Abstract: A door module and a method of packaging and assembling the door module (10) to a vehicle door (12) is disclosed. The door module (10) comprises a non-structural substrate carrier (14), a door trim panel (15) configured to be coupled to the substrate carrier, a door trim interface member (32) integrally molded with the carrier (14) as a single unitary article, and a carrier interface member (33) extending from the door trim panel (15). The door trim panel is releasably coupled to the carrier by releasable engagement of the door trim interface member (32) and the substrate carrier interface member (33). The carrier (14) may also have an integrally molded impact absorber (24, 26) or an integrally molded pull cup support (28). The method of preparing a module vehicle door (12) for transportation to a location for assembly of a vehicle door comprises mounting the trim panel (15) to the carrier (14) by engaging a projection (33) on the trim panel (15) with a retainer (32) integrally molded with the carrier (14).

Abstract: A method of forming a panel is disclosed. The method includes forming a flexible skin (22); coupling a compressible material (24) to the skin (22); positioning the skin (22) and compressible material (24) in a mold; and forming a rigid substrate (20) around the skin (22) and compressible material (24) providing a first soft region (12) wherein the compressible material (24) is disposed between the skin (22) and the substrate (20) so that a first soft region (12) is defined by the compressible material (24).