Abstract: A process for manufacturing a door trim panel with an integral soft armrest pad is provided which includes providing male and female steam chest mold halves, loading and restraining a cover material onto the female mold half, closing the male mold half to a fill position to form a cavity, inserting a divider into the cavity to separate the cavity into a low density volume and a high density volume, filling the high density volume with first polymeric material, filling the low density volume of the mold cavity with second polymeric material, withdrawing the divider from the mold cavity, and heating the first and second polymeric materials such that the first and second polymeric materials are melt bonded together, including at positions where particles from the first polymeric material contact particles from the second polymeric material. The low density volume creates the soft armrest pad.

Abstract: A mold apparatus and method for forming a shaped laminate in one step are provided where the laminate includes a cladding layer and a foam backing layer. The apparatus includes a male mold half matable to a female mold half that define a mold cavity. An inlet is mounted on the mold apparatus for introducing foamable materials into the mold cavity. Edge folding members, carried by one of the mold halves, movable from a retracted position to an extended position, fold the cladding layer over at least part of the edge of the foam backing layer. Trim blades are located adjacent to the edge folding members movable from a retracted position adjacent the cavity to an extended position engaging the other mold half to sever the cladding layer to define the finished shape of the laminate.

Abstract: A mold apparatus and method for forming a shaped laminate in one step are provided where the laminate includes a cladding layer and a foam backing layer. The apparatus includes a male mold half matable to a female mold half that define a mold cavity. An inlet is mounted on the mold apparatus for introducing foamable materials into the mold cavity. Edge folding members, carried by one of the mold halves, movable from a retracted position to an extended position, fold the cladding layer over at least part of the edge of the foam backing layer. Trim blades are located adjacent to the edge folding members movable from a retracted position adjacent the cavity to an extended position engaging the other mold half to sever the cladding layer to define the finished shape of the laminate.

Abstract: A mold apparatus and method for forming a shaped laminate in one step are provided where the laminate includes a cladding layer and a foam backing layer. The apparatus includes a male mold half matable to a female mold half that define a mold cavity. An inlet is mounted on the mold apparatus for introducing foamable materials into the mold cavity. Edge folding members, carried by one of the mold halves, movable from a retracted position to an extended position, fold the cladding layer over at least part of the edge of the foam backing layer. Trim blades are located adjacent to the edge folding members movable from a retracted position adjacent the cavity to an extended position engaging the other mold half to sever the cladding layer to define the finished shape of the laminate.

Abstract: A door trim panel assembly and method of making same for attachment to structure of a vehicle includes a door trim panel and a carrier formed from a plastic material attached to the door trim panel and for attachment to the structure of the vehicle. The door trim panel assembly also includes a seal integral with the carrier for contacting the structure to seal the carrier to the structure.

Abstract: The present invention provides, in a preferred embodiment, an interior trim component for a motor vehicle including a first membrane with a connected foam backing, an apertured second membrane spread adjacent the foam backing of the first membrane, and a moldable rigid polymeric material providing a backing for the second membrane and supporting the first membrane, the moldable polymeric material penetrating the apertures of the second membrane and adhering to the foam backing of the first membrane.

Abstract: A method and mold apparatus are provided for forming and trimming a vehicle inner door panel. The panel is a shaped laminate including a vinyl cover layer and a structural foam backing layer having a glass fiber reinforcing substrate. Upper and lower mold members have peripheral seals which define a mold cavity when the mold is closed. A plurality of movable trim blades are carried by the lower mold member adjacent the seal. The trim blades move among retracted, intermediate and extended positions. Hydraulic rams open and close the mold and move the trim blades. Sheets of vinyl and substrate are placed across the lower mold member and the mold is closed to seal the substrate and vinyl layer about their periphery. As the mold closes, abutment surfaces on both mold members advance the trim blades to an intermediate position to pinch the cover layer against the substrate inwardly of the peripheral seals. A two-part polyurethane liquid foam system is injected into the cavity.

Abstract: The present invention provides, in a preferred embodiment, an interior trim component for a motor vehicle including a first membrane with a connected foam backing, an apertured second membrane spread adjacent the foam backing of the first membrane, and a moldable rigid polymeric material providing a backing for the second membrane and supporting the first membrane, the moldable polymeric material penetrating the apertures of the second membrane and adhering to the foam backing of the first membrane.

Abstract: A hook and pin fastener assembly for connecting and reliably locating a molded door trim panel to an apertured inner door panel of a motor vehicle without the need for conventional fasteners. A pair of conventional hooks are molded into the upper and lower portions of a molded door trim panel, and a locator pin is molded into a center portion of the molded door trim panel. The pair of hooks extend through corresponding apertures in the inner door panel and slidably engage the inner door panel so that movement of the upper and lower portions of the molded door trim panel is restricted in the lateral direction. The locator pin has a main body and a free end, wherein the free end is integral with and extending from the main body. The free end is slightly smaller than a locating aperture in the inner door panel, and the main body is larger than the locating aperture.

Abstract: The present invention provides a new and improved method for manufacturing vehicle interior trim panels such as door panels and instrument panels in which different regions of the trim panel have different colors or other aesthetic characteristics. Two pieces of sheet vinyl having the desired color or other aesthetic characteristic desired in the manufactured trim panel are cut to shape and then bonded together edge-to-edge to form a composite two-tone vinyl sheet. This composite vinyl sheet is draped over a mold having a blade projecting from the mold surface. A retainer is installed onto the backside of the composite vinyl sheet to attach the composite vinyl sheet to the blade and thereby hold the vinyl in place with the bond between the two sheets located at the apex of the blade. The mold is closed and urethane is poured against the backside of the composite vinyl sheet to encapsulate the retainer.

Abstract: A retainer for receiving a fastener and adapted for loading into a mold for embedment in a trim article molded of molding material. The retainer has a housing having an upper portion for accepting the fastener and a lower portion for embedment in the molded trim article. A flexible lip encompasses the housing for sealingly engaging with the mold thereby preventing the molding material from making contact with the upper portion of the housing and allowing the molding material to make contact with the lower portion of the housing.