Abstract: A vehicle panel with a folded-over or wrapped edge is disclosed. The vehicle panel comprises a main body portion. The main body portion includes a first layer and a second layer. The first layer is formed of a substantially rigid material and has a first surface, a second surface and an edge. The second layer is coupled to the second surface of the first layer and formed of a substantially flexible material. The vehicle panel also comprises a flap integrally formed with the main body portion at the edge and comprises at least the second layer. The vehicle panel further comprises a hinge separating the flap from the main body portion, the hinge is defined by at least a portion of the first layer having a reduced thickness. The flap is folded back about the hinge towards the first surface of the first layer to substantially conceal the edge.

Abstract: A vehicle panel with a folded-over or wrapped edge is disclosed. The vehicle panel comprises a main body portion. The main body portion includes a first layer and a second layer. The first layer is formed of a substantially rigid material and has a first surface, a second surface and an edge. The second layer is coupled to the second surface of the first layer and formed of a substantially flexible material. The vehicle panel also comprises a flap integrally formed with the main body portion at the edge and comprises at least the second layer. The vehicle panel further comprises a hinge separating the flap from the main body portion, the hinge is defined by at least a portion of the first layer having a reduced thickness. The flap is folded back about the hinge towards the first surface of the first layer to substantially conceal the edge.

Abstract: A trim panel for a vehicle is formed with a pinch-sealed edge by compression molding. The mold is designed with one or more cutting surfaces that compress or pinch the trim panel material to the point of severing the trim panel to form a tightly compressed and cut edge.

Abstract: A vehicle panel with a folded-over or wrapped edge is disclosed. The vehicle panel comprises a main body portion. The main body portion includes a first layer and a second layer. The first layer is formed of a substantially rigid material and has a first surface, a second surface and an edge. The second layer is coupled to the second surface of the first layer and formed of a substantially flexible material. The vehicle panel also comprises a flap integrally formed with the main body portion at the edge and comprises at least the second layer. The vehicle panel further comprises a hinge separating the flap from the main body portion, the hinge is defined by at least a portion of the first layer having a reduced thickness. The flap is folded back about the hinge towards the first surface of the first layer to substantially conceal the edge.

Abstract: A trim panel for a vehicle is formed with a pinch-sealed edge by compression molding. The mold is designed with one or more cutting surfaces that compress or pinch the trim panel material to the point of severing the trim panel to form a tightly compressed and cut edge.

Abstract: A vehicle headliner having a panel formed of a compressed and molded thermoplastic polymer fiber batt, wherein the fibers are thermally fused together at a multiplicity of locations to impart to the panel a self-supporting rigidity to allow the headliner to retain its shape while also rendering the panel highly deformable and resilient to allow the panel to be bent during installation and thereafter resiliently recover its original shape, is prepared by a process in which improved loft retention of the batt is achieved by appropriate selection of heating parameters and/or selection of polymeric fibers. Also, a process for achieving reduced plastic deformation and improved mechanical properties by modifying the crystallinity of the binder fibers of the batt is disclosed.

Abstract: A vehicle headliner having a panel formed of a compressed and molded thermoplastic polymer fiber batt, wherein the fibers are thermally fused together at a multiplicity of locations to impart to the panel a self-supporting rigidity to allow the headliner to retain its shape while also rendering the panel highly deformable and resilient to allow the panel to be bent during installation and thereafter resiliently recover its original shape, is prepared by a process in which improved loft retention of the batt is achieved by appropriate selection of heating parameters and/or selection of polymeric fibers. Also, a process for achieving reduced plastic deformation and improved mechanical properties by modifying the crystallinity of the binder fibers of the batt is disclosed.