Abstract: An energy absorbing knee bolster for use in an interior of a vehicle is disclosed. The knee bolster is configured to absorb energy from the vehicle's occupants during a crash. The knee bolster is formed of a collapsible cylinder which is welded to an impact plate on its first end and to a vehicle's cross-car beam at its second end. A coupling flange is disposed between the impact plate and a medial portion of the collapsible cylinder. The collapsible cylinder is configured to axially collapse at a predetermined force when impacted by a moving occupant.

Abstract: A knee bolster system is capable of automatic extension and retraction during specified scenarios that are determined based on sensor input. A microprocessor electrically controls an actuator capable of extending at least one telescoping mechanism which is rigidly engaged to a knee bolster pad located in the lower portion of an instrument panel at knee height to an occupant. Each telescoping mechanism houses a plowing mechanism. This plowing mechanism generates reaction forces during actuation.

Abstract: An airbag module is shown for an occupant restraint system of a motor vehicle. The airbag module has a housing in which a folded inflatable airbag is accommodated. A part of the housing is designed as a covering which is movable into the vehicle interior and which supports the knees of the occupant during the unfolding of the airbag. The airbag is designed in such a manner that it can be unfolded through an opening at the housing past the covering and into the vehicle interior when the covering is at least partly moved into the vehicle interior.

Abstract: The present invention relates to a collapsible support (1) for absorbing energy during an impact, particularly to a support for an automobile knee bolster (50). The collapsible support (1) has the form of a tubular body with closed ends. The body extends along a longitudinal axis (3) along which it will collapse during an impact. The support (1) has two opposing end walls (4,10) substantially perpendicular to the axis (3). The two end walls (4,10) are connected by four similar stepped side walls (8) of rectangular plan form that substantially enclose the longitudinal axis (3) such that the side and end walls (8,4,10) of the collapsible support (1) substantially enclose an internal volume. The tubular body is adapted to deform so that sections (31-35) of side walls 8 collapse with one section moving inside another adjacent section upon the application of a compressive force applied to said body along said axis 3.

Abstract: A knee protector is arranged in front of a seat in a vehicle, and includes a load receiving part that is comprised of an upper portion positioned or shaped suitably for a person who is relatively large in stature and a lower portion positioned or shaped suitably for a person who is relatively small in stature. Therefore, the load receiving part of the knee protector is positioned substantially in front of the knees of drivers of various statures. The knee protector can absorb the impact applied by the knees of drivers of varying statures without requiring an increase in weight or cost.

Abstract: An energy absorbing knee bolster assembly for a vehicle includes a knee deflector for partially surrounding a steering column of the vehicle. The energy absorbing knee bolster assembly also includes left and right energy absorbing knee bolster brackets on opposite sides of the knee deflector. The knee deflector and the energy absorbing knee bolster brackets are integral, unitary, and one-piece.

Abstract: The present invention relates to a structure for mounting a crash pad of an automobile and more particularly, to the structure for mounting a crash pad of an automobile which can prevent from easy separation of a pin from a cap by employing an interlocking structure between the pin of a crash pad and the cap of a cowl panel and ensure better efficient processability by having a locking means formed at a lower end of the pin to lock a low portion of a cap.

Abstract: The invention concerns a protective assembly (1, 101) for the lower limbs (31) of a motor vehicle passenger comprising an actuating device (2, 103) secured to the vehicle and capable of displacing a rod (3, 108) which is linked to a protective system. The invention is characterised in that: i) the actuating device contains a pyrotechnic system (9); ii) the protective system comprises a protective cushion (6) mounted on a shaft (5, 105) integral with the vehicle; iii) said protective cushion is mobile in rotation under the effect of the displacement of the rod so as to accompany, in the contact zone provided between the passenger's lower limbs and said protective cushion, the movement of said lower limbs.

Abstract: A cross car structure member including a beam comprising a hollow extended aluminum metal tube extending across the vehicle between the vehicle pillars, preferably, with the interior of the tube being used as a heating, ventilating and air conditioning duct.

Abstract: A knee bolster for absorbing the impact to the knees of the occupant during car crash and controlling the posture of the occupant by receiving the knee load securely comprises a pair of left and right panels 1 for receiving the knees and disposed to oppose to the knees, upper stays 2 provided to each of the panels 1 having the rear side of which fixed to the upper area of the corresponding panel 1, lower stays 3 provided to each of the panels 1 having the lower end of which fixed to the lower area of the corresponding panel 1 and the upper end of which fixed to the front end of the corresponding upper stay 2, and a connecting member 4 for connecting the pair of deltoid assembled bodies each composed of said panel 1, said upper stay 2 and said lower stay 3, the assembled bodies disposed side by side and spaced apart when being connected to the connecting member 4. The upper and lower stays 2, 3 are arced, and the curvature radius of the lower stays 3 is smaller than that of the upper stays 2.

Abstract: A knee support is arranged inside a body of the motor vehicle and exhibits a transverse frame member, which extends at right angles to the longitudinal direction of the motor vehicle, is held at rigid, lateral body structures, and is provided with at least one deformation element. This deformation element comprises several hollow brackets, defined by bracket walls, and is covered by a support wall, facing the occupants' knees. The deformation element exhibits a first hollow bracket segment, which runs along the support wall, and a second additional hollow bracket segment, which is arranged at an angle to the first hollow bracket segment, whereby the second hollow bracket segment is attached to the transverse frame member.

Abstract: An instrument panel assembly (22) comprises a structural carrier member (30) which is formed as one piece and has a first section (40) defining a first chamber (54) for receiving and supporting a first component (110). The structural carrier member (30) has a second section (80) defining a second chamber (92) for receiving and supporting a second component (130). The first component (110) comprises a first inflatable vehicle occupant protection device (114) received in the first chamber (54). The structural carrier member (30) further defines a deployment opening (55) through which the first protection device (114) is inflatable from the first chamber (54). The second component (130) comprises an occupant knee protection device (132) received in the second chamber (92) for helping to protect the vehicle occupant's legs in the event of a vehicle collision.

Abstract: The present invention is directed to an assembly structure designed to improve the process of accurately assembling an instrument panel supported by a steering support member in a vehicle. The assembly structure includes side brackets (16), (17) arranged to mount both ends of a steering support member (15) to a car body. Side bracket (16) includes an extended portion (20) provided with an instrument panel mounting seat (22), a car body mounting seat (23), and a side trim mounting seat (24). The upper side of an instrument panel (14) is mounted to the cylindrical portion of the steering support member (15) and the lower end portion thereof is mounted to the instrument panel mounting seat (22). The car body mounting seat (23) of the side bracket (16) is mounted to the car body, while a dash side trim (31) is mounted to the side trim mounting seat (24). Instead of mounting the instrument panel (14) so as to be directly coupled to the car body, it is mounted to the car body via the steering support member (15).

Abstract: An energy absorbing knee bolster assembly for a vehicle includes a knee deflector for partially surrounding a steering column of the vehicle. The energy absorbing knee bolster assembly also includes left and right energy absorbing knee bolster brackets on opposite sides of the knee deflector. The knee deflector and the energy absorbing knee bolster brackets are integral, unitary, and one-piece.

Abstract: A method for manufacturing an object out of a plurality of materials having differing structural characteristics and capable of being placed in a molten state, the melted materials are deposited in an open mold having a pair of complementary mold portions. Various non-melted but possibly pre-heated structural, reinforcing, or energy absorbing materials can be placed in the mold with the melted materials. A closing force is applied to the mold and the item is removed after it has cured. According to one embodiment, a molding apparatus is provided to form a cross car beam with integral HVAC ductwork and knee energy absorbers.

Abstract: An energy absorbing bracket assembly (20) for supporting a knee bolster (22) on a vehicle instrument panel (12) includes a pair of brackets (30) that are each formed from sheet metal with a construction that is capable of absorbing energy even in confined spaces. Each bracket (30) includes a mounting flange (34) for mounting on the instrument panel (12), a support flange structure (38) for mounting the knee bolster (22), and a vertically extending energy absorbing section (40) having a peripheral portion (42) and a web (44) that extends from the peripheral portion adjacent the mounting flange (34) to the peripheral portion adjacent the support flange structure (38). A pair of peripheral legs (46) and (48) of the peripheral portion are located on opposite sides of the web (44) and cooperate therewith to define a pair of spaced openings (50, 52). The web (44) reinforces the bracket (30) to position the knee bolster (22) but buckles under loading to absorb energy.

Abstract: A master vac (6) is connected and fixed to a dash panel (20) side via a bendable pedal bracket (1), and a striker (4) extends forward toward a longitudinal direction of a vehicle and is arranged in such a manner as to protrude a front end (4a) thereof from the dash panel (20) at a normal time when an external force is not applied. When the external force is applied, the striker (4) is pressed, the pedal bracket (1) is deformed on the basis of a weakened portion (16) together therewith, and a master cylinder (7) moves to a position apart from a knee (31), whereby an interference between both elements can be avoided. As a result, in the case that the external force is applied to a front surface of the cab, it is possible to prevent the knee (31) of a driver from interfering with a clutch master vac mounting portion (24) and a brake master vac mounting portion (25) and it is possible to improve a safety of the driver.

Abstract: An improved vehicle glareshield having a structural body having a predetermined size and shape adapted to protect an instrument panel in a vehicle from glare; and a plurality of controlled strength members carried in said structural body which collapse in a controlled manner upon high force impact by an occupant in order to reduce a deceleration force experienced by an occupant upon impact with said instrument panel.

Abstract: A one-piece knee bolster for a motor vehicle includes a knee bolster cover adapted to mount to vehicle structure in an interior of a motor vehicle and at least one hollow reinforcing channel member extending along the knee bolster cover to reinforce the knee bolster cover.

Abstract: A knee airbag system disposed in an instrument panel accommodates one or more members extending from the instrument panel and through the system. The system includes a housing secured to the instrument panel or to a firewall of the vehicle. The housing may be configured with a housing aperture to allow the member to extend through. The system includes an inflator stored within the housing and operational in an accident situation. The system further includes an inflatable airbag stored within the housing and in communication with the inflator. The airbag has an airbag aperture in-line with the housing aperture. The airbag is sealed around the perimeter of the airbag aperture to enable inflation of the airbag. A bolster panel is secured to the airbag and includes a bolster aperture that is in-line with the housing aperture and the airbag aperture.

Abstract: The present invention involves a knee bolster airbag system to dissipate impact energy during an impact of a vehicle in which the system is disposed. The system includes a base which has a first surface disposed toward a vehicle compartment of the vehicle, and a cover having an inner surface attached adjacent the first surface of the base to define a cavity. The cover further has opposite first and second edges, wherein the first edge pivotally attaches the cover to the base about an axis to hinge the first edge of the cover to the base. The system further includes an airbag housing member adjacent which an airbag and a gas source are disposed. The system further includes a tether connected to the base and the cover. The tether allows a predetermined displacement of the second edge away from the base when the airbag is in a deployed state.

Abstract: A deformation element (5; 6; 7) for the interior of motor vehicles (1), preferably for being mounted in hollow spaces between the vehicle body parts (2; 3; 4), such as vehicle columns (2; 3), and an inner lining (15), is constructed as a ledge, which can be deformed over its longitudinal extent (L) and adapted to the outer outline configuration of car body parts (2; 3; 4) and which has several deformable regions (12; 13; 14) over its longitudinal extent (L).

Abstract: A knee restraint device for vehicles comprises a base plate and a knee protector part fastened to the base plate. The knee protector part has a load distributor plate with openings and has a covering of plastic. The covering has a rear face facing the load distributor plate and a front face directed in an opposite direction. The covering is provided with pins formed on the rear face and is fastened in a form-fitting manner to the load distributor plate by the pins projecting through the openings in the load distributor plate. The pins have free ends which are shaped such that the free ends project radially outwards and over the openings.

Abstract: A knee area protection apparatus for the protection of a vehicle occupant is provided which includes a deployment guiding plate and a support plate each having a top transverse edge, a bottom transverse edge, and side edges. The support plate is securable to the vehicle in a lower area of a seat compartment thereof. The knee area protection apparatus also includes retaining bands to retain and guide an air bag sack as it is deployed as well as to retain and guide the deployment guiding plate, which is moved by the deployment of the air bag sack.

Abstract: An air bag module which includes a panel member having an integral reaction canister having a plurality of reaction walls and a manifold assembly having a manifold. The manifold includes at least one deployment door retaining channel and is operable for retaining an air bag cushion, an inflator, and a deployment door. The deployment door includes at least one retaining bead and a trim portion which are separated by a pliant spacing leg. As the reaction canister is incorporated into the panel member, the need for a separate reaction canister component is eliminated, thereby reducing cost, weight and overall size of the air bag module and allowing the manifold assembly to be used across a wider range of vehicles. The retaining bead and spacing leg flexibly couple the cover door to the manifold and allow the cover door to be repositioned during installation of the manifold assembly into the panel member so as to eliminate gaps, puckering and other defects in the appearance or the vehicle interior.

Abstract: A crash pad for use in vehicle interiors. The crash pad includes an energy-absorbing honeycomb which has a cover plate attached thereon to prevent noise from being generated due to contact between the crash pad and vehicle interior surface during normal vehicle operation. The cover plate is attached on one side to the honeycomb with the other side being molded to match the shape of the interior surface of the vehicle. The cover plate includes positioning devices which locate and hold the crash pad during interior panel fabrication. The cover plate protects the honeycomb and the technician during handling and installation. The cover plate also helps to retain the shape of the honeycomb and provides a suitable surface for labels that may contain product identification and other information needed during use of the pads in mass production of vehicles.

Abstract: In a structure for absorbing energy in an upper portion of a motor vehicle body, an energy absorbing body is disposed between a roof side rail and a roof lining. The energy absorbing body is a resin-made rib member having three longitudinal ribs and transverse ribs that are more in number than the longitudinal ribs. The three longitudinal ribs are formed so as to compensate for a reduced amount of displacement that is allowed for a longitudinal rib for a purpose of energy absorption in a section of the energy absorbing body taken on an imaginary plane extending along at least one of the transverse ribs, by varying at least one of a pitch between two longitudinal ribs provided adjacent to each other in the section, an angle formed by each longitudinal rib with respect to an imaginary horizontal plane in the section, and a thickness of each longitudinal rib.

Abstract: A one-piece knee bolster for a motor vehicle includes a knee bolster cover adapted to mount to vehicle structure in an interior of a motor vehicle and at least one hollow reinforcing channel member extending along the knee bolster cover to reinforce the knee bolster cover.

Abstract: Inflatable knee bolster module assemblies are provided wherein a knee bolster panel and an associated reaction plate engage to form a bolster housing containing an inflatable knee cushion and a knee cushion inflator assembly. Upon actuation, the knee cushion inflator assembly provides an inflation fluid effective to inflate the knee cushion and to deploy the knee bolster panel to provide lower torso restraint for an oppositely positioned vehicle occupant while the knee bolster panel remains engaged with the reaction plate.

Abstract: The present invention relates to a protective device, preferably an airbag device, disposed in a panel of a vehicle, and preferably to a knee airbag housed in the vehicle instrument panel. The invention comprises an expanding protective device which is secured in an interior panel (1) or part of said panel in vehicle compartments, said device comprising an expansion means (5) housed behind an opening in said panel, and a surface cover (3) secured in front of said opening. The surface cover has a larger extension than said opening and is also secured to the surrounding panel. In addition, the surface cover (3) is adapted to cover substantially the whole of the expansion means (5) towards the compartment space, also in the expanded condition of said means.

Abstract: A knee guard on the passenger side of a vehicle includes left and right knee guard brackets disposed along left and right side faces of a glove box and secured at a front end thereof to a steering support beam, a connecting member transversely connecting these left and right knee guard brackets and a closure member of the glove box. The closure member includes a reinforcement therein and the reinforcement has a closed cross section which extends in the widthwise direction of the vehicle. When the knees of a passenger abut against the closure member of the glove box in the event of a head-on impact, the closure member is displaced forwardly and abuts against the left and right knee guard brackets, thereby an impact load is transmitted to the knee guard brackets.

Abstract: The present invention provides an integral passenger restraint system which has the passenger airbag system and knee bolster system integrated into one unit. The passenger airbag system of the present invention has an outer surface which is capped at opposite ends by a pair of end plates. Each end plate has a support zone and at least one crush zone. The support zone serves to cover the outer surface and encapsulate the air bag. The crush zone acts as the impact absorbing medium to absorb the impact from a vehicle passenger's knees during a vehicle crash.

Abstract: An advanced automobile passenger restraint and deceleration system is defined, the design of which is centered on retractible belts comprised of a unique, two-part combination of a single lap belt and dual shoulder belt restraints with the lap belt retractors automatically electrically locking upon application of restraint for firmly-located, tension-free lap belt comfort. This belt system features a padded body-centered, abdominal-force-distributing and fastening plate consisting of two halves, each half being attached to one shoulder belt and to one half of the lap belt with the two halves snapping together to apply said belt restraint system with one simple manual action.

Abstract: A passenger protection apparatus for a motor vehicle is provided comprising a first interior trim member and a second interior trim member. The first interior trim member, preferably an instrument panel, is attached to the motor vehicle and the second interior trim member attached to the first interior trim member. The second trim member is attached to the first trim member such that the second interior trim member is removable from the first interior trim member without detaching the first interior tnm member from the motor vehicle The second interior trim member is located in the knee impact region of the motor vehicle and comprises a first energy management device in the form of an inflatable restraint apparatus having an airbag and an inflator.

Abstract: In a supporting structure for an instrument panel of a motor vehicle, an energy absorbing member made of a synthetic resin foam is placed between a reinforcing member which is linked to the vehicle body and an instrument panel which is made of a synthetic resin and supported by the reinforcing member, and when the head of an occupant collides with the upper surface of the instrument panel the collision energy is absorbed by destroying foamed cells of the energy absorbing member 9 as the instrument panel is deformed or destroyed. Thus, the impact caused when the head of the occupant collides with the upper surface of the instrument panel can effectively be absorbed while enabling the reinforcing member and the instrument panel to be placed close to each other.

Abstract: A panel with an airbag is provided including a mounting flange portion. The mounting flange portion breaks at a thin wall portion of the mounting flange portion when a door insert is pushed toward the passenger compartment of a vehicle by the inflating pressure of an airbag during airbag deployment. The thin wall portion is formed between a plate portion of the door insert and protrusions formed on the mounting flange portion for engagement with a peripheral edge portion of an opening of the instrument panel insert. After the thin portion of the mounting flange portion breaks, substantially only the plate portion of the door insert is deployed toward the passenger compartment, leaving the mounting flange portion of the door insert at an airbag case side.

Abstract: The present invention is an automobile knee bolster structure capable of absorbing knee impact loads originating from various directions, and also having an upper portion able to absorb greater magnitude loads than the bottom portion of the bolster.

Abstract: An instrument panel structure provided in front of a driver's seat and a front passenger seat in a car has a steering support beam therein. An instrumental panel covers the steering support beam on the side of the driver's seat and the front passenger seat. Knee guards are disposed between the steering support beam and the instrument panel. An air-conditioning duct is fixed to the instrument panel above the knee guards, for preventing the knee guards from moving upwardly and for forming a duct space with the instrument panel. The air-conditioning duct and knee guards can support the legs of the passenger during an accident, thereby preventing the “submarine” phenomenon and improving passenger's safety. Additionally, the air-conditioning duct reinforces the instrument panel, thereby reducing the need for other reinforcing elements in the instrument panel.

Abstract: A light weight, structurally stiff instrument panel reinforcement structure for motor vehicle bodies. The reinforcement structure includes driver side and passenger side cross tubes that are preferably aluminum alloy extrusions, and a center stack support that is preferably a magnesium alloy casting connecting the cross tubes. The driver side cross tube supports a steering column assembly. The driver side cross tube has a greater average wall thickness than the passenger side cross tube. The driver side cross tube is hydroformed so that a middle portion has larger bending and torsion resistance than the end portions.

Abstract: A deformation element in a motor vehicle, especially for a dashboard, comprises at least one deformation body with a honeycomb cross section and encloses a cavity which is open on both sides. The wall of the cross section is closed all the way around, and is deformable to absorb energy and is subjected to an impact in the vicinity of one honeycomb side of the cross section for that purpose. The wall of the deformation body is formed from at least two partial sections connected with one another.

Abstract: A molded instrument panel having a plastic front panel and incorporating an integral air bag door is disclosed wherein the air bag door is hinged to the front panel by overlapping integral plastic members to ensure that the door does not separate from the instrument panel during air bag deployment. The instrument panel also includes a plastic frame integrally formed on an inner surface of the front panel which together with the door, encloses an uninflated air bag. Preferably, the hinge and portions of the frame are formed by a pressurized fluid so as to be hollow, thereby facilitating swinging movement of the door while preventing sink marks on an outer surface of the front panel.

Abstract: A crash pad for use in vehicle interiors. The crash pad includes an energy-absorbing honeycomb which has a cover plate attached thereon to prevent noise from being generated due to contact between the crash pad and vehicle interior surface during normal vehicle operation. The cover plate is attached on one side to the honeycomb with the other side being molded to match the shape of the interior surface of the vehicle. The cover plate includes positioning devices which locate and hold the crash pad during interior panel fabrication. The cover plate protects the honeycomb and the technician during handling and installation. The cover plate also helps to retain the shape of the honeycomb and provides a suitable surface for labels that may contain product identification and other information needed during use of the pads in mass production of vehicles.

Abstract: An automotive safety airbag installation includes a padded instrument panel having a U-shaped tearable seam in the panel skin, and a concealed airbag assembly having two hinged lids spaced from the instrument panel internal surface, such that during inflation of the airbag the lids swing outwardly to cause a flap-like section of the panel to deflect upwardly for expansion of the airbag into the passenger compartment. One of the lids closes a gap between the airbag and instrument panel to guide the airbag through the instrument panel and to protect both the airbag and the instrument panel from damage. The padded instrument panel is designed to achieve good shock absorbing action when struck by a human body, in the absence of airbag deployment.

Abstract: A knee bolster assembly is provided for use in a vehicle having a vehicle driver and including a steering column. The knee bolster assembly includes a central bracket adapted for partially surrounding the steering column and a foam element mounted on the central bracket. The knee bolster further includes left and right knee brackets mounted on opposite sides of the central bracket. The knee brackets each have a generally D-shaped cross-section including a convex rear wall positionable adjacent a vehicle driver such that upon loading by the vehicle driver, the knee brackets deform about multiple, nonspecific bend lines for absorption of energy. The knee brackets preferably include inner and forward walls rigidly secured to the central bracket and outer and rear walls that significantly deform for absorption of energy.

Abstract: A knee protection device in a motor vehicle comprises a bending-resistant load distributor plate which is arranged in the lower area of the dashboard. The device, which is made of plastic, extends in the transverse direction of the vehicle and is supported in the vehicle on at least one holder which can be bent in an energy-absorbing manner. An impact-resistant panel plate is disposed in front of this load distributor plate in the direction of the vehicle interior.

Abstract: An improved cross car beam is tailored to be utilized in either right hand or left hand drive applications. The cross car beam has channels which extend for elongate distances such that components mounted to the cross car beam can be mounted in the channels at an infinite number of locations. This allows the use of a single cross car beam for both right hand and left hand drive applications.

Abstract: An airbag module 20 is described having side walls 28, 29 which are weakened by being out of plane so that upon contact from a knee bolster 17 they collapse in a controlled manner.

Abstract: A knee restraint device for vehicles comprises a knee protector plate movable in the direction of the knees of a vehicle occupant, a base plate connectable to a vehicle structure having at least one opening for connection to a gas generator and a wall of flexible material folded between said base plate and said knee protector plate in the resting condition. Said wall is connected along a first closed rim to said base plate and along a second closed rim to said knee protector plate. To control the movement path of the knee protector plate during the inflation action a first edge of said knee protector plate oriented in the vehicle transverse direction is held swivable and releasable on said base plate and a second edge of said knee protector plate located opposite said first edge is secured to said base plate by a fastener which releases on activation of said gas generator due to the expansion pressure of said wall being deployed.

Abstract: A vehicle instrument panel assembly includes a vehicle console with first and second movable instrument panel pods positioned on opposing sides of the console. Each pod is independently movable in forward and rearward directions with respect to the console. Each pod includes a first airbag positioned at a forward side thereof and a second airbag positioned at a rearward side thereof for improved energy management.

Abstract: An energy-absorbing deformation profile for a motor vehicle such as a knee protection device for an underside of a center console area has a rigid linkage profile section for fastening the deformation profile on a center console cross member. The linkage profile section is designed so that it can be deformed while absorbing energy.