Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of loading a trim blank into a cavity of a first side of a mold and depositing a molten thermoplastic material onto a core on the first side of the mold. The method also includes the steps of closing the mold, moving the slide in a channel of the core, and injecting a molten thermoplastic material into a second side of the mold to form the interior trim panel.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of placing a trim insert into a cavity of an apparatus and over a first seal thereof. The method also includes the steps of loading a retainer over the trim insert to sandwich the trim insert between the retainer and the first seal and closing the apparatus. The method further includes the steps of filling the cavity with a plastic material and introducing steam into the apparatus to expand the plastic material to form a substrate and bonding the substrate against the trim insert to form an interior trim panel.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of placing a trim insert into a cavity of an apparatus and over a first seal thereof. The method also includes the steps of loading a retainer over the trim insert to sandwich the trim insert between the retainer and the first seal and closing the apparatus. The method further includes the steps of filling the cavity with a plastic material and introducing steam into the apparatus to expand the plastic material to form a substrate and bonding the substrate against the trim insert to form an interior trim panel.

Abstract: A method of making a panel by depositing a first extrudate into a mold cavity and pressing the first extrudate with a mold core to form a skin layer. The skin layer is cooled inside the mold cavity. A core material is loaded in the mold cavity onto the skin layer. A second extrudate is deposited into the mold cavity and onto the core. The second extrudate forms a structure layer. The mold core is pressed against the structure layer so that the structure layer forms around the core. The pressure of the mold core against the structure layer also presses the core into the skin layer. The structure layer and the skin layer cool while the mold core is pressed against the structure layer and the core material and the skin layer to form a panel. The panel is removed from the mold cavity.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of loading a trim blank into a cavity of a mold and loading an edge of the trim blank on a movable slide of the mold. The method also includes the steps of depositing a molten thermoplastic material onto a core of the mold and partially closing the mold. The method further includes the steps of moving the slide into a channel of the core, completely closing the mold, and forcing the molten plastic material into a down-turned flange area of the mold to form the interior trim panel with a down-turned flange.

Abstract: A method for manufacturing an object out of a plurality of materials having differing structural characteristics and capable of being placed in a molten state, the melted materials are deposited in an open mold having a pair of complementary mold portions. Various non-melted but possibly pre-heated structural, reinforcing, or energy absorbing materials can be placed in the mold with the melted materials. A closing force is applied to the mold and the item is removed after it has cured. According to one embodiment, a molding apparatus is provided to form a cross car beam with integral HVAC ductwork and knee energy absorbers.

Abstract: A method for manufacturing an object out of a plurality of materials having differing structural characteristics and capable of being placed in a molten state, the melted materials are deposited in an open mold having a pair of complementary mold portions. Various non-melted but possibly pre-heated structural, reinforcing, or energy absorbing materials can be placed in the mold with the melted materials. A closing force is applied to the mold and the item is removed after it has cured. According to one embodiment, a molding apparatus is provided to form a cross car beam with integral HVAC ductwork and knee energy absorbers.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of loading a trim blank into a cavity of a mold and loading an edge of the trim blank on a movable slide of the mold. The method also includes the steps of depositing a molten thermoplastic material onto a core of the mold and partially closing the mold. The method further includes the steps of moving the slide into a channel of the core, completely closing the mold, and forcing the molten plastic material into a down-turned flange area of the mold to form the interior trim panel with a down-turned flange.

Abstract: An apparatus having a single screw extruder and a twin screw extruder. The extruders are designed to operate intermittently in a batch-type process. The single screw extruder contains a plurality of barrel segments with an internal cavity, an inlet and a transfer die located at an outlet. The barrel segments provide processing flexibility in that the L/D ratio of the single screw extruder can be varied to accommodate various materials, fillers and material throughputs. The twin screw extruder includes a body having an internal cavity disposed therein. The body includes an inlet at a first end, an outlet at a second end and an inlet located along the length of the twin screw extruder to accept fiber material (fibers) from a side stuffer. A transfer valve is connected to the outlet of the twin screw extruder. The transfer valve controls the flow of melt from the twin screw extruder into an injection plunger.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of loading a trim blank into a cavity of a first side of a mold and depositing a molten thermoplastic material onto a core on the first side of the mold. The method also includes the steps of closing the mold, moving the slide in a channel of the core, and injecting a molten thermoplastic material into a second side of the mold to form the interior trim panel.

Abstract: A frangible cover for a vehicle air bag assembly is provided. The cover includes at least one tear seam across the inner surface of the cover which tear seam is substantially invisible at the exterior surface. The tear seam is made up of a multiplicity of spaced apart depressions of substantially uniform depth extending from the inner surface of the cover towards the outer surface of the cover thereby reducing the thickness of the cover to a substantially uniform level at the locations of the depressions. The depressions are spaced at substantially regular intervals along the length of the tear seam substantially without preferential concentration of the depressions at any one location along the tear seam. The depressions may be of variable width along the length of the tear seam as measured in the direction substantially transverse to the tear seam.

Abstract: A molded inner door panel for an automotive vehicle having a header extending above a beltline. The inner door panel has a notched metal frame insert, and a polymeric molded frame encasing the metal frame insert within the header. Advantageously, the notches provide precise inboard and outboard adjustability of the header of the inner door panel during assembly to the vehicle. The molded inner door panel has a resilient insert, e.g., elastomeric thermoplastic, disposed between the notches of the metal frame insert and the polymeric molded frame. Additionally, the polymeric material of the polymeric molded frame is substantially thinner in the area covering the notches than in the area bordering the notches. These features prevent the polymeric material from cracking upon adjustment.

Abstract: A method of making a door trim panel assembly for attachment to an inner panel of an automotive vehicle includes the steps of placing a door trim substrate into a cavity of a mold and placing at least one component into the cavity against the door trim substrate. The method also includes as an alternative of pre-joining the at least one component to the door trim substrate. The method also includes the steps of filling the cavity with a plastic material. The method further includes the steps of introducing steam into the mold to expand the plastic material to form a carrier and bond the carrier against the at least one component and door trim substrate to form a single door trim panel assembly.

Abstract: A mold is provided having the shape of the trim panel and having a blade projecting from the mold at the juncture between the first and second regions to be covered by the different sheet materials. A first sheet material is provided and cut to fit the first region and also extend over the blade. This first sheet is draped over the mold and the blade. A second sheet material is bonded to a rigid substrate material, with the rigid substrate material having a flange structure along the edge margin thereof which is adapted to snap-fit over the blade of the mold and thereby hold in place the first sheet material which had previously been draped over the blade. The mold is then closed and a suitable molding material is injected to adhere to the back side of the first sheet material and the substrate layer of the second sheet material to thereby form the rigid trim panel. The mold is opened and the rigid trim panel is removed from the blade.

Abstract: A vehicle door assembly according to the invention includes a structural framework, including a rear end for mounting a latch, a front end for mounting a hinge and a beam portion extending between the front and rear ends. An outer door panel is provided for mounting on the structural framework to provide the outer surface of the door assembly. A structural inner panel is provided for mounting on the structural framework and is of molded plastic and has a generally planar trim wall facing toward the occupant compartment and edge wall portions which extend transverse to the planar trim wall to thereby envelope the structural framework within the structural inner panel.