Abstract: A method of manufacturing a door for a vehicle may include forming an interior panel having a geometry including contours and vehicle accessories disposed thereon; forming a foam member having a varying thickness coinciding with the geometry of the interior panel, the foam member being resiliently compressible; retaining a moisture shield against the foam member; fixing the foam member to the exterior-facing side of the interior panel, the varied thickness of the foam member being aligned with the geometry of the exterior-facing side of the interior panel; and fixing the interior panel to the exterior door, the foam member resiliently biasing the moisture shield against an interior-facing side of the exterior door. The moisture shield, the foam member, and the interior panel form a pre-assembled module prior to fixing the interior panel to the exterior door.

Abstract: A door assembly comprises an interior panel and an exterior panel. A first semi-rigid barrier sheet is disposed between the interior and exterior panels. One or more features are formed in the first semi-rigid barrier sheet accommodating components housed between the interior and exterior panels. A second semi-rigid barrier sheet is offset from the first semi-rigid barrier sheet to diffuse sound waves directed toward an aperture formed through the first semi-rigid barrier sheet.

Abstract: A molded water shield integrated between an exterior panel assembly and a trim panel of a vehicle includes a semi-rigid barrier sheet and a seal integrally molded into the semi-rigid barrier sheet. The seal includes reliefs formed therein and is detachable from the semi-rigid barrier sheet to define an opening through the semi-rigid barrier sheet.

Abstract: A molded water-shield integrated between an exterior panel assembly and a trim panel of a vehicle. The molded water-shield includes a semi-rigid barrier sheet and a series of resonance frequency diffusion (RFD) reliefs formed in the semi-rigid barrier sheet. The RFD reliefs diffuse sound waves directed at the semi-rigid barrier sheet.

Abstract: A water and sound attenuating barrier for positioning between the interior surface of a vehicle door exterior panel and the door interior trim panel. The barrier is formed of a sheet of semi-rigid material having an inner face and an outer face. A thick layer of sound attenuating material is bonded to the sheet inner face and pressure sensitive adhesive is applied upon the sheet outer face. The sheet and trim panel are fastened together with the layer against the trim panel and with the adhesive bearing face exposed, to form a unitary module. To assemble the module with the door panel, the module exposed face is pressed against the door panel interior surface for securing the adhesive on the sheet outer face thereto. Mechanical fasteners removeably secure the sheet and the trim panel together and, also, secure the trim panel to the door panel during the assembly.

Abstract: A system for adhesively fastening water deflector type panel liners upon supporting panel surfaces of automotive vehicle doors and the like substrates, includes forming shallow, narrow channels in the liners and positioning thick strips of pressure sensitive adhesive within the channels. The liners are applied upon the panel surfaces and pressure is applied against the channels towards the panel surfaces to partially collapse the channels and flow the adhesive into contact with the panel surfaces. The adhesive flows into, and smooths any irregularities on the panel surfaces while adhering the liners thereto. The exposed faces of the adhesive strips may be covered with a wide mesh fabric to normally prevent the adhesive on one strip from sticking to adjacent surfaces of other similar liners in a stack or a roll of liners. When pressure is applied to the channels, the adhesive flows through the mesh into contact with the supporting panels.

Abstract: A baffle for a liquid container, such as a vehicle gasoline tank or the like, is formed of a resilient, cellular foam plastic material placed within the container. The cells of the plastic are interconnected, and the volume of the solid material forming the foam plastic is only a minor portion of the overall volume of the material including its open cells. The plastic material is tightly compressed into a long strip which is surrounded by a casing formed of a thin sheet. The plastic material is chemically inert relative to the liquid, but the casing sheet is substantially soluble in the liquid. A predetermined length section of the strip may be inserted in a container. When liquid is poured into the container, the casing is substantially dissolved to free the compressed material, which resiliently expands to substantially fill the container and form a cellular baffle therein.