Abstract: A thermal membrane for manufacturing a vehicle interior panel. The thermal membrane includes a flexible body, a part contour in the flexible body, and a thermal array that includes a thermal temperature control element. The thermal array follows the part contour of the flexible body, and the thermal temperature control element is at least partially embedded in the flexible body. The thermal array of the thermal membrane can be used to heat and activate an adhesive layer during a method of manufacturing a vehicle interior panel, such as during a vacuum forming process to attach a skin layer to a substrate.

Abstract: An upholstery layer of a vehicle interior panel includes an airbag tear seam formed as a plurality of blind cuts arranged along a tear seam pattern. Each one of the blind cuts is formed by laser material removal at a plurality of locations along the pattern. Laser energy is delivered to the upholstery layer in a series of ultra-short pulses to form the blind cuts, which are formed in the upholstery layer while separate from a substrate of the panel. This technique is particularly useful with leather upholstery materials, in which non-visible airbag tear seams have been proven difficult to form.

Abstract: An upholstery layer of a vehicle interior panel includes an airbag tear seam formed as a plurality of blind cuts arranged along a tear seam pattern. Each one of the blind cuts is formed by laser material removal at a plurality of locations along the pattern. Laser energy is delivered to the upholstery layer in a series of ultra-short pulses to form the blind cuts, which are formed in the upholstery layer while separate from a substrate of the panel. This technique is particularly useful with leather upholstery materials, in which non-visible airbag tear seams have been proven difficult to form.

Abstract: A variety of embodiments are disclosed, in both apparatus and method form, that relate to the use of fabric material in the manufacture of an air bag deployment system. In addition, fabric weakening is disclosed according to a technique that does not result in physical alteration of the fabric. This invention therefore includes an air bag cover for an air bag safety system for a vehicle comprising a fabric outer layer having a frontside and a backside and a substrate containing an opening wherein the opening has a periphery. The substrate is preferably formed by low pressure molding, wherein the fabric outer layer overlies the opening in the substrate, and wherein the fabric outer layer is weakened at a location that is adjacent or overlies the substrate opening periphery.

Abstract: An air bag door construction for air bag deployment comprises a trim panel and air bag door of unitary construction, at least a portion of the door defined by an area of reduced cross-section outlining at least a portion of the periphery thereof. One or more tethers are formed in the panel, outlined by an area of reduced cross-section, preferably in a dovetail shape which does not direct the propagation of tearing into the tether. A tear stop may be formed at the ends of the tether. The improvement comprises a stiffening frame that is attached to the backside of the panel just outboard of the air bag door periphery but not located across the tethers to improve deployment performance.

Abstract: An airbag door construction for airbag deployment comprising an instrument panel having an area outlining at least a portion of an airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. The reaction plate contains first and second molded features, each such feature having a flexural strength (Fs), wherein the first molded feature's Fs is lower than the second molded feature's Fs. A tether is included that engages with the molded features in the reaction plate whereupon airbag deployment the tether is not retained by the first molded feature but is retained by the second molded feature.

Abstract: A variety of embodiments are disclosed, in both apparatus and method form, that relate to the use of fabric material in the manufacture of an air bag deployment system. In addition, fabric weakening is disclosed according to a technique that does not result in physical alteration of the fabric. This invention therefore includes an air bag cover for an air bag safety system for a vehicle comprising a fabric outer layer having a frontside and a backside and a substrate containing an opening wherein the opening has a periphery. The substrate is preferably formed by low pressure molding, wherein the fabric outer layer overlies the opening in the substrate, and wherein the fabric outer layer is weakened at a location that is adjacent or overlies the substrate opening periphery.

Abstract: An air bag door construction for air bag deployment comprises a trim panel and air bag door of unitary construction, at least a portion of the door defined by an area of reduced cross-section outlining at least a portion of the periphery thereof. One or more tethers are formed in the panel, outlined by an area of reduced cross-section, preferably in a dovetail shape which does not direct the propagation of tearing into the tether. A tear stop may be formed at the ends of the tether. The improvement comprises a stiffening frame that is attached to the backside and/or the topside of the panel just outboard of the air bag door periphery but not located across the tethers to improve deployment performance.

Abstract: An airbag door construction for airbag deployment comprising an instrument panel having an area outlining at least a portion of an airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. The reaction plate contains first and second molded features, each such feature having a flexural strength (Fs), wherein the first molded feature's Fs is lower than the second molded feature's Fs.

Abstract: An airbag door construction for airbag deployment comprising an instrument panel having an area outlining at least a portion of an airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. The reaction plate contains first and second molded features, each such feature having a flexural strength (Fs), wherein the first molded feature's Fs is lower than the second molded feature's Fs.

Abstract: A variety of embodiments are disclosed, in both apparatus and method form, that relate to the use of fabric material in the manufacture of an air bag deployment system. In addition, fabric weakening is disclosed according to a technique that does not result in physical alteration of the fabric. This invention therefore includes an air bag cover for an air bag safety system for a vehicle comprising a fabric outer layer having a frontside and a backside and a substrate containing an opening wherein the opening has a periphery. The substrate is preferably formed by low pressure molding, wherein the fabric outer layer overlies the opening in the substrate, and wherein the fabric outer layer is weakened at a location that is adjacent or overlies the substrate opening periphery.

Abstract: An airbag door construction for airbag deployment comprising a hard instrument panel having a weakened area outlining at least a portion of an integrally molded airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. A deployment chute is molded with the reaction plate and attached to the hard instrument panel just outboard of the outline of the airbag door. A tether is included that engages with the reaction plate whereupon airbag deployment the tether allows the airbag door/reaction plate welded combination to break loose from the hard instrument panel in a controlled manner.

Abstract: An air bag door construction for air bag deployment comprises a trim panel and air bag door of unitary construction, at least a portion of the door defined by an area of reduced cross-section outlining at least a portion of the periphery thereof. One or more tethers are formed in the panel, outlined by an area of reduced cross-section, preferably in a dovetail shape which does not direct the propagation of tearing into the tether. A tear stop may be formed at the ends of the tether. The improvement comprises a stiffening frame that is attached to the backside of the panel just outboard of the air bag door periphery but not located across the tethers to improve deployment performance.

Abstract: An air bag door construction for air bag deployment comprises a trim panel and air bag door of unitary construction, at least a portion of the door defined by an area of reduced cross-section outlining at least a portion of the periphery thereof. One or more tethers are formed in the panel, outlined by an area of reduced cross-section, preferably in a dovetail shape which does not direct the propagation of tearing into the tether. A tear stop may be formed at the ends of the tether. The improvement comprises a stiffening frame that is attached to the backside and/or the topside of the panel just outboard of the air bag door periphery but not located across the tethers to improve deployment performance.

Abstract: An airbag door construction for airbag deployment comprising an instrument panel having an area outlining at least a portion of an airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. The reaction plate contains first and second molded features, each such feature having a flexural strength (Fs), wherein the first molded feature's Fs is lower than the second molded feature's Fs.

Abstract: A metal cross-car beam for support of components in a vehicle comprises a hollow metal tube of unitary construction including end sections, said tube formed to accommodate direct attachment of vehicle components at various points to said tube, wherein said end sections are formed into flanges which attach directly to a vehicle body.

Abstract: A variety of embodiments are disclosed, in both apparatus and method form, that relate to the use of fabric material in the manufacture of an air bag deployment system. In addition, fabric weakening is disclosed according to a technique that does not result in physical alteration of the fabric. This invention therefore includes an air bag cover for an air bag safety system for a vehicle comprising a fabric outer layer having a frontside and a backside and a substrate containing an opening wherein the opening has a periphery. The substrate is preferably formed by low pressure molding, wherein the fabric outer layer overlies the opening in the substrate, and wherein the fabric outer layer is weakened at a location that is adjacent or overlies the substrate opening periphery.

Abstract: An airbag door construction for airbag deployment comprising a hard instrument panel having a weakened area outlining at least a portion of an integrally molded airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. A deployment chute is molded with the reaction plate and attached to the hard instrument panel just outboard of the outline of the airbag door. A tether is included that engages with the reaction plate whereupon airbag deployment the tether allows the airbag door/reaction plate welded combination to break loose from the hard instrument panel in a controlled manner.

Abstract: An airbag door construction for airbag deployment comprising a hard instrument panel having a weakened area outlining at least a portion of an integrally molded airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. A deployment chute is molded with the reaction plate and attached to the hard instrument panel just outboard of the outline of the airbag door. A tether is included that engages with the reaction plate whereupon airbag deployment the tether allows the airbag door/reaction plate welded combination to break loose from the hard instrument panel in a controlled manner.

Abstract: An airbag door construction for airbag deployment comprising a hard instrument panel having a weakened area outlining at least a portion of an integrally molded airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. A deployment chute is molded with the reaction plate and attached to the hard instrument panel just outboard of the outline of the airbag door. A tether is included that engages with the reaction plate whereupon airbag deployment the tether allows the airbag door/reaction plate welded combination to break loose from the hard instrument panel in a controlled manner.

Abstract: An apparatus and method are disclosed for holding a generally cylindrical workpiece for honing or otherwise machining an internal bore. The workpiece is held by a gripping surface over most of the innermost turn of a spirally wound spring and coil. The workpiece is grasped circumferentially over its outer surface without excess contact pressure at any particular point. A tendency of the machining operation to rotate the workpiece serves to secure the workpiece more tightly in position by tightening the outer turns of the spring band coil. A rotatable tensioning member acts under the influence of a biasing spring to decrease the diameter of the innermost turn of the spring band coil to bring the gripping surface into contact with the workpiece. A method for adapting the work-holding apparatus to smaller or irregularly shaped workpieces consists of molding an annular piece around the workpiece.