molding during a first shot to form the first substrate member. The cover member is molded onto the first substrate member during a second shot of the molding operation. In one embodiment, the first and second substrate members are connected together through cooperating locking structures formed on each of the first and second substrate members.
    Type: Application
    Filed: November 9, 2004
    Publication date: May 11, 2006
    Inventors: Glenn Cowelchuk, Michael Hier, David Dooley, Randy Reed, Todd DePue
  • Publication number: 20060082173
    Abstract: The present invention provides for an improved trim part, e.g. a bolster or trim plate, with integrated appliqué for use in a trim assembly, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, the trim part, i.e. a bolster, includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An appliqué is provided in a second shot mold cavity then a cover is formed between the substrate and appliqué by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The formed cover is integrally molded to at least a portion of the substrate and the appliqué to form a trim part with integrated appliqué.
    Type: Application
    Filed: October 19, 2004
    Publication date: April 20, 2006
    Inventors: Glenn Cowelchuk, Todd DePue, David Dooley, Michael Hier, Randy Reed
  • Publication number: 20060082179
    Abstract: An automotive trim assembly including a substrate made from a first material and having a front surface adapted to face the interior of the automobile and a back surface opposite the front surface. A cover member made from a second foamed material is molded onto at least a portion of the front surface of the substrate so as to provide a soft feel to the trim assembly. An impact countermeasure, also made from the second foamed material, is molded onto at least a portion of the back surface to absorb an impact force from a vehicle occupant. The trim assembly may be made in a two shot molding operation with the substrate being formed in the first shot of the molding process and the cover member and countermeasure being formed in the second shot of the molding process.
    Type: Application
    Filed: October 19, 2004
    Publication date: April 20, 2006
    Inventors: Todd DePue, Michael Hier, Glenn Cowelchuk, David Dooley, Randy Reed
  • Publication number: 20060082190
    Abstract: The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.
    Type: Application
    Filed: October 19, 2004
    Publication date: April 20, 2006
    Inventors: Glenn Cowelchuk, Todd DePue, David Dooley, Michael Hier, Randy Reed
  • Publication number: 20060082175
    Abstract: The present invention provides for an improved trim part with a multi-feel cover for use in a trim assembly, e.g. a door panel, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes a substrate having an integrated armrest and/or integrated bolster formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. A cover then is molded to at least a portion of the integrated trim part by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The molded cover defines a first and second thickness with the second thickness being greater than the first thickness to provide a softer feel.
    Type: Application
    Filed: October 19, 2004
    Publication date: April 20, 2006
    Inventors: Glenn Cowelchuk, Todd DePue, David Dooley, Michael Hier, Randy Reed
  • Publication number: 20060082109
    Abstract: A method of making an automotive trim assembly includes injection molding a first curable polymer to form a substrate including a deployment door in a first shot of a molding operation. A cover is then formed on at least a portion of both the substrate and deployment door by injection molding a second curable polymer in a second shot of the molding operation. The cover includes an inner and outer layer of the second polymer having a substantially non-cellular structure and a core of the second polymer having a cellular structure between the inner and outer layers. At least one score line is formed in the substrate to define the deployment door therein. The score line may be formed during the molding operation or in a post-molding process, such as a laser scoring process.
    Type: Application
    Filed: October 20, 2004
    Publication date: April 20, 2006
    Inventors: Michael Hier, Glenn Cowelchuk, Randy Reed, David Dooley, Todd DePue
  • Publication number: 20060082174
    Abstract: The present invention provides for an improved trim part, such as an automotive handle, with a soft feel, for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, an automotive handle includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. A handle cover is molded to at least a portion of the substrate by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the handle with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the handle.
    Type: Application
    Filed: October 19, 2004
    Publication date: April 20, 2006
    Inventors: Glenn Cowelchuk, Todd DePue, David Dooley, Michael Hier, Randy Reed
  • Publication number: 20060082106
    Abstract: An automotive trim assembly adapted to have an airbag deploy through the trim assembly includes a substrate with a deployment door integrally molded with the substrate and having a front surface adapted to face the interior of the automobile and a back surface opposite the front surface. The airbag is adapted to be stored behind the deployment door, which is adapted to open when the airbag is deployed. A cover is molded onto at least a portion of the substrate and deployment door and includes an inner and outer layer of a polymer material having a substantially non-cellular structure and an inner core having a cellular structure positioned between the inner and outer layers. The cover is adapted to keep the door attached to the trim assembly when the airbag is deployed.
    Type: Application
    Filed: October 20, 2004
    Publication date: April 20, 2006
    Inventors: Michael Hier, Glenn Cowelchuk, Randy Reed, David Dooley, Todd DePue
  • Publication number: 20060066088
    Abstract: An automotive interior component including a substrate adapted to be mounted inside a passenger cabin of a vehicle and a covering on at least a portion of the substrate adapted to define an airbag cushion deployed as a passenger restraint in the event of a collision. The covering includes a core of a cellular material that loses cohesion when an inflation fluid is injected to define a space between a substrate and an elastic outer layer. As the space fills with inflation fluid, the outer layer elastically expands for defining the airbag cushion. The automotive interior component may be made in a multi-shot molding operation with the substrate being formed in one shot and the covering being formed in another shot.
    Type: Application
    Filed: September 30, 2004
    Publication date: March 30, 2006
    Inventors: Michael Hier, Glenn Cowelchuk, David Dooley, Todd DePue, Randy Reed
  • Publication number: 20060068193
    Abstract: A method and apparatus for forming an interior component part having a relatively rigid substrate portion and a padded portion. The molding tool used to form the substrate portion includes a first mold part and a second mold part that form a substrate molding cavity into which a thermoplastic olefin is injected. The padded portion is formed by the first mold part and a third mold part that define a pad forming cavity. A mixture of a thermoplastic elastomer and a blowing agent is injected into the pad forming cavity. The expanded blown elastomer is enveloped within a skin formed when the blown elastomer contacts a cooled mold surface.
    Type: Application
    Filed: September 29, 2004
    Publication date: March 30, 2006
    Applicant: Lear Corporation
    Inventors: Glenn Cowelchuk, Todd DePue, Robert Adams
  • Patent number: 7014208
    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.
    Type: Grant
    Filed: May 8, 2003
    Date of Patent: March 21, 2006
    Assignee: Lear Corporation
    Inventors: Todd DePue, Robert J. Adams, Michael J. Hier, Glenn A. Cowelchuk