Lear Corporation

International Automotive Components Group North America, Inc.

Toyota Technical Center, U.s.a., Inc.

Todd DePue

Glenn A Cowelchuk

Michael J Hier

David Dooley

Randy S Reed

Robert J Adams

Michael W Cass

David Anthony Hein

Richard Morabito

Joseph T Donatti

Arun Chickmenahalli

Kenneth William Paul Shaner

Mark Heinze

Charles Bruce Banter

Charles A Haba

Richard David George

Paul Nagy

Sarkis B Mikhjian

David J Cauvin

Steven M Christian

Jerry G Yatros

An energy absorber for a vehicle includes an elongate member having lateral and longitudinal axes. The elongate member may include one or more channels which are oriented to have walls which extend in the general direction of the lateral axis. An upper surface of at least one of the channels may have an engagement feature that may be configured to engage a stationary member of a vehicle when an impact force brings the engagement feature into contact with the stationary member. The channels may be configured to deform and collapse to absorb at least some of the impact force.

Energy absorbing countermeasure

A console assembly for a vehicle includes a console body defining an opening communicating with a storage bin. The storage bin has opposing side walls each having a groove formed therein. A sliding member is slidably mounted within the grooves of each of the side walls within the storage bin. A console cover is pivotally mounted to the sliding member and defines a cover assembly. The cover assembly is slidably movable between a closed position wherein the console cover covers the opening of the console body and a partially open position wherein a portion of the opening of the console body is exposed. The console cover is pivotally movable between the partially open position and a fully open position wherein the console opening and the sliding member are exposed. The console cover includes at least one follower extending outwardly therefrom, wherein the follower is slidably mounted within the grooves in the storage bin wall.

Vehicle console

In at least one embodiment, the present invention relates an airbag assembly comprising a panel having a tear seam forming at least one airbag door, and a door chute assembly comprising a laterally extending flange connected to the panel proximate the airbag door. The door chute assembly includes a chute depending from the flange away from the panel and the chute has at least one opening. The airbag assembly further comprises a door panel assembly including at least one door panel disposed within the chute and connected to the airbag door. The door panel has a downwardly depending flange having at least one projection extending laterally through the at least one opening of the chute. The airbag assembly further comprises an inflatable airbag mounted on the door chute.

Airbag assembly

In at least one embodiment, the present invention relates to a trim panel for concealing an air bag. The panel comprises a substrate and a cover over the substrate. The cover includes a cover skin. The panel also comprises a tear seam having at least a portion comprising a pattern of alternating residual wall thicknesses in the panel. At least one embodiment of the present invention also relates to a method for making a trim panel for concealing an air bag.

Trim panel having foam bridge supported hidden tear seam

In at least certain embodiments, the present invention relates to automobile interior door panel having an insert molded bolster. In at least one embodiment, the automobile interior door panel is made by providing a bolster within a first mold cavity, introducing a first resin into the first mold cavity to form a door panel sub assembly comprising a door panel portion secured to the bolster, with the door panel portion having a first upper door panel portion above the bolster and a lower door panel portion below the bolster, providing the door panel sub assembly within a second mold cavity, and introducing a second resin less rigid that the first material into the second mold cavity to form a second upper door panel portion over and secured to the first upper door panel portion.

Insert molded bolster in two-shot door panel

A pocketed panel assembly for a vehicle door is disclosed herein. The pocketed panel assembly includes a trim panel, a partial pocket structure, and a living hinge. The trim panel has a pivotal edge, and the partial pocket structure also has a pivotal edge. The living hinge integrally joins the pivotal edge of the trim panel to the pivotal edge of the partial pocket structure. In such a configuration, the partial pocket structure can be rotated about the living hinge and substantially abutted against the trim panel so as to form an open pocket on the trim panel.

Pocketed panel assembly

The present invention provides for an improved trim part, such as an automotive handle, with a soft feel, for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, an automotive handle includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. A handle cover is molded to at least a portion of the substrate by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the handle with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the handle.

Automotive handle with soft feel and method of making the same

The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Automotive armrest with soft feel and method of making the same

An automotive trim assembly adapted to have an airbag deploy through the trim assembly includes a substrate with a deployment door integrally molded with the substrate and having a front surface adapted to face the interior of the automobile and a back surface opposite the front surface. The airbag is adapted to be stored behind the deployment door, which is adapted to open when the airbag is deployed. A cover is molded onto at least a portion of the substrate and deployment door and includes an inner and outer layer of a polymer material having a substantially non-cellular structure and an inner core having a cellular structure positioned between the inner and outer layers. The cover is adapted to keep the door attached to the trim assembly when the airbag is deployed.

Automotive trim assembly having an integrated airbag door

In one advantageous embodiment of the claimed invention, an integral cushioned trim panel (-) for a vehicle passenger cabin () is provided. The integral cushioned trim panel (-) includes a substrate () for attachment to a predetermined portion (-) of the vehicle. The substrate () has a cover member () coupled thereto for substantially covering the substrate (). In addition, the substrate () and the cover member () have a cushioning member () disposed therebetween. The cushioning member () is injection molded between the substrate () and the cover member () for forming an integral construction, minimizing the manufacturing cycle time, and decreasing the costs associated therewith.

Integral cushioned trim panel for a vehicle

In at least one embodiment, the present invention relates an airbag assembly for use with a trim panel having a tear seam forming at least one airbag door, and a door chute assembly comprising a laterally extending flange connected to the panel proximate the airbag door. The door chute assembly includes a chute depending from the flange away from the panel and the chute has at least one opening. The airbag assembly further comprises a door panel assembly including at least one door panel disposed within the chute and connected to the airbag door. The door panel has a downwardly depending flange having at least one projection extending laterally through the at least one opening of the chute.

An injection molding system () includes a first mold half () and a second mold half (), which forms a cavity () with the first mold half (). A cavity intrusion element () is displaceable to extend within the cavity (). A displacement mechanism () is coupled to the cavity intrusion element (). A controller () is coupled to the displacement mechanism () and controls the intrusion depth (D) of the cavity intrusion element () during an injection molding process. A method of forming an article includes the pressurizing of the cavity () within a mold () via a gas. A material having a blowing agent is injected into the cavity (). The gas pressure within the cavity () is released. The cavity intrusion element () is backed out from within the cavity (). The material is cured.

Low-density part injection molding system

A portable tray for use at multiple locations of the interior of a vehicle includes a body adapted to be operatively supported to the interior of the vehicle and defining at least one substantially planar work surface. The tray also includes a support mechanism connected to the body and adapted to removably support the body to structural components of the interior of the vehicle such that the tray can be manually moved and used at various locations within the interior of the vehicle.

Portable tray for vehicle interior

A method of manufacturing an airbag assembly and a trim component for vehicle including the step of providing a first mold structure having a first surface formed therein, a second mold structure having a second surface formed therein and a third mold structure having a third surface formed therein. The first mold structure and the second mold structure are positioned to define a first cavity. A first material is introduced into the first cavity to form a substrate. The substrate and the third mold structure are positioned to define a second cavity. A second material is introduced into the second cavity to form at least one of a portion of an airbag assembly and an outer layer overmolded onto the substrate. Additionally, a scrim material may be disposed within the second cavity to produce a hinge having an embedded layer of scrim material.

Method of manufacturing an airbag assembly and vehicle trim component

The present invention provides for an improved bolster with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, the bolster includes a substrate formed by co-injecting a first and second material into a first shot mold cavity in a first shot of a molding operation. In a second shot mold cavity, a cover is formed on at least a portion of the substrate by co-injecting into a mold chamber a third and fourth material in a second shot of the molding operation. The fourth material defines an outer skin surrounding the third material which may include a foamed material to provide a soft, light cellular inner core such that when a force is applied to the cover, the outer skin will deform and compress the inner core, providing a soft feel to the bolster.

Growing community of inventors

Brighton, MI, United States of America

Todd DePue