Abstract: A trim panel assembly and a method of manufacture. The trim panel assembly includes a trim panel and a backplate. The trim panel includes a speaker grill that allows sound to transmit from a speaker into the interior of a vehicle. The backplate is attached to the trim panel and includes a speaker mounting portion located adjacent to the speaker grill and a seal located adjacent to the speaker mounting portion that is configured to inhibit sound leakage.

Abstract: An automotive interior trim component includes a rigid substrate member that forms the structural support for the trim component. A portion of the substrate member has a thickness that is reduced relative to surrounding portions of the substrate member to define a target area for providing a soft feel to the trim component. The trim component may further include a flexible cover layer and a backing member disposed on a side of the substrate member opposite the cover layer. The substrate member and cover layer may be formed in a two-shot molding operation.

Abstract: A system and method for spray application of polyurethane used to spray form an article is disclosed. A spray nozzle is rotated as the polyurethane composition is sprayed onto a mold surface to apply a swath of polyurethane to the mold surface. The spray nozzle may be of an internal mixing or external mixing type that is moved relative to a mold surface in a path to create a skin layer with multiple partially overlapping swaths being applied in multiple passes. A motor and gear drive are used to rotate the nozzle tip and associated structure.

Abstract: A method and system for storage comprising a console and base. The console being slidable within the base so as to permit it to be easily re-positionable. The method and system relating to re-positioning the base, such as to facilitate folding a second row load floor, to facilitate removing the console, and/or to optimize positioning of the console relative to passengers.

Abstract: An instrument panel for an automobile that eliminates the gaps between the lateral ends of the instrument panel and adjacent door panels, when the doors of the automobile are in their closed positions. In one embodiment, the instrument panel includes a rigid substrate and a pliable cover layer that extends beyond lateral ends of the substrate to form flexible flanges. The flexible flanges contact the door panels when the doors are closed, and deform toward the substrate so as not to interfere with the closing of the doors. In another embodiment, the substrate includes central and lateral sections connected by the pliable cover layer. As the doors of the automobile are closed, the lateral substrate sections contact the door panels and are deformed toward to central substrate section.

Abstract: A method of manufacturing an overmolded trim component includes providing a first mold portion and a movable mold element. The movable mold element includes first and second mold surfaces positioned at a first angle with respect to one another. The movable mold element is then positioned into the first position to define a first cavity. A first material is then introduced into the first cavity, thereby forming a substrate. The substrate includes a first substrate surface is at a second angle with respect to a second substrate surface. The movable mold element is then positioned into the second position to define a second cavity. A second material is then introduced into the second cavity, thereby forming an overmolded trim component. The movable mold element is oriented at a third angle with respect to the first substrate surface and at a fourth angle with respect to the second substrate surface.

Abstract: A duct assembly for a vehicle. The duct assembly includes a trim panel and an air duct. A seal having multiple seal portions is disposed on the air duct to inhibit air leakage. The seal portions are integrally connected and formed from a common material.

Abstract: An automotive interior trim assembly has at least one area which provides an enhanced tactile feel that is soft to the touch. The interior trim assembly includes a substrate member forming at least part of a structural support of a trim assembly and a cover member formed of thermoplastic elastic foam supported on the substrate member. In one embodiment, the interior trim assembly is formed in a two-shot molding operation wherein a first material is molding during a first shot to form the substrate member. The cover member is molded onto the substrate member during a second shot of the molding operation to form the interior trim assembly.

Abstract: A door trim panel for a door frame of a motor vehicle. The door trim panel includes a main body portion adapted to be removably secured to the door frame and a bolster removably secured to the main body portion. The bolster covers an access opening in the main body portion. The bolster includes a substrate having a bolster portion integrally formed with an armrest portion. A cover is integrally molded with the substrate and includes a first portion overlying the bolster portion and having a first thickness, and a second portion overlying the armrest portion and having a second thickness greater than the first thickness to provide a softer feel. The bolster may be made in a two shot molding process with the substrate being formed in the first shot of the molding process and the multi-feel cover being formed in the second shot of the molding process.

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.

Abstract: An automotive interior trim assembly has at least one area which provides an enhanced tactile feel that is soft to the touch. The interior trim assembly includes a first substrate member forming at least part of a structural support of a trim assembly and a cover member formed of thermoplastic elastic foam supported on the first substrate member. A second substrate member is connected to the first substrate member. In one embodiment, a portion of the interior trim assembly is formed in a two-shot molding operation wherein a first material is molding during a first shot to form the first substrate member. The cover member is molded onto the first substrate member during a second shot of the molding operation. In one embodiment, the first and second substrate members are connected together through cooperating locking structures formed on each of the first and second substrate members.

Abstract: In at least certain embodiments, the present invention provides a method and system for making a vehicle interior trim panel. The method comprises providing a spray mold, heating the spray mold to a first temperature, spraying powdered polymeric material proximate the surface of the tool to form a polymeric skin layer, and cooling the spray mold to a second temperature. The method further comprises removing the skin layer from the tool and positioning the skin layer in a mold in a spaced apart relationship from a substrate, and introducing a foam material between the substrate and the skin layer to form a foam layer between the substrate and the skin layer.

Abstract: A method of making an interior trim panel for a vehicle door and the interior trim panel are disclosed. The method comprises forming a bolster that is spray coated with a polyurethane skin in an open mold. The bolster and polyurethane skin are then placed in a mold tool with a glass fiber mat and foam polyurethane is injected over the polyurethane skin in the portions of the mold outboard of the bolster. The glass fiber mat is trimmed in the area behind the bolster and a foam pad is formed in place or assembled behind the bolster and retained in place by a cover panel.

Abstract: A method of making an automotive trim assembly includes injection molding a first curable polymer to form a substrate including a deployment door in a first shot of a molding operation. A cover is then formed on at least a portion of both the substrate and deployment door by injection molding a second curable polymer in a second shot of the molding operation. The cover includes an inner and outer layer of the second polymer having a substantially non-cellular structure and a core of the second polymer having a cellular structure between the inner and outer layers. At least one score line is formed in the substrate to define the deployment door therein. The score line may be formed during the molding operation or in a post-molding process, such as a laser scoring process.

Abstract: An automotive trim assembly including a substrate made from a first material and having a front surface adapted to face the interior of the automobile and a back surface opposite the front surface. A cover member made from a second foamed material is molded onto at least a portion of the front surface of the substrate so as to provide a soft feel to the trim assembly. An impact countermeasure, also made from the second foamed material, is molded onto at least a portion of the back surface to absorb an impact force from a vehicle occupant. The trim assembly may be made in a two shot molding operation with the substrate being formed in the first shot of the molding process and the cover member and countermeasure being formed in the second shot of the molding process.

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: 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: 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 trim part with a multi-feel cover for use in a trim assembly, e.g. a door panel, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes a substrate having an integrated armrest and/or integrated bolster formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. A cover then is molded to at least a portion of the integrated trim part by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The molded cover defines a first and second thickness with the second thickness being greater than the first thickness to provide a softer feel.