Abstract: Aspects of the present invention include interior vehicle trim panel having a sprayed expanded polyurethane layer and method of making same. In at least one embodiment, the method of making the vehicle interior trim panel comprises providing a skin layer on a spray tool, spraying expandable polyurethane reactive components onto the skin layer to form a resilient layer, and securing a rigid substrate on the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim panel.

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 automotive center console is adjustable in fore and aft directions. In one embodiment, the console includes a console housing slidably mounted within the vehicle interior and a controllable damper having high and low damping states. In the high damping state, the controllable damper maintains the console housing in a selected position. When it is desired to relocate the console housing to a new position, the controllable damper is actuated to the low damping state, whereby the console housing may be freely moved to the desired position. The controllable damper is actuated back to the high damping state to maintain the console housing in the new position.

Abstract: A center console for an automobile includes an armrest that is selectively adjustable by vehicle occupants to and between a first position wherein the armrest is in a substantially horizontal orientation, and a second position wherein the armrest extends angularly away from the console. The console further includes a controllable damper coupled to the armrest and actuable between high and low damping states. In the low damping state, the armrest may be selectively placed at any position desired by the vehicle occupants. When the damper is actuated to the high damping state, the damper maintains the selected position of the armrest.

Abstract: A vehicle storage assembly includes a storage compartment having an opening to permit access to the compartment. A door adjacent the opening is moveable between a closed position that covers the opening and an open position that permits access to the compartment through the opening. The storage assembly further includes a controllable damper coupled to the door and actuable between high and low damping states, such that the door is maintained in one of the closed position, the open position, or any position therebetween when the controllable damper is in the high damping state. To move the door to a new position, the controllable damper is actuated from the high damping state to the low damping state whereby the door can then be freely moved to the desired position. The controllable damper may then be actuated from the low damping state to the high damping state to retain the door in the selected position.

Abstract: A method for forming a low density polyurethane skin for automobile interior applications is provided. The method of the invention comprises spraying an expandable polyurethane composition over a mold cavity surface or a mold cavity surface pre-coated with a primer polyurethane layer to form the low density polyurethane skin. A sufficient amount of the expandable polyurethane composition is sprayed so that the low density polyurethane skin has a thickness from about 0.5 to about 3 mils. The expandable polyurethane composition includes an isocyanate, a polyol, a blowing agent, an optional catalyst, and an optional surfactant. An article made by the method of the invention is also disclosed.

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: 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: Aspects of the present invention include interior vehicle trim panel having a sprayed expanded polyurethane layer and method of making same. In at least one embodiment, the method of making the vehicle interior trim panel comprises providing a skin layer on a spray tool, spraying expandable polyurethane reactive components onto the skin layer to form a resilient layer, and securing a rigid substrate on the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim panel.

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 a vehicle part includes spraying material proximate a surface of a tool to form a skin layer, and spraying material onto the skin layer to form a resilient layer. The method further includes removing the skin layer and the resilient layer from the tool and positioning the layers in a mold. Next, the method involves applying material onto the resilient layer to form a rigid substrate on the resilient layer.

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: Apparatus for automatically measuring aperture size of apertured material includes a means for supporting and transporting the apertured material and a light source providing a light beam directed for passage through the apertured material to a light detector and is characterized by a comparator mask of alternate light transparent and opaque sectors of a given dimension and means for overlaying the apertured material with the comparator mask to provide a given length of light transparent slot and responsive to signals representing light transmitted through the given length of slot for deriving a signal representing the width of the slots of the slotted material. Also, a process for automatically measuring aperture size includes the steps of overlaying the slotted material with the comparator mask and utilizing a signal from the light detector representing light transmission of the slots of a given length to derive a signal representative of the slot width.

Abstract: There is disclosed a method for simultaneously applying a relatively thin coating of photosensitive material to both sides of a continuously moving horizontally aligned metallic strip wherein the strip is submerged within a tank assembly having the material therein. The strip is then withdrawn at a predetermined rate and in a substantially vertical direction from the tank assembly through a drying chamber having at least one pair of heater members positioned therein.