Abstract: A ribbed armrest for inclusion in an automobile door assembly includes a substrate section and a ribbed armrest section. The ribbed armrest section is over-molded onto the substrate section which provides support thereto. The ribbed armrest section includes a plurality of ribs that provide flexibility and a soft cushioned feel. A method of forming the ribbed armrest include a step in which the substrate is injection molded followed by a step in which the armrest section is injection molded onto the substrate section. Trim panels and door assemblies incorporating the ribbed armrest are also provided.

Abstract: A mold assembly for forming an automotive trim panel includes a first mold section having a mold cavity, a mold core moveable relative to the first mold section, a flange lifter having a recess and capable of movement relative to the mold core and first mold section, and a flange slide selectively engagable with the flange lifter. A cover material is placed in the mold cavity and the flange lifter placed in a molding position to define a first mold chamber portion. The flange slide is engaged with the flange lifter to position the cover material in the recess and to define a second mold chamber portion in communication with the first mold chamber portion. The second mold chamber portion defines the turn down flange. A polymeric material is injected into the mold cavity and the mold core is moved to compress the material into the first and second mold chamber portions.

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.