Toyota Motor Engineering & Manufacturing North America, Inc.

Toyota Jidosha Kabushiki Kaisha

Logan R Astrike

Toshinao Wada

Skylar C Watson

Chad Eric Anderson

A method of forming a headliner for a vehicle includes forming the headliner into a desired shape from one or more materials. The headliner includes a headliner cutout portion corresponding to an opening through the headliner. A reinforcement bracket preform is formed into the headliner cutout portion during the step of forming the headliner. The headliner cutout portion is removed from the headliner. The reinforcement bracket preform is removed from the headliner cutout portion and a shaped reinforcement bracket is formed.

Method of forming a headliner that includes shaped reinforcement brackets

A method of installing an overhead panel to another panel is provided. The method includes connecting a base of a positioning structure to a surface of the overhead panel. The positioning structure includes the base, a stem that extends outwardly from the base and an enlarged head that extends outwardly from the stem and overhangs the base. The enlarged head of the positioning structure is moved against a ledge of the another panel. The ledge contacts the enlarged head and moves the enlarged head from a catch configuration to an insertion configuration where the enlarged head reduces in dimension. The enlarged head is passed by the ledge such that the enlarged head moves from the insertion configuration to the catch configuration of increased dimension. The enlarged head is hung on the ledge such that the positioning structure supports the overhead panel in a pre-installation position that is different from an installed position.

Positioning structures that allow for temporary placement of overhead panels

A duct system, and more particularly, a rigid endcap of the duct system can be configured to prevent a register from being damaged and from being displaced upon a curtain side airbag deployment. The duct system can include a headliner defining an opening, and a soft duct operatively connected to the headliner. The duct system can include a rigid endcap operatively connected to the headliner and to the soft duct. An airflow channel can be defined by the headliner, the soft duct, and the rigid endcap. Additionally, the rigid endcap can define a terminal end of the airflow channel, and the opening can be located along the airflow channel directly below the rigid endcap.

Rigid endcap for a duct system in a headliner

A vehicle includes a roof assembly including a roof panel. A headliner is located interior of the roof panel. An overhead console assembly is connected to the headliner. An overhead console wire bracket includes a longitudinal portion that extends in a vehicle longitudinal direction from the overhead console assembly toward a front edge of the headliner and a lateral portion that extends from the longitudinal portion in a vehicle lateral direction. The lateral portion engages a wire that extends over the front edge of the headliner.

Overhead console wire brackets for wire management

A seat belt assembly, a garnish to cover a vehicular pillar and a method of making a vehicular pillar garnish. The garnish used in the assembly cooperates with a belt with a connected latch such that when the latch is disengaged from a corresponding seat belt buckle, a latch-receiving structure with a recessed portion formed in the garnish prevents contact with latch such that vibratory movement imparted to the disengaged latch as a result of vehicular movement does not result in the latch knocking or banging against the garnish. The recessed portion includes more than one region that may be used to provide extra functionality to the garnish, such as one or more of temporary storage for a portable electronic device and seat belt rerouting.

Vehicles including pillar garnish assemblies with seat belt latch-receiving structures

A vehicle includes a vehicle floor. The vehicle floor includes a rigid floor structure and a floor covering for the floor structure. The floor covering includes carpeting with a corrugated section where the carpeting has a nominal surface contour corresponding to the shape of the floor structure, and is repeatedly doubled over itself in a corrugation direction to define a series of adjacent ridges and valleys along the corrugation direction.

Vehicle floor with corrugated carpeting for increased rigidity

A cargo bed extension assembly includes a tailgate structured to be movable between a raised configuration and a lowered configuration. The tailgate includes a cavity formed therein. An extension mechanism is positioned within in the cavity. The extension mechanism includes an extension member coupled to the tailgate so as to be movable between a stowed configuration and an extended configuration, and so as to enable rotation of the extension member from the extended configuration to a raised configuration. The mechanism also includes a cover portion coupled to the extension member so as to be movable between a stowed configuration and a deployed configuration in which the cover portion covers at least a portion of the bed.

Cargo bed extension assembly including cover for a tailgate

A trim panel assembly for a vehicle is provided having a pillar and a trim panel adapted to attach to at least a portion of the pillar. The trim panel having an upper edge and a lower edge. At least one ledge extending generally orthogonally away from the lower edge of the trim panel. The assembly further includes a headliner, the upper edge of the trim panel abutting the headliner to compress the headliner when the trim panel is in an installed position. The trim panel is adapted to closely abut a headliner wherein the ledge provides the installer to apply a greater force to the trim panel during installation to provide for a greater headliner crush. In order to finish installing the trim panel, the installer must push upwards on the ledges thereby creating greater interference with the headliner to properly secure the trim panel.

Push-up ledge for trim panel

A trim cap with a tether. The trim cap includes a cap with a tether. The tether has a distal end with a living hinge and a J-shaped hook extending from the living hinge. An assist grip with an attachment section having a tether aperture is also included. The J-shaped hook and the living hinge allow for the J-shaped hook to lay directly against the tether in an install position such that the distal end and J-shaped hook can pass through the tether aperture of the attachment section. The J-shaped hook and the living hinge spring into a release position after the J-shaped hook has passed through the tether aperture. Also, the J-shaped hook is spaced apart from the tether and cannot pass back through the tether aperture. In this manner the trim cap is tethered to the level one part during installation of the component.

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Dexter, MI, United States of America

Logan R Astrike