Ford Motor Company Limited

James H Zimmerman

Gerald Arthur Heath

Thomas William Pietila

Richard K Leung

A vehicular assembly incorporating knee bolsters. The assembly is fabricated largely from integrally injection molded plastic that is capable of reinforcing the knee bolsters, supporting the instrument panel and forming the ducts of an air distribution system. In the event of a collision, the knee bolster plates are stabilized so that they can cushion and limit the movement of the knees of a driver or passenger.

Cross vehicular assembly including knee bolsters

A method of manufacturing an article having a substructure with a wall having a wall surface and a foam layer along the wall surface, including the steps of: placing the substructure in a tool having a die surface being spaced apart from the wall surface; injecting a foamable material between the die surface and the wall; applying a clamp load between the die surface and the foamable material; allowing the foamable material to expand and exert a force on the wall; and reducing the clamp load on the foamable material to reduce the force exerted on the wall by the expanding material whereby the force exerted on the wall does not deform the article.

Growing community of inventors

Saline, MI, United States of America

James H Zimmerman