Abstract: A vehicle interior component is disclosed. The component may be a trim component configured to support an airbag module providing an airbag configured to be deployed through an opening into the vehicle interior. The trim component may comprise a panel comprising a first material and providing a front side and a back side; and a structure formed from a second material molded on the back side of the panel. The panel may comprise a compression-formed component. The compression-formed component may be configured to provide the opening through a door established upon deployment of the airbag to facilitate deployment of the airbag. The structure may be configured to support the airbag module and to direct the airbag toward the door during deployment of the airbag.

Abstract: An airbag deployment system is provided that includes a support structure, and a fabric material configured to form a show surface of a vehicle interior panel. A first portion of the fabric material is coupled to the support structure by a rigid connection, a second portion of the fabric material is coupled to the support structure by a detachable connection, and the detachable connection is configured to release the second portion of the fabric material from the support structure upon contact between an airbag and the fabric material.

Abstract: A vehicle interior component is disclosed. The component may be a trim component configured to support an airbag module providing an airbag configured to be deployed through an opening into the vehicle interior. The trim component may comprise a panel comprising a first material and providing a front side and a back side; and a structure formed from a second material molded on the back side of the panel. The panel may comprise a compression-formed component. The compression-formed component may be configured to provide the opening through a door established upon deployment of the airbag to facilitate deployment of the airbag. The structure may be configured to support the airbag module and to direct the airbag toward the door during deployment of the airbag.

Abstract: A method of manufacturing a vehicle trim component includes disposing a fiber panel within a mold cavity, and aligning an airbag chute assembly with the fiber panel. The method also includes compressing the fiber panel within the mold cavity to form the fiber panel into a desired shape. At least a portion of the fiber panel is compressed between a surface of the mold cavity and a surface of the airbag chute assembly.

Abstract: A vehicle interior comprises a zero-gap joint formed by a first component that holds a sheet-like flexible material that is supported by supports, and a protrusion of a second component that contacts and deforms the material. The material may comprise a fabric or coated material that is coordinated with the design of the interior. The joint may be formed between components that move relative to one another during normal operation of the vehicle, such as between an instrument panel and a vehicle door panel.

Abstract: An airbag deployment system is provided that includes a support structure, and a fabric material configured to form a show surface of a vehicle interior panel. A first portion of the fabric material is coupled to the support structure by a rigid connection, a second portion of the fabric material is coupled to the support structure by a detachable connection, and the detachable connection is configured to release the second portion of the fabric material from the support structure upon contact between an airbag and the fabric material.

Abstract: A method of manufacturing a vehicle trim component includes disposing a fiber panel within a mold cavity, and aligning an airbag chute assembly with the fiber panel. The method also includes compressing the fiber panel within the mold cavity to form the fiber panel into a desired shape. At least a portion of the fiber panel is compressed between a surface of the mold cavity and a surface of the airbag chute assembly.

Abstract: An airbag deployment system is provided that includes a support structure, and a fabric material configured to form a show surface of a vehicle interior panel. A first portion of the fabric material is coupled to the support structure by a rigid connection, a second portion of the fabric material is coupled to the support structure by a detachable connection, and the detachable connection is configured to release the second portion of the fabric material from the support structure upon contact between an airbag and the fabric material.

Abstract: A vehicle interior assembly includes a class A visible surface material having a first layer formed from a thermal plastic olefin and a second layer formed from a foam. The vehicle interior assembly also includes a substrate supporting the class A visible surface material. The substrate defines an opening for receiving a drop-in chute having an outer surface. In addition, the vehicle interior assembly includes a retention mechanism for securing the outer surface of the drop-in chute to the substrate.

Abstract: An airbag deployment system is provided that includes a support structure, and a fabric material configured to form a show surface of a vehicle interior panel. A first portion of the fabric material is coupled to the support structure by a rigid connection, a second portion of the fabric material is coupled to the support structure by a detachable connection, and the detachable connection is configured to release the second portion of the fabric material from the support structure upon contact between an airbag and the fabric material.

Abstract: A vehicle interior assembly that includes airbags and a method of forming thereof.

Abstract: In at least one embodiment, the present invention relates an airbag assembly comprising a panel having a tear seam forming at least one airbag door, and a door chute assembly comprising a laterally extending flange connected to the panel proximate the airbag door. The door chute assembly includes a chute depending from the flange away from the panel and the chute has at least one opening. The airbag assembly further comprises a door panel assembly including at least one door panel disposed within the chute and connected to the airbag door. The door panel has a downwardly depending flange having at least one projection extending laterally through the at least one opening of the chute. The airbag assembly further comprises an inflatable airbag mounted on the door chute.

Abstract: In at least one embodiment, the present invention relates to a trim panel for concealing an air bag. The panel comprises a substrate and a cover over the substrate. The cover includes a cover skin. The panel also comprises a tear seam having at least a portion comprising a pattern of alternating residual wall thicknesses in the panel. At least one embodiment of the present invention also relates to a method for making a trim panel for concealing an air bag.

Abstract: In at least certain embodiments, the present invention relates to automobile interior door panel having an insert molded bolster. In at least one embodiment, the automobile interior door panel is made by providing a bolster within a first mold cavity, introducing a first resin into the first mold cavity to form a door panel sub assembly comprising a door panel portion secured to the bolster, with the door panel portion having a first upper door panel portion above the bolster and a lower door panel portion below the bolster, providing the door panel sub assembly within a second mold cavity, and introducing a second resin less rigid that the first material into the second mold cavity to form a second upper door panel portion over and secured to the first upper door panel portion.

Abstract: The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Abstract: The present invention provides for an improved trim part, such as an automotive handle, with a soft feel, for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, an automotive handle includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. A handle cover is molded to at least a portion of the substrate by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the handle with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the handle.

Abstract: An automotive trim assembly adapted to have an airbag deploy through the trim assembly includes a substrate with a deployment door integrally molded with the substrate and having a front surface adapted to face the interior of the automobile and a back surface opposite the front surface. The airbag is adapted to be stored behind the deployment door, which is adapted to open when the airbag is deployed. A cover is molded onto at least a portion of the substrate and deployment door and includes an inner and outer layer of a polymer material having a substantially non-cellular structure and an inner core having a cellular structure positioned between the inner and outer layers. The cover is adapted to keep the door attached to the trim assembly when the airbag is deployed.

Abstract: The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Abstract: An interior trim panel for a vehicle door is provided according to alternative methods. The interior trim panel includes a bolster to which a polyurethane skin is molded by a spraying operation. Expanded polyurethane foam is sprayed over the polyurethane skin and a backing panel is either integrally formed or assembled to the polyurethane foam layer.

Abstract: In one advantageous embodiment of the claimed invention, an integral cushioned trim panel (14a-14c) for a vehicle passenger cabin (10) is provided. The integral cushioned trim panel (14a-14c) includes a substrate (22) for attachment to a predetermined portion (12a-12c) of the vehicle. The substrate (22) has a cover member (24) coupled thereto for substantially covering the substrate (22). In addition, the substrate (22) and the cover member (24) have a cushioning member (16) disposed therebetween. The cushioning member (16) is injection molded between the substrate (22) and the cover member (24) for forming an integral construction, minimizing the manufacturing cycle time, and decreasing the costs associated therewith.