Abstract: The present invention relates to a two-shot, non-shut-off method of manufacturing a 100% grained trim component for a vehicle. The method includes actuating a tool insert between a mold cavity and a secondary void to form a molded trim component having a groove. A first shot of material is injected to form a first trim element having a grained class-A side. During the first shot, flash enters the secondary void to provide a non-shut-off condition. The tool insert is retracted to define a ditch in the first trim element. A second shot of material is injected to form a second trim element having a grained class-A side, during which time a portion of the second shot enters the ditch to provide a non-shut-off condition. The trim elements are then bonded where a portion the second trim element bonded to the first trim element within the groove.

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.

Abstract: A mold assembly for forming a multi-shot molded part includes a mold system defining a mold cavity, and a retracting member disposed in the mold system selectively movable between extended and retracted positions in the mold cavity. A first molding material is injected in the mold cavity when the mold system is in a configuration with the retracting member in the extended position, forming a first portion of a molded part including a thin wall portion. A second molding material is injected in the mold cavity when the mold system is in another configuration with the retracting member in the retracted position, forming a second portion of the molded part and providing open cavity portions adjacent both surfaces of the thin wall portion. The second material penetrates the thin wall portion, filling the open cavity portions and forming a connection between the first and second portions of the molded part.

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.