The present invention is directed to a 4-bar kinematic link component and method for forming the 4-bar kinematic link using a single rotary molding tool. The invention eliminates the need to form individual components of the bracket from several different tools, which will then requires additional assembly steps. The 4-bar kinematic link is formed from two different materials each having a different in mold shrinkage value. This allows for hinge pins to be formed through a base component in a way that will prevent sticking of the components together thereby allowing the parts to have it relative to one another using the hinge pin. The final component is a 4-bar kinematic link that can be used as a 4 bar link mechanism for providing motion.

There is described a method of creating a hinge in a body of expandable material, said body being substantially flat and having at least two planar regions connected by said hinge to facilitate folding of the planar regions about said hinge, comprising: expanding said expandable material to form said body; creating a region of excess expandable material in said body adjacent said hinge; and compressing said region of excess expandable material into the hinge of said body after the expandable material has fused to create a hinge having a concentrated volume of expanded material when compared to said at least two planar regions of said body.

A vehicle console includes a housing having an interior volume. A console bin is disposed within the interior volume. The console bin is an injection molded member having a base and a plurality of bin walls coupled to the base at living hinges, wherein the plurality of bin walls form an interior surface that extends orthogonally from the base.

A vehicle console includes a housing having an interior volume. A console bin is disposed within the interior volume. The console bin is an injection molded member having a base and a plurality of bin walls coupled to the base at living hinges, wherein the plurality of bin walls form an interior surface that extends orthogonally from the base.

A hinged component fabrication method in which, in a layup stage of fabrication, the component includes a live hinge joining uncured material portions together at a hinge region and comprising a layer of tensile fabric at least partially infiltrated by an uncured elastomer layer at least partially interposed between the tensile fabric and the uncured material portions such that the uncured elastomer blocks the uncured material portions from infiltrating the hinge region. The method may include locating overlapped tensile fabric and elastomer layers in a tool and introducing polymer-based material into the tool such that polymer-based material portions overlap respective opposite ends of the fabric and elastomer layers. The polymer-based material portions are formed to a desired shape using the forming tool so that the fabric and elastomer layers form a live hinge between the polymer-based material portions.

A one-piece cast component having at least one integrated attachment part is disclosed. The component includes at least one pin which is rigidly connected to an attachment part; a housing at least partially enclosing the pin in a contactless manner; the pin being arranged in the axial direction between two axial connecting webs and being rigidly connected via the latter to the housing; the pin being arranged in the radial direction between a plurality of radial connecting webs and being rigidly connected via the latter to the housing; wherein the connecting webs are dimensioned in such a way that only the latter break at respective predetermined breaking points when pivoting the attachment part for the first time relative to the housing, whereafter the attachment part, together with the pin, is mounted so as to be pivotable with respect to the housing. The regions of the connecting webs that remain on the housing after the breaking operation prevent the pin from being removed from the housing. The disclosure further relates to a method for producing such a cast component having an integrated attachment part.

A paint delivery tool or paint tray, suitable for use in a paint bucket, includes a paint roller grid mounted to a shelf that includes an auxiliary paint receptacle or cut bucket intended for separate use with a paint brush. The upper shelf includes a semicircular rim and lip for mounting the tool or paint tray to the top of a circular bucket. The paint roller grid extends from an opposite straight edge of the shelf and downward into the paint bucket. A paint roller and a paint brush can then be stored and used separately to reduce waste, messes and clean up. The paint roller grid and the shelf can be an integral one piece member, and they can be joined by a living hinge if molded as a plastic member.

A vehicle console includes a housing having an interior volume. A console bin is disposed within the interior volume. The console bin is an injection molded member having a base and a plurality of bin walls coupled to the base at living hinges, wherein the plurality of bin walls form an interior surface that extends orthogonally from the base.

There is described a method of creating a hinge in a body of expandable material, said body being substantially flat and having at least two planar regions connected by said hinge to facilitate folding of the planar regions about said hinge, comprising: expanding said expandable material to form said body; creating a region of excess expandable material in said body adjacent said hinge; and compressing said region of excess expandable material into the hinge of said body after the expandable material has fused to create a hinge having a concentrated volume of expanded material when compared to said at least two planar regions of said body.

A composite structure with an integrated hinge is disclosed. In various embodiments, the composite structure includes a plurality of layers of fiber reinforced polymer material; and a hinge structure comprising one or more layers of bendably flexible hinge material a first region of which is interleaved between adjacent layers of said layers of fiber reinforced polymer material comprising the composite structure and bonded to said adjacent layers by bonding material comprising said composite structure, and a second region of which extends beyond said layers of fiber reinforced polymer material comprising the composite structure.