Abstract: A console assembly for a vehicle includes a console body defining an opening communicating with a storage bin. The storage bin has opposing side walls each having a groove formed therein. A sliding member is slidably mounted within the grooves of each of the side walls within the storage bin. A console cover is pivotally mounted to the sliding member and defines a cover assembly. The cover assembly is slidably movable between a closed position wherein the console cover covers the opening of the console body and a partially open position wherein a portion of the opening of the console body is exposed. The console cover is pivotally movable between the partially open position and a fully open position wherein the console opening and the sliding member are exposed. The console cover includes at least one follower extending outwardly therefrom, wherein the follower is slidably mounted within the grooves in the storage bin wall.

Abstract: In at least one embodiment, the present invention relates an airbag assembly comprising a panel having a tear seam forming at least one airbag door, and a door chute assembly comprising a laterally extending flange connected to the panel proximate the airbag door. The door chute assembly includes a chute depending from the flange away from the panel and the chute has at least one opening. The airbag assembly further comprises a door panel assembly including at least one door panel disposed within the chute and connected to the airbag door. The door panel has a downwardly depending flange having at least one projection extending laterally through the at least one opening of the chute. The airbag assembly further comprises an inflatable airbag mounted on the door chute.

Abstract: In at least one embodiment, the present invention relates to a trim panel for concealing an air bag. The panel comprises a substrate and a cover over the substrate. The cover includes a cover skin. The panel also comprises a tear seam having at least a portion comprising a pattern of alternating residual wall thicknesses in the panel. At least one embodiment of the present invention also relates to a method for making a trim panel for concealing an air bag.

Abstract: A console assembly for a vehicle includes a console body having a first end defining an opening communicating with a storage bin. The storage bin has opposing side walls each having a groove formed therein. A sliding member is slidably mounted within the storage bin. A console cover is pivotally mounted to the sliding member and defines a cover assembly. The cover assembly is slidably movable between a closed position wherein the console cover covers the opening of the console body and a partially open position wherein a portion of the opening of the console body is exposed. The cover is pivotally movable between the partially open position and a fully open position wherein the console opening and the sliding member are exposed. The cover includes at least one boss extending outwardly therefrom, wherein the boss is slidably mounted within the groove in the storage bin wall.

Abstract: In at least certain embodiments, the present invention relates to automobile interior door panel having an insert molded bolster. In at least one embodiment, the automobile interior door panel is made by providing a bolster within a first mold cavity, introducing a first resin into the first mold cavity to form a door panel sub assembly comprising a door panel portion secured to the bolster, with the door panel portion having a first upper door panel portion above the bolster and a lower door panel portion below the bolster, providing the door panel sub assembly within a second mold cavity, and introducing a second resin less rigid that the first material into the second mold cavity to form a second upper door panel portion over and secured to the first upper door panel portion.

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.

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.

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.

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.

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.

Abstract: In at least one embodiment, the present invention relates an airbag assembly for use with a trim panel having a tear seam forming at least one airbag door, and a door chute assembly comprising a laterally extending flange connected to the panel proximate the airbag door. The door chute assembly includes a chute depending from the flange away from the panel and the chute has at least one opening. The airbag assembly further comprises a door panel assembly including at least one door panel disposed within the chute and connected to the airbag door. The door panel has a downwardly depending flange having at least one projection extending laterally through the at least one opening of the chute.

Abstract: In at least one embodiment, the present invention relates an airbag assembly for use with a trim panel having a tear seam forming at least one airbag door, and a door chute assembly comprising a laterally extending flange connected to the panel proximate the airbag door. The door chute assembly includes a chute depending from the flange away from the panel and the chute has at least one opening. The airbag assembly further comprises a door panel assembly including at least one door panel disposed within the chute and connected to the airbag door. The door panel has a downwardly depending flange having at least one projection extending laterally through the at least one opening of the chute.

Abstract: A trim panel assembly includes a first trim panel and a second trim panel. The first trim panel has an attachment portion, and the second trim panel has an attachment portion that cooperates with the attachment portion of the first trim panel to connect the first and second trim panels together to provide a trim panel assembly that allows relatively sliding movement between the first and second trim panels. The first trim panel can have a single attachment portion that extends continuously throughout the length thereof, while the second trim panel can have a plurality of discrete portions that extends along the length thereof, or vice versa. The attachment portion of the second trim panel can be molded either about or within the attachment portion of the first trim panel.

Abstract: In at least one embodiment, the present invention relates an airbag assembly comprising a panel having a tear seam forming at least one airbag door, and a door chute assembly comprising a laterally extending flange connected to the panel proximate the airbag door. The door chute assembly includes a chute depending from the flange away from the panel and the chute has at least one opening. The airbag assembly further comprises a door panel assembly including at least one door panel disposed within the chute and connected to the airbag door. The door panel has a downwardly depending flange having at least one projection extending laterally through the at least one opening of the chute. The airbag assembly further comprises an inflatable airbag mounted on the door chute.

Abstract: An airbag assembly is provided including an instrument panel substrate with an outer display surface and a panel opening formed therein. A door panel is positioned over the panel opening. A chute element is positioned behind and mounted to the instrument panel substrate. It includes an upper chute mating surface mounted to the instrument panel substrate, a chute chamber orientated coincident with the panel opening, and a plurality of chute sidewalls. A living hinge assembly includes a hinge sidewall portion slidably engaged to one of the chute sidewalls, a hinge door portion attached to the hinge sidewall portion by a living hinge portion allowing them to relatively rotate. The hinge door portion is mounted to the door panel. An airbag module is mounted to the chute element and deploys upward through the chute chamber. The living hinge assembly slides upward during deployment to clear the outer display surface.

Abstract: A method of forming a trim panel is provided comprising molding an interior panel substrate including a main body portion, a lock portion molded as a portion of the interior panel substrate and having a locking element, a first living hinge positioned between the lock portion and the main body portion, a lock engagement portion, and a second living hinge positioned between the lock engagement portion and the main line portion. The method molds an exterior cover stock, including a belt line skin portion, onto an outer surface of the interior panel substrate. The lock portion is rotated about the first living hinge to trap the belt line skin portion between the lock portion and the lock engagement portion in order to create a mechanical skin lock. The lock engagement portion is then rotated about the second living hinge towards an inner surface of the interior panel substrate.

Abstract: An injection molding system (10) includes a first mold half (20) and a second mold half (22), which forms a cavity (23) with the first mold half (20). A cavity intrusion element (34) is displaceable to extend within the cavity (23). A displacement mechanism (36) is coupled to the cavity intrusion element (34). A controller (38) is coupled to the displacement mechanism (36) and controls the intrusion depth (D) of the cavity intrusion element (34) during an injection molding process. A method of forming an article includes the pressurizing of the cavity (23) within a mold (14) via a gas. A material having a blowing agent is injected into the cavity (23). The gas pressure within the cavity (23) is released. The cavity intrusion element (34) is backed out from within the cavity (23). The material is cured.

Abstract: A portable tray for use at multiple locations of the interior of a vehicle includes a body adapted to be operatively supported to the interior of the vehicle and defining at least one substantially planar work surface. The tray also includes a support mechanism connected to the body and adapted to removably support the body to structural components of the interior of the vehicle such that the tray can be manually moved and used at various locations within the interior of the vehicle.

Abstract: The present invention provides for an improved bolster 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, the bolster includes a substrate formed by co-injecting a first and second material into a first shot mold cavity in a first shot of a molding operation. In a second shot mold cavity, a cover is formed on at least a portion of the substrate by co-injecting into a mold chamber a third and fourth material in a second shot of the molding operation. The fourth material defines an outer skin surrounding the third material which may include a foamed material to provide a soft, light cellular inner core such that when a force is applied to the cover, the outer skin will deform and compress the inner core, providing a soft feel to the bolster.

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.