Abstract: In at least certain embodiments, the present invention relates to a trim panel and an apparatus and method of making the same. In at least one embodiment, the trim panel comprises a first portion and a second portion with a transition portion extending therebetween with the first portion and the second portion having curved portions having radii of less than 5 mm.

Abstract: A method of sewing a decorative seam includes providing a material suitable for receiving stitches, folding a first portion of the material onto a second portion of the material to form a bend, sewing a first stitch to join the first portion to the second portion, the stitch being substantially parallel to the bend and spaced apart therefrom, the first stitch forming a seam, unfolding the material and sewing a second and third stitch into the material such that the second and third stitches are substantially parallel to the seam and arranged such that the second and third stitches are on opposite sides of the seam.

Abstract: 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.

Abstract: A method of sewing a decorative seam includes providing a material suitable for receiving stitches, folding a first portion of the material onto a second portion of the material to form a bend, sewing a first stitch to join the first portion to the second portion, the stitch being substantially parallel to the bend and spaced apart therefrom, the first stitch forming a seam, unfolding the material and sewing a second and third stitch into the material such that the second and third stitches are substantially parallel to the seam and arranged such that the second and third stitches are on opposite sides of the seam.

Abstract: In at least certain embodiments, the present invention relates to a trim panel and an apparatus and method of making the same. In at least one embodiment, the trim panel comprises a first portion and a second portion with a transition portion extending therebetween with the first portion and the second portion having curved portions having radii of less than 5 mm.

Abstract: In at least certain embodiments, the present invention relates to a trim panel and an apparatus and method of making the same. In at least one embodiment, the trim panel comprises a first portion and a second portion with a transition portion extending therebetween with the first portion and the second portion having curved portions having radii of less than 5 mm.

Abstract: In one advantageous embodiment of the claimed invention, an integral cushioned trim panel (14a-14c) for a vehicle passenger cabin (10) is provided. The integral cushioned trim panel (14a-14c) includes a substrate (22) for attachment to a predetermined portion (12a-12c) of the vehicle. The substrate (22) has a cover member (24) coupled thereto for substantially covering the substrate (22). In addition, the substrate (22) and the cover member (24) have a cushioning member (16) disposed therebetween. The cushioning member (16) is injection molded between the substrate (22) and the cover member (24) for forming an integral construction, minimizing the manufacturing cycle time, and decreasing the costs associated therewith.

Abstract: A trim part for use with a vehicle includes a substrate and a trim cover overlaying the substrate. The trim cover has first and second portions that are folded together to form a flexible edge seal that is engageable with the vehicle. A method of making such a trim part is also disclosed.

Abstract: A trim system configured to be received by a vehicle door substrate is provided. Some embodiments of the trim system include a locator and a feature. The feature is moveable relative to the locator after the locator is assembled with the substrate. Some embodiments of the trim system include a first and second feature. The second feature is moveable relative to the first feature after the first feature is assembled with the substrate.

Abstract: An energy absorbing countermeasure for motor vehicle doors comprises a body having at least a first zone and a second zone. Each zone has at least one surface with recesses in the surface and portions between recesses. The portions are broken upon impact and enter into the recess to exhibit energy absorbing efficiency. The recesses in the first zone are arranged or configured to absorb a first desired peak load during impact and the recesses in the second zone are arranged or configured to absorb a second desired peak load during impact. The first desired peak load is different from the second desired peak load.

Abstract: A trim system configured to be received by a vehicle door substrate is provided. Some embodiments of the trim system include a locator and a feature. The feature is moveable relative to the locator after the locator is assembled with the substrate. Some embodiments of the trim system include a first and second feature. The second feature is moveable relative to the first feature after the first feature is assembled with the substrate.

Abstract: A method of forming a vehicle trim component includes providing a first component layer having a vent aperture formed therethrough. A second component layer is then formed adjacent a surface of the first component layer, wherein gas may flow through the vent aperture of the first component layer during the step of forming the second component layer.

Abstract: A method of forming a vehicle trim component includes providing a first component layer having a vent aperture formed therethrough. A second component layer is then formed adjacent a surface of the first component layer, wherein gas may flow through the vent aperture of the first component layer during the step of forming the second component layer.

Abstract: A trim panel assembly includes a first trim panel and a second trim panel. The first trim panel has an attachment portion, and the second trim panel has an attachment portion that cooperates with the attachment portion of the first trim panel to connect the first and second trim panels together to provide a trim panel assembly that allows relatively sliding movement between the first and second trim panels. The first trim panel can have a single attachment portion that extends continuously throughout the length thereof, while the second trim panel can have a plurality of discrete portions that extends along the length thereof, or vice versa. The attachment portion of the second trim panel can be molded either about or within the attachment portion of the first trim panel.

Abstract: The present invention relates to an automobile interior trim panel, and a method and a tool for making the same. In at least one embodiment, the method comprises providing a first mold half and a second mold half, wherein the first mold half has a protrusion retractable between a first position in contact with the second mold half and a second position spaced from the second mold half. The first and second mold halves, when the protrusion is in the first position, cooperates to form a first mold cavity. The method further comprises introducing a first resin into the first mold cavity to form a panel subassembly circumscribing the protrusion. The method further comprises moving the protrusion towards the second position to reveal an opening in the panel subassembly and forming a panel portion on a portion of the upper surface of the panel subassembly.

Abstract: A method of dielectrically embossing material comprising the steps of providing a dielectric embossing machine having a dielectric tool, providing a coloring agent, providing a material, applying the coloring agent to the dielectric tool, placing the material in the dielectric embossing machine, bringing the dielectric tool into contact with the material, energizing the dielectric tool, dielectrically embossing the material, de-energizing the dielectric tool, allowing the material and the coloring agent to cool, and backing the dielectric tool away from the material.

Abstract: A method of forming a trim panel is provided comprising molding an interior panel substrate including a main body portion, a lock portion molded as a portion of the interior panel substrate and having a locking element, a first living hinge positioned between the lock portion and the main body portion, a lock engagement portion, and a second living hinge positioned between the lock engagement portion and the main line portion. The method molds an exterior cover stock, including a belt line skin portion, onto an outer surface of the interior panel substrate. The lock portion is rotated about the first living hinge to trap the belt line skin portion between the lock portion and the lock engagement portion in order to create a mechanical skin lock. The lock engagement portion is then rotated about the second living hinge towards an inner surface of the interior panel substrate.

Abstract: An injection molding system (10) includes a first mold half (20) and a second mold half (22), which forms a cavity (23) with the first mold half (20). A cavity intrusion element (34) is displaceable to extend within the cavity (23). A displacement mechanism (36) is coupled to the cavity intrusion element (34). A controller (38) is coupled to the displacement mechanism (36) and controls the intrusion depth (D) of the cavity intrusion element (34) during an injection molding process. A method of forming an article includes the pressurizing of the cavity (23) within a mold (14) via a gas. A material having a blowing agent is injected into the cavity (23). The gas pressure within the cavity (23) is released. The cavity intrusion element (34) is backed out from within the cavity (23). The material is cured.

Abstract: A locking system (12) for a mold (14) includes a first mold half (20), a second mold half (22), and a lock assembly that is coupled to one of the mold halves (20, 22). The lock assembly includes a wear plate (80), that is disposed between the first mold half (20) and the second mold half (22), and an adjustment element (86), which is disposed between the wear plate (80) and one of the mold halves (20,22). The lock assembly also includes a wear plate locking fastener (84), that locks the position of the wear plate (80), and an adjustment fastener (88), which is separate therefrom and adjusts the position of the wear plate (80).

Abstract: A method of manufacturing a laminated vehicle trim panel includes initially positioning a flexible first material within a mold cavity of a first mold portion. A second mold portion for closing the cavity of the first mold portion is then provided. A second material is introduced into the mold cavity to form a substrate, such that the substrate and the first material form a laminated vehicle trim panel. A portion of the substrate between the outer peripheral edge of the substrate and a second portion of the substrate defines a brim. The brim has a mounting feature for attaching the laminated vehicle trim panel to a second panel.