Abstract: In at least certain embodiments, the present invention relates to a trim panel and an apparatus and method of making the same. In at least one embodiment, the trim panel comprises a first portion and a second portion with a transition portion extending therebetween with the first portion and the second portion having curved portions having radii of less than 5 mm.

Abstract: In at least certain embodiments, the present invention relates to a trim panel and an apparatus and method of making the same. In at least one embodiment, the trim panel comprises a first portion and a second portion with a transition portion extending therebetween with the first portion and the second portion having curved portions having radii of less than 5 mm.

Abstract: In at least certain embodiments, the present invention relates to a trim panel and an apparatus and method of making the same. In at least one embodiment, the trim panel comprises a first portion and a second portion with a transition portion extending therebetween with the first portion and the second portion having curved portions having radii of less than 5 mm.

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: The present invention provides for an improved hardware carrier for use in a trim panel assembly, and a method of making the same. To this end, the hardware carrier includes a body having a front and back surface and a seal molded to the front surface of the body for contacting the doorframe structure of a motor vehicle to seal the carrier thereto. A two-shot molding process utilizing a single mold assembly is used to form the carrier, with the body being formed in the first shot and the seal being formed in the second shot so that the seal is bonded thereto. The molded seal advantageously is provided with a non-linear configuration, such as a substantially repeating v-shaped configuration, and includes a planar top surface. The non-linear configuration of the seal, in conjunction with the top planar surface, advantageously provides a substantial surface area for contacting the doorframe to prevent water leakage within the vehicle.

Abstract: The present invention provides a two-shot injection molded polymeric component having first and second shots made from polymeric materials. The first shot is made from a relatively hard polymeric material, while the second shot is made from a polymeric material which may differ from the first shot by way of color or polymer type. In this way, the second shot provides texture and aesthetic value to the component. Integrally molded with the second shot is an attachment feature that allows an accessory to be attached proximate the back side of the component without the use of a separate fastener or other separate attachment feature.

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 forms a movable wall. The substrate and the movable wall define a vehicle trim panel, wherein the movable wall includes a fold formed therein for permitting movement of the movable wall to expand the storage compartment.

Abstract: The present invention relates to a trim panel assembly for a vehicle having integrated energy management characteristics and method of manufacture. The trim panel assembly comprises a panel made of a first material having a first panel surface and a second panel surface, a skin covering at least a portion of the first panel surface of the panel, with the skin being made of a second material less rigid then the first material, and a rib depending from the second panel surface away from the skin. The rib has at least a first portion being made of the second material.

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 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: 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 manufacturing two trim components with a common mold assembly includes providing a mold assembly having a first cavity, a second cavity, and a movable mold element. The movable mold element is movable between a first position to expose the second cavity, and a second position to obstruct the second cavity. One of the two trim components is then produced. A first trim component is produced by positioning the mold element into the first position and then introducing a first material into the first and second cavities. A second trim component is produced subsequent to the mold assembly being provided. Then, the mold element is positioned into the second position. One of the first material and a second material is then introduced into the first cavity. The mold element is then moved into the first position, and a third material is introduced into the second cavity.

Abstract: A mold assembly for forming a multi-shot molded part includes a mold system defining a mold cavity, and a retracting member disposed in the mold system selectively movable between extended and retracted positions in the mold cavity. A first molding material is injected in the mold cavity when the mold system is in a configuration with the retracting member in the extended position, forming a first portion of a molded part including a thin wall portion. A second molding material is injected in the mold cavity when the mold system is in another configuration with the retracting member in the retracted position, forming a second portion of the molded part and providing open cavity portions adjacent both surfaces of the thin wall portion. The second material penetrates the thin wall portion, filling the open cavity portions and forming a connection between the first and second portions of the molded part.

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 armrest bun. The armrest bun inserts within an armrest to provide cushioning. The armrest bun includes a support substrate and a poured foam layer. The bun inserting within a cavity of the armrest. The foam layer shaped to match the armrest cavity to limit dead-spots. The bun can be manufactured by position a support substrate in a pouring tool. Foam is poured into a cavity of the pouring tool. The poured foam solidifies to bond to the support substrate. The bun can then be inserted into the armrest.

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: A trim panel module for a vehicle. The trim panel module includes a carrier and a trim panel. The carrier has first and second attachment members. The trim panel has first and second mating members configured to engage the first and second attachment members. The trim panel is movable between a first position in which the first mating member and the first attachment member are engaged and a second position in which the first mating member and the first attachment member are disengaged to allow the trim panel to pivot with respect to the carrier.

Abstract: The present invention provides for an improved automotive ashtray, and to a two shot molding method for making the same, having a reduced number of parts and that is adapted to be coupled to a substrate of an interior trim assembly, e.g. a door panel, in a vehicle. To this end, the ashtray includes a compartment body and a cover with each including at least one integrally formed connecting member being pivotally coupled together so that the cover may be moved between an open and a closed position for accessing a cavity within the body.

Abstract: In at least certain embodiments, the present invention relates to a trim panel assembly and a method of making the same. The trim panel assembly comprises a housing having a perimeter portion defining an opening. The housing comprises a housing panel and a housing skin covering at least a portion of the housing panel. The trim panel assembly further comprises a door moveable between a first position wherein the door closes the opening to a second position wherein the door provides access to the opening. The door comprises a door panel and a door skin covering at least a portion of the door panel. The trim panel assembly further comprises a bumper disposed between the housing and the door. The bumper and at least one of the skins are made during the same injection molding step.

Abstract: An automotive door trim assembly includes an interior door trim panel with an access opening that facilitates installing and servicing various accessories installed within the interior of an automotive door, between the door's exterior skin and the interior trim panel. The access opening is covered by an access panel that is slidably coupled to the interior trim panel for movement between a first position wherein the access panel is removable from the door trim panel to expose the access opening, and a second position wherein the access panel is secured to the door trim panel and covers the access opening. The access panel is coupled to the interior trim panel by cooperating first connecting members disposed on the interior trim panel and second connecting members disposed on the access panel.