Abstract: A method for forming a molded panel comprising a rigid substrate, a cover material, and a localized composite pad. The method comprises providing a molding tool having a first mold and a second mold, the first mold having a cavity; inserting a cover material between the first mold and the second mold; placing a composite pad comprising an impregnable layer and a non-impregnable layer in the cavity of the first mold, wherein the non-impregnable layer is facing the second mold and the impregnable layer is abutting the first mold; introducing resin into the molding tool; and solidifying the resin to form the molded panel whereby the non-impregnable layer of the composite pad is located adjacent the cover material.

Abstract: The present invention generally relates to interior trim parts such as door panels that are attached to an interior sheet in a motor vehicle. In accordance with the preferred embodiment of the present invention, a method of forming the trim part having an outer surface and an inner surface is disclosed. The method comprises providing a substrate having a first side and a second side and disposing the substrate in a molding tool, the molding tool has an upper mold and a lower mold. Engaging the first side of the substrate with the upper mold and the second side of the substrate with the lower mold. The first side is subject to compression molding such that the first side forms the outer surface of the trim part and injection molding an attachment surface to the second side of the substrate.

Abstract: The present invention provides a door panel having a decorative insert integrally attached to the door panel. In one embodiment, the method of forming the door panel comprises forming the decorative insert by preheating a substrate and placing a coverskin on top of the substrate. The substrate and the, coverskin are subject to a compression molding process to form the decorative insert. The decorative insert is then disposed inside a second molding tool and a plastic material is injected into the cavity of the second molding tool. The plastic material then forms the door panel.

Abstract: The present invention provides a door panel insert having an integral cover skin material. The door panel insert comprises a first layer or the decorating layer, a second layer, a recylate layer and a fourth layer. The recylate layer is sandwiched between the second layer and the fourth layer. The first layer is tacked on to the second layer before the molding process such that during compression and heating of the trim panel the first layer is chemically bonded to the second layer.

Abstract: The present invention generally relates to interior trim parts such as door panels that are attached to an interior sheet in a motor vehicle. In accordance with the preferred embodiment of the present invention, a method of forming the trim part having an outer surface and an inner surface is disclosed. The method comprises providing a substrate having a first side and a second side and disposing the substrate in a molding tool, the molding tool has an upper mold and a lower mold. Engaging the first side of the substrate with the upper mold and the second side of the substrate with the lower mold. The first side is subject to compression molding such that the first side forms the outer surface of the trim part and injection molding an attachment surface to the second side of the substrate.