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 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 blind load vehicle door module includes a first exposed side having interior trim and a second hidden side with at least a door latch actuator and window regulator mechanism, wherein the module has a plurality of connectors extending from the hidden side including at least two lower connectors insertable into corresponding slots of a door frame to allow pivoting during assembly of the module about the lower connectors to insert at least one upper connector into a corresponding slot of the door frame, the plurality of connectors being slidable within the corresponding slots of the door frame from an inserted position to a locking position to secure the module to the door frame. One or more threaded fasteners may be used to secure the module in the locking position.

Abstract: The present invention relates to a two-shot, non-shut-off method of manufacturing a 100% grained trim component for a vehicle. The method includes actuating a tool insert between a mold cavity and a secondary void to form a molded trim component having a groove. A first shot of material is injected to form a first trim element having a grained class-A side. During the first shot, flash enters the secondary void to provide a non-shut-off condition. The tool insert is retracted to define a ditch in the first trim element. A second shot of material is injected to form a second trim element having a grained class-A side, during which time a portion of the second shot enters the ditch to provide a non-shut-off condition. The trim elements are then bonded where a portion the second trim element bonded to the first trim element within the groove.

Abstract: A connector for securing an interior trim assembly to a support of an automobile. The connector includes a connector body having a head portion formed at a proximal end of the connector body and a shank portion extending from the head portion toward a distal end of the connector body. A sealing gasket is integrally molded onto the connector body distally of the head portion. A two-shot molding process may be used to form the connector with the connector body being formed in the first shot of the molding process and the sealing gasket being formed onto the connector body in the second shot of the molding process.

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 trim assembly comprises a substrate member including a moveable panel integrally formed in the substrate and moveable between an open and closed position. A flexible skin overlies at least a portion of the substrate member and is integrally coupled to the substrate. The substrate and flexible skin are configured to define a cavity having an opening. The cavity opening is accessible when the moveable panel is in the open position. A resilient foam pad is positioned within the cavity to provide a soft feel to the trim assembly. The foam pad is inserted into the cavity using a tool that pulls a vacuum and compresses the foam pad. The foam pad is inserted into the cavity and the vacuum is released thereby expanding the foam pad to fill the cavity. The tool is removed and the moveable panel is moved to and secured in the closed position.

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: A trim assembly comprises a substrate member including a moveable panel integrally formed in the substrate and moveable between an open and closed position. A flexible skin overlies at least a portion of the substrate member and is integrally coupled to the substrate. The substrate and flexible skin are configured to define a cavity having an opening. The cavity opening is accessible when the moveable panel is in the open position. A resilient foam pad is positioned within the cavity to provide a soft feel to the trim assembly. The foam pad is inserted into the cavity using a tool that pulls a vacuum and compresses the foam pad. The foam pad is inserted into the cavity and the vacuum is released thereby expanding the foam pad to fill the cavity. The tool is removed and the moveable panel is moved to and secured in the closed position.

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: 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: 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 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: An interior trim assembly comprises a substrate member forming at least a part of the structural support of the trim assembly and having a front surface adapted to face the interior of the automobile and a back surface adapted to face opposite the front surface. The substrate member includes a connecting member integrally molded with the substrate member and having an aperture formed therethrough. A grommet is integrally molded in the aperture. Preferably, the substrate member has a hardness and the grommet has a hardness that is relatively lower than the hardness of the substrate member. A two-shot molding process may be used to make the trim assembly with the substrate member and connecting member being formed in the first shot and the grommet being formed in the second shot.

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: A method of making an interior vehicle part for use with a motor vehicle includes spraying material proximate a surface of a mold portion of a mold to form a skin layer, the surface defining a mold cavity of the mold portion. The method further includes positioning an insert proximate the mold cavity, the insert being configured for attachment to the vehicle, and introducing material into the mold cavity to form a foam layer that contacts the skin layer and the insert.

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: A method for producing a vehicle trim component including a two-shot polymeric closeout panel and a substrate having at least one opening therein is provided. A first portion of the closeout panel is injection molded. The first portion includes at least one cavity forming structure that is configured to cooperate with a corresponding opening in the substrate. This forms a corresponding cavity that is accessible through the substrate. A second portion of the closeout panel is injection molded, and covers at least some of the at least one cavity forming structure.

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: 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.