Lear Corporation

Ford Global Technolgoies, LLC

Ford Motor Company Limited

Ut Automotive Dearborn, Inc.

International Automotive Components Group North America, Inc.

Bari W Brown

George Bernard Byma

John Marstan Tiesler

Steven P Ireland

Frank Qiukui Liu

Bernard Gerard Marchetti

James Hugh Fowler

Kelly Michael Kohlstrand

Alan Perelli

Derren Woods

Ryan Mowery

Manoj Patnala

Heidi Ann Dibble

A method of forming a thin-walled skin includes coating at least one side of a mold cavity of a molding tool, evacuating air from the mold cavity, and filling the mold cavity with a molten polymeric resin. Among other optional variations of the disclosed method, an inert gas is injected into the molten polymeric resin simultaneously with the step of filling the mold cavity with a molten polymeric resin. As a result, high quality, large, thin-walled skins are produced by the teachings of the present disclosure.

Process for molding thin-walled skins

A vehicle interior trim system such as an instrument panel or a door panel includes a panel substrate defining a deployment aperture. An inflatable device such as an air bag is adapted to deploy through the aperture during a crash. A natural, tanned leather skin covers the substrate, wherein the skin has a tear seam corresponding to the aperture on a hidden surface of the skin. An aperture door may be fitted within the deployment aperture which is adapted to open against the skin in response to deployment of the inflatable device. The tear seam is comprised of a region on the hidden surface of the skin having a disrupted fiber matrix from exposure to an alkaline solution such as ammonia, bleach, sodium tetraborate, sodium hydroxide, sodium bicarbonate, trisodium phosphate, potassium hydroxide, and potassium carbonate.

Leather trim panel skin hidden tear seam with disrupted fiber matrix

A seat integrated tether system for use in a vehicle for the secure placement of an article on a vehicle seat. One or more retractable or extendable tethers are adapted for attachment to the side of the vehicle seat. By use of the system with the front passenger seat of a vehicle the driver may have ready access to the contents of the retained article, which may be an item storage article such as an open top bag, case or storage net.

Seat integrated tether system

A vehicle headliner assembly () includes a headliner structural layer. A foam beam () is joined to the headliner structural layer. An NVH pad () is partially embedded within the foam beam (). A method of forming a headliner structure is provided. The method includes forming a headliner main body (). The headliner main body () is positioned in a mold () that has a recess (). The mold () is closed. Foam is introduced into the recess () to form a foam beam () and to join the foam beam () to the headliner main body (). A portion of an NVH pad () is embedded in the foam.

Headliner apparatus with foam imbedded NVH pad

The present invention is directed toward providing a headliner for a motor vehicle comprising an interior layer adapted to present a surface that is exposed to the interior of the vehicle, a flexible film assembly that is supported by the interior layer opposite to the interior of the vehicle; and a fill layer adapted to be flowed over the flexible film and subsequently hardened to form a main supporting body of the headliner. The flexible film assembly has a first film layer adapted to establish a generally flat base surface that is mounted to the interior layer and a second film layer supported on the first film layer having a plurality of voids formed by portions of the second film layer that are spaced from said first film layer at predetermined intervals so as to establish an undulating upper surface of the film assembly. The plurality of voids are adapted to act as a plurality of resonating cavities to attenuate acoustical frequencies within the vehicle.

Acoustically attenuating headliner and method for making same

A method for forming a headliner assembly includes forming a main body blank having a periphery in a shape corresponding to a desired shape of the headliner assembly, the mold has a correspondingly shaped surface with a recess including an intermediate wall portion. The method includes introducing foam into the recess to simultaneously form at least one foam beam enclosing a selected component area, and join the at least one beam to the main body. The intermediate wall can be an accessory, and the beam may be formed to surround the component area. Additional foam application may be included to acoustically control the headliner's response to buzz, squeaks and rattles.

Foam in place urethane for structural headliners

A method of manufacturing a foamed plastic article includes disposing a release film on a mold surface of a mold cavity. At least a portion of a bushing is inserted through the release film to form an aperture in the release film. The bushing defines an inlet for foamable material. The mold cavity is then sealed. The foamable material is then injected into the mold cavity through the inlet, wherein the foamable material is conformed to the shape of the mold cavity.

Method and apparatus for injection foam molding

A cushion structure having multiple indentation load deflection areas created by using inflatable preformed containers within a base cushion foam and method for making same. The invention can be utilized to make cushions for use with separately manufactured upholstery covers as well as for pour-in-place or foam-in-cover upholstered cushions. Such cushions are suitable for use in commercial and residential furniture as well as automobiles, buses, trains and aircraft.

Multiple indentation load deflection foam molding

A headliner assembly for an automotive vehicle is provided. The headliner assembly utilizes a pre-formed headliner and a preformed inflatable permanent air duct liner which is molded in place using foam to substantially surround and adhere said air duct liner to said headliner.

Foam in place integral air duct

This process and apparatus use at least one chopper unit. The fiber choppers may be laser beam choppers or existing standard chopper units. The process and apparatus for producing a fiber-reinforced molded composite comprises providing a moldable composition, sequentially spraying a moldable composition into the mold, subsequently providing chopped fibers to the moldable composition and depositing the moldable composition and chopped fibers in mold and molding the moldable composition and fibers in the apparatus under heat and pressure to form the molded composite. One industrial application for these choppers is compression molding of interior trim panels for automobile doors. The choppers spray chopped glass fiber strands into a resin mixture. The glass and a polyol, isocyanate (&mdash;NCO) urethane resin mixture at the proper glass loading, distribution and pattern is fed to the mold.

Fiber choppers for molding processes

This process and apparatus use at least two chopper units. The fiber choppers may be laser beam choppers or existing standard chopper units. The process and apparatus for producing a fiber-reinforced molded composite comprises providing a moldable composition, a first fiber chopper providing chopped fibers to the apparatus from a first direction, a second fiber chopper providing chopped fibers to the apparatus from a second direction, wherein the first direction is different from the second direction and molding the moldable composition and fibers in the apparatus under heat and pressure to form the molded composite. One industrial application for these choppers is compression molding of interior trim panels for automobile doors. The choppers spray chopped glass fiber strands into a resin mixture. The glass and a polyol, isocyanate (&mdash;NCO) urethane resin mixture at the proper glass loading, distribution and pattern is fed to the mold.

Multiple fiber choppers for molding processes

This apparatus uses a programmable controller to control laser beam and standard fiber chopper units. The units usually are affixed to resin mix heads. The conventional choppers use steel blades that are randomly spaced, angled and sized. The PC also varies the speed of the standard chopper. The laser device operates in a manner that allows one to set the pulse rate for the specific purpose of varying the fiber length. During operation, the intensity of the laser may be adjusted to accommodate cutting or different sizes and kinds of fibers. The apparatus preferably produces fiber reinforced urethane substrates such as interior door panels for automobile doors.

Programmable fiber chopper and method therefor

This apparatus uses laser beams in place of existing standard glass chopper units affixed to resin mix heads. Conventional glass choppers use steel blades that eventually wear out or break, adding to maintenance costs. The laser device operates in a manner that allows one to set the pulse rate for the specific purpose of varying the fiber length. During the injection operation, intensity of the laser may be adjusted to accommodate cutting or different sizes and kinds of fibers. The laser apparatus preferably produces long fiber reinforced urethane substrates such as interior door panels for automobile doors.

Growing community of inventors

Ann Arbor, MI, United States of America

Bari W Brown