Abstract: A combination energy absorption and environmental insulating barrier incorporated into a vehicle door trim panel assembly. A thermoformed and hardened shell has an exterior facing surface and an opposite recessed interior facing surface. A three-dimensional structural component is constructed of a durable plasticized and expanded foam material and exhibiting the properties of moisture imperviousness and impact resistance. The structural component has a specified length, width and thickness and is configured to substantially seat against the recessed interior facing surface of the shell. A dimensional misalignment tolerancing being established between the opposing facing surfaces of the thermoformed shell and the expanded structural component and owing to tolerancing vagaries associated with the expanded foam of the structural component. An exposed facing surface of the structural component secures against an inner associated surface of a vehicle door.

Abstract: A combination energy absorption and environmental insulating barrier incorporated into a vehicle door assembly, the assembly including an assembleable trim pad. A three dimensional structural component has a specified length, width and thickness and with at least one impact absorbing portion being designed into the structural component. A plurality of projections and recesses are defined in at least one of first and second faces of the structure component, the component further being molded into the desired three dimensional shape using an impact absorbing material. A moisture impervious barrier is placed upon an inner face of the trim pad and the structural component is adapted to being secured to an inner face of the trim pad and prior to installation of the trim pad against an opposing and inner facing side of the vehicle door.

Abstract: A sealing gasket for use with a vehicle part, the part having a specified shape with at least one sealing surface. The gasket includes a carrier strip constructed of a flexible material having a first face and a second face, a specified width and thickness and further being constructed of a high-tear strength plasticized material. An adhesive is exhibited upon the first face of material and includes a tacking surface applied to or impregnated with the first face of the carrier strip. A peel-away backing surface is secured over the first face of material. At least one elongate bead of material is fixedly applied to the second face in a desired pattern, the bead typically including a foam-in-place silicone material. The adhesive surface is applied to the sealing surface of the part, after removal of the peel-away backing, to affix the carrier strip and so that the bead pattern projects from the sealing surface.

Abstract: A sealing gasket for use with a vehicle part, the part having a specified shape with at least one sealing surface. The gasket includes a carrier strip constructed of a flexible material having a first face and a second face, a specified width and thickness and further being constructed of a high-tear strength plasticized material. An adhesive is exhibited upon the first face of material and includes a tacking surface applied to or impregnated with the first face of the carrier strip. A peel-away backing surface is secured over the first face of material. At least one elongate bead of material is fixedly applied to the second face in a desired pattern, the bead typically including a foam-in-place silicone material. The adhesive surface is applied to the sealing surface of the part, after removal of the peel-away backing, to affix the carrier strip and so that the bead pattern projects from the sealing surface.

Abstract: A sound and water and dust barrier (20) for a vehicle and method for making the same are disclosed. The water barrier (20) includes a laminated body (24) having a central layer (34) made of a filled plastic which provides sound dampening characteristics to the water barrier (20), and preferably two outer layers (36,38) of unfilled plastic sandwiching about the central layer (34). Ideally, the body (24) has a vacuum formed speaker recess (44) or contoured shape formed therein. Also, flexible clip pockets (50) may be sealingly attached about openings (70) in the body (24) to allow the water barrier (20) to be clipped to inner and outer door panels (25, 22) of a vehicle door (23). Further, an adhesive (30) and a release agent (32) may be applied on the opposing outer layers (36, 38). Preferably, the central and outer layers (34, 36, 38) are coextruded together.