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: A method and apparatus for forming an interior component part having a relatively rigid substrate portion and a padded portion. The molding tool used to form the substrate portion includes a first mold part and a second mold part that form a substrate molding cavity into which a thermoplastic olefin is injected. The padded portion is formed by the first mold part and a third mold part that define a pad forming cavity. A mixture of a thermoplastic elastomer and a blowing agent is injected into the pad forming cavity. The expanded blown elastomer is enveloped within a skin formed when the blown elastomer contacts a cooled mold surface.

Abstract: An interior component for a motor vehicle comprises a substrate having a surface and flexible elements on the surface, and a cover covering at least a portion of the substrate and the flexible elements.

Abstract: A motor vehicle interior trim component comprises a substrate and covering material injection molded onto at least a portion of the substrate. The covering material has gas-encapsulating elements therein. The gas-encapsulating elements have a property of elastic recovery when the gas-encapsulating elements are pressed until they are deformed and then the pressure is relieved. A method for forming the trim component comprises a step of forming a first mold space and injecting a first material into the first mold space so that the first material substantially conforms to the shape of the first mold space to form a substrate. In another step, a second mold space is formed and a second material is injected into the second mold space so that the second material substantially conforms to the shape of the second mold space to form a covering material over the substrate. The second material is softer than the first material and has gas-encapsulating elements therein.

Abstract: A method of manufacturing a vehicle trim panel having a storage compartment includes providing a first mold assembly comprising a first mold section and a second mold section, wherein the first mold assembly defines a first cavity. A second mold assembly is provided and comprises a third mold section and a fourth mold section. The second mold assembly defines a second cavity. A first material is introduced into the first cavity, thereby producing a substrate. A second material is introduced into the second cavity, such that the second material defines a flexible member. The substrate and the flexible member define a vehicle trim panel, such that the flexible member defines an expandable portion of the storage compartment.

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 comprising a window portion communicating with an angled channel portion. 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: An energy absorption device for use in a vehicle interior includes a first body having a protrusion defining an axially extending outer serrated surface, and a second body having a cavity defining an axially extending inner serrated surface. The protrusion is at least partially inserted into the cavity to at least partially support the first body relative to the second body. Upon an impact at least partially in the axial direction, one of the protrusion and the cavity is moved relative to the other to absorb at least some of the impact energy. An energy absorption vehicle interior assembly includes an energy absorption device connected between an interior vehicle trim member and a vehicle trim mounting member.

Abstract: An injection molding system (10) includes a first mold half (20) and a second mold half (22), which forms a cavity (23) with the first mold half (20). A cavity intrusion element (34) is displaceable to extend within the cavity (23). A displacement mechanism (36) is coupled to the cavity intrusion element (34). A controller (38) is coupled to the displacement mechanism (36) and controls the intrusion depth (D) of the cavity intrusion element (34) during an injection molding process. A method of forming an article includes the pressurizing of the cavity (23) within a mold (14) via a gas. A material having a blowing agent is injected into the cavity (23). The gas pressure within the cavity (23) is released. The cavity intrusion element (34) is backed out from within the cavity (23). The material is cured.

Abstract: A method of making an integrated inner trim panel for a vehicle door and an inner trim panel made thereby are disclosed. The method includes sequentially spraying a skin layer, a padding layer, and applying a structural layer in an open mold that defines the facing surface of the inner panel of a door. The integrated inner trim panel may be provided with areas of greater and lesser padding. The skin layer may be formed from a reactant mixture of polyurethane. The padding layer may be a foam polyurethane composition. The structural layer may be a glass-reinforced polyurethane reactant mixture. The inner door panel is an integrated layered structure including a skin layer, a padding layer, and a structural layer. The padding layer may be varied in thickness to provide selectively variable padding in predetermined areas.

Abstract: A method of making a part includes introducing expandable material into a cavity of a mold containing a substrate, the mold including at least one projection extending into the cavity. The method further includes retracting the at least one projection to allow the expandable material to expand in the cavity, such that the expandable material forms an expanded material layer on the substrate.

Abstract: An interior vehicle trim panel includes a substrate having a front face and an under face. The under face has a tear seam to allow an airbag to exit the substrate when the airbag is deployed. The tear seam defines an airbag door. The outer layer is bonded to the front face of the substrate. A portion of the outer layer defines a hinge member for the airbag door. The outer layer is preferably mechanically bonded to the substrate in a mold, thereby forming an overmolded interior vehicle trim panel. Preferably, the hinge member of the outer layer is thicker relative to a region of the outer layer adjacent the airbag door.

Abstract: A thematic vehicle interior (10) is provided. The thematic vehicle interior (10) is comprised of a passenger cabin, a cosmetic trim (14) for attachment to the vehicle (12) within the passenger cabin, and a feedback system (16) for playing one or more audio programs. The audio programs are utilized in combination with the cosmetic trim (14) for creating a predetermined theme. Additionally, the audio programs are also utilized for indicating one or more predetermined vehicle conditions. The vehicle conditions include one or more of the following: an open-door condition, a low-fuel condition, a maintenance-required condition, a low-tire-pressure condition, a headlights-on condition, a key-in-the-ignition condition, an unfastened-seatbelt condition, an engine-start condition, and an engine-shut-off condition. Also, the thematic vehicle interior (10) includes a sensor (18) for detecting a vehicle condition and actuating the feedback system (16) to play the audio program.

Abstract: The present invention provides for an improved trim part, e.g. a bolster or trim plate, with integrated appliqué for use in a trim assembly, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, the trim part, i.e. a bolster, includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An appliqué is provided in a second shot mold cavity then a cover is formed between the substrate and appliqué by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The formed cover is integrally molded to at least a portion of the substrate and the appliqué to form a trim part with integrated appliqué.

Abstract: In at least certain embodiments, the present invention relates to automobile interior trim panel having an insert molded trim cover sheet. In at least one embodiment, the automobile interior trim panel is made by providing a trim cover sheet within a first mold cavity and introducing a first resin into the first mold cavity to form a door panel sub assembly comprising a door panel portion secured to the trim cover sheet. In this embodiment, the door panel portion has a first upper door panel portion having a portion circumscribing the trim cover sheet and a lower door panel portion below the first upper door panel portion. The method further comprises 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 at least a portion of the first upper door panel portion.

Abstract: In at least certain embodiments, the present invention relates to a trim panel made by providing a molding tool system comprising a first mold half, a second mold half, and a third mold half and positioning the first mold half and the second mold half proximate each other to form a first mold cavity. In certain embodiments, the method further comprises introducing a first resin into the first mold cavity to form a trim panel skin and positioning the first mold cavity with the trim panel skin and the third mold half with a trim panel substrate spaced from the trim panel skin to form a second mold cavity. In this embodiment, the method further comprises introducing a second resin into the second mold cavity to form a resilient layer extending between and connecting the trim panel skin and the trim panel substrate.

Abstract: The present invention provides a method for making a multi-piece vehicle interior trim panel. In at least one embodiment, the method comprises providing a major panel having a major substrate, a sprayed urethane major skin layer disposed over at least a portion of the major substrate, and a foam layer between the major substrate and the major skin layer. The method further includes forming a minor panel by spraying polyurethane material proximate a relatively small mold surface to form a sprayed urethane minor skin layer, spraying expandable polyurethane material onto the minor skin layer to form a first resilient layer, placing a mounting substrate onto the first resilient layer, and spraying expandable polyurethane material onto the first resilient layer and the mounting substrate to form a second resilient layer. The method further comprises removing the minor panel from the mold and securing the minor panel to the major panel portion.

Abstract: A ribbed armrest for inclusion in an automobile door assembly includes a substrate section and a ribbed armrest section. The ribbed armrest section is over-molded onto the substrate section which provides support thereto. The ribbed armrest section includes a plurality of ribs that provide flexibility and a soft cushioned feel. A method of forming the ribbed armrest include a step in which the substrate is injection molded followed by a step in which the armrest section is injection molded onto the substrate section. Trim panels and door assemblies incorporating the ribbed armrest are also provided.

Abstract: A method of making an integrated inner trim panel for a vehicle door and an inner trim panel made thereby are disclosed. The method includes sequentially spraying a skin layer, a padding layer, and applying a structural layer in an open mold that defines the facing surface of the inner panel of a door. The integrated inner trim panel may be provided with areas of greater and lesser padding. The skin layer may be formed from a reactant mixture of polyurethane. The padding layer may be a foam polyurethane composition. The structural layer may be a glass-reinforced polyurethane reactant mixture. The inner door panel is an integrated layered structure including a skin layer, a padding layer, and a structural layer. The padding layer may be varied in thickness to provide selectively variable padding in predetermined areas.

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: An automotive assembly having an integrated spring mechanism. The assembly includes a first member and a second member pivotally coupled to the first member and moveable between a first and second position with respect to the first member. The assembly further includes a resilient element integrally molded with one of the first and second members. The resilient element includes an extension portion having a free end that is coupled to the other one of the first and second members. The extension portion imposes a force on the second member to bias the second member in at least one direction. A method of making the assembly includes a two shot molding process where the one of the first and second members is formed in a first shot of the molding operation and the resilient element is integrally molded thereto in the second shot of the molding operation.