Abstract: In at least certain embodiments, the present invention relates to a method of making an interior trim panel, a mold for forming the interior trim panel, and the interior trim panel. In at least one embodiment, the vehicle trim panel comprises a substrate portion comprising a substrate shell layer and a substrate core layer substantially disposed within the substrate shell layer, and a padded cover portion integrally molded onto at least a portion of the substrate portion, with the padded cover portion comprising a cover shell layer and a cover core layer substantially disposed within the cover shell layer.

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 foldable sheet for making a storage box for a vehicle. The foldable sheet has multiple portions foldably connected together along at least one fold line. The portions are foldable to at least a partially define a storage box. A hinge may be configured to allow the storage box to pivot with respect to the vehicle.

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 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: 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 cover member. The substrate and the cover member define a vehicle trim panel, such that the cover member defines an expandable portion of the storage compartment.

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: The present invention provides a method for molding an over-molded part by a multi-shot molding method. The method of the invention comprises combining a first mold section having one or more retractable tool portions and a second mold section to form a first mold cavity. A first thermoplastic resin is injected into a first mold cavity to form a first molded part. Subsequently, the second mold section is separated from the second mold section such that the first molded part remains in contact with the first mold section. The retractable tool portion is retracted to expose one or more channels. Next, a third mold section is combined with the first mold section to form a second mold cavity. A second thermoplastic resin is then injected into the second mold cavity to form the over-molded part which may then be removed from the mold section.

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 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: A door trim panel including a cover stock, an armrest coupled to the cover stock and having a first density, an upper energy absorber disposed above the armrest and having a second density higher than the first density, and a lower energy absorber disposed below the armrest and having a third density higher than the first density.

Abstract: A blow molded structure comprising a body made out of a first polymeric material and an integrally molded, coextruded living hinge made out of a second, more flexible polymeric material. A method of making a blow molded article having a coextruded living hinge.

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: 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 for producing a two-shot polymeric component having one shot wrapped around an edge of the other shot, includes injection molding a first portion having first and second opposing sides and an edge adjacent the first and second sides. A second portion is injection molded such that some of the second portion contacts the first side of the first portion, some of the second portion contacts the second side of the first portion, and some of the second portion contacts the edge. The second portion forms a unitary structure wrapping around the edge of the first portion.

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 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 automotive interior trim component includes a rigid substrate member that forms the structural support for the trim component. A portion of the substrate member has a thickness that is reduced relative to surrounding portions of the substrate member to define a target area for providing a soft feel to the trim component. The trim component may further include a flexible cover layer and a backing member disposed on a side of the substrate member opposite the cover layer. The substrate member and cover layer may be formed in a two-shot molding operation.

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.