Abstract: A vehicle interior panel (10) includes a decorative covering (16) with a non-visible tear seam that forms a deployment opening through the covering during airbag deployment. The tear seam is formed by mechanical piercing of a skin layer (20) of the covering using a piercing tool (30) having a compound chamfer (40). Such piercing tools allow the mechanical piercing process to produce non-visible and functional tear seams in polymeric materials and non-polymeric materials such as leather, including materials with relatively low elastic recovery characteristics. Tear seams formed in this manner can offer larger processing windows, lower manufacturing and equipment cost, and/or shorter cycle times when compared to other methods such as laser scoring.

Abstract: A vehicle interior panel (10) includes a decorative covering (16) with a non-visible tear seam that forms a deployment opening through the covering during airbag deployment. The tear seam is formed by mechanical piercing of a skin layer (20) of the covering using a piercing tool (30) having a compound chamfer (40). Such piercing tools allow the mechanical piercing process to produce non-visible and functional tear seams in polymeric materials and non-polymeric materials such as leather, including materials with relatively low elastic recovery characteristics. Tear seams formed in this manner can offer larger processing windows, lower manufacturing and equipment cost, and/or shorter cycle times when compared to other methods such as laser scoring.

Abstract: A self-tearing wrap and methods for its manufacture are disclosed, the wrap being useful for incorporation onto interior trim panels. The wrap includes an unscored skin such as leather affixed to a foam layer made of an open or closed cell foam material having specific properties. Interior trim panels including the self-tearing leather wrap may include weakened substrates operable to facilitate the deployment of an airbag.

Abstract: An article of manufacture and method are disclosed which may include a skin including a molded groove, the skin having an exposed surface and a lower surface, the skin forming a sheet of material; a seal having an upper surface disposed adjacent to the lower surface of the skin and covering a region of the lower surface of the skin including the molded groove; at least one strand of stitching material threaded between the exposed surface of the skin and the foam backing layer; and a backing layer forming a backing for the skin and the seal, the backing layer having an upper surface secured to the skin and the seal, and a lower surface.

Abstract: A bilaminate wrap and methods for its manufacture are disclosed, the wrap being useful for incorporation onto interior trim panels. The bilaminate wrap comprises a skin integrated with a foam layer made of a plastics material, most preferably a thermoplastic polyolefin. The plastics material permits thin constructions and the use of skiving to incorporate different profiles of variable thicknesses into the panels.

Abstract: Vehicle foam assemblies and methods of creating vehicle interior trim are provided for placing one or more insert components onto and/or into a foam tool; laying a skin proximate to the one or more insert components; placing a substrate proximate to the skin; and introducing foam to form or re-form the skin against and/or around the one or more insert components.

Abstract: An article of manufacture and method are disclosed which may include a skin including a molded groove, the skin having an exposed surface and a lower surface, the skin forming a sheet of material; a seal having an upper surface disposed adjacent to the lower surface of the skin and covering a region of the lower surface of the skin including the molded groove; at least one strand of stitching material threaded between the exposed surface of the skin and the foam backing layer; and a backing layer forming a backing for the skin and the seal, the backing layer having an upper surface secured to the skin and the seal, and a lower surface.

Abstract: The present invention relates to a method of producing a carpeted vehicle interior panel. A rigid backing having a carpeted surface and a mating surface is molded such that the backing mating surface is 3-dimensional and self-supporting after molding. The backing is overlaid atop the panel with the mating surface juxtaposed a mating surface of the panel. The backing is secured to the panel by linear welding.