Abstract: A method of forming a thin-walled skin includes coating at least one side of a mold cavity of a molding tool, evacuating air from the mold cavity, and filling the mold cavity with a molten polymeric resin. Among other optional variations of the disclosed method, an inert gas is injected into the molten polymeric resin simultaneously with the step of filling the mold cavity with a molten polymeric resin. As a result, high quality, large, thin-walled skins are produced by the teachings of the present disclosure.

Abstract: A method of forming wrapped components includes positioning an injection molded skin in a mold, forming a foam-in-place (FIP) foam substrate against the injection molded skin, removing the injection molded skin from the FIP foam substrate, bonding an external wrap to the FIP foam substrate, and reusing the injection molded polyolefin skin to form additional FIP foam substrates. A spacer layer may be bonded between and to the FIP foam substrate and the external wrap. The injection molded skin may be formed from a polyolefin polymer and may be a thermoplastic elastomer such as a thermoplastic vulcanizate. The FIP foam substrate may a FIP urethane foam substrate and the external wrap may be a leather wrap or a faux leather wrap. The injection molded skin reusable and may used a predetermined number of times, e.g., at least ten times, before being replaced by a replacement injection molded skin.

Abstract: A method of forming a thin-walled skin includes coating at least one side of a mold cavity of a molding tool, evacuating air from the mold cavity, and filling the mold cavity with a molten polymeric resin. Among other optional variations of the disclosed method, an inert gas is injected into the molten polymeric resin simultaneously with the step of filling the mold cavity with a molten polymeric resin. As a result, high quality, large, thin-walled skins are produced by the teachings of the present disclosure.

Abstract: The present invention in one or more embodiments provides a method of forming a polymeric skin of a vehicle interior part such as an instrument panel, the method including the steps of heating a molding cavity having a shape of the vehicle interior part, injecting a polymer into the molding cavity to form the polymeric skin, and cooling the molding cavity. The heating may be carried out prior to the injecting. The heating may overlap in time with the injecting. The cooling may be carried out subsequent to the injecting. The cooling may overlap in time with the injecting. The polymeric skin may then positioned next to a cushion layer which is in turn positioned next to a substrate layer to form the vehicle interior part.

Abstract: A vehicle headliner assembly (152) includes a headliner structural layer. A foam beam (174) is joined to the headliner structural layer. An NVH pad (156) is partially embedded within the foam beam (174). A method of forming a headliner structure is provided. The method includes forming a headliner main body (170). The headliner main body (170) is positioned in a mold (220) that has a recess (224). The mold (220) is closed. Foam is introduced into the recess (224) to form a foam beam (174) and to join the foam beam (174) to the headliner main body (170). A portion of an NVH pad (156) is embedded in the foam.

Abstract: An automotive headliner including a headliner support having upper and lower surfaces and a pair of opposite side edges with foam impact countermeasures integrally molded to the upper surface. The countermeasures form a pair of rails positioned adjacent the side edges and are adapted to absorb an impact from a vehicle occupant. A method of making the headliner includes inserting the headliner into a mold having first and second mold plates and corresponding first and second molding surfaces so that the lower surface faces the first molding surface. A release film is inserted into the mold between the upper surface and the second molding surface. The mold is closed and foam is injected into the mold between the upper surface and the release film. The mold is then opened and the headliner removed. The headliner may be removed prior to the foam being substantially completely cured.