Abstract: A method of forming a decorative article comprising placing a decorative cover sheet comprising an untextured skin layer, a cushion foam layer and an adhesive layer in a mold space between a front mold half and a rear mold half, placing a substrate on the rear mold half, heating a textured front mold surface and the skin layer with a first heater arrangement between the front mold half and the cover sheet, heating the cover sheet and the substrate with a second heater arrangement between the cover sheet and the rear mold half, forming the skin layer of the decorative cover sheet into contact with the textured front mold surface, forming into the skin layer a textured surface from the textured front mold surface, pressing the substrate against the adhesive layer of the decorative cover sheet, and bonding the cover sheet to the substrate with the adhesive layer.

Abstract: A method of forming a decorative article comprising placing a decorative cover sheet comprising an untextured skin layer, a cushion foam layer and an adhesive layer in a mold space between a front mold half and a rear mold half, placing a substrate on the rear mold half, heating a textured front mold surface and the skin layer with a first heater arrangement between the front mold half and the cover sheet, heating the cover sheet and the substrate with a second heater arrangement between the cover sheet and the rear mold half, forming the skin layer of the decorative cover sheet into contact with the textured front mold surface, forming into the skin layer a textured surface from the textured front mold surface, pressing the substrate against the adhesive layer of the decorative cover sheet, and bonding the cover sheet to the substrate with the adhesive layer.

Abstract: A panel includes a bolster and a covering. The bolster has a bolster aperture formed therethrough that includes a pleat notch portion. The covering is positioned on the bolster and has a covering aperture formed therethrough that is aligned with the bolster aperture. The covering includes a pleated seam that is received in the pleat notch portion of the bolster aperture.

Abstract: A method of sewing a decorative seam includes providing a material suitable for receiving stitches, folding a first portion of the material onto a second portion of the material to form a bend, sewing a first stitch to join the first portion to the second portion, the stitch being substantially parallel to the bend and spaced apart therefrom, the first stitch forming a seam, unfolding the material and sewing a second and third stitch into the material such that the second and third stitches are substantially parallel to the seam and arranged such that the second and third stitches are on opposite sides of the seam.

Abstract: In at least certain embodiments, the present invention relates to automobile interior door panel having an insert molded bolster. In at least one embodiment, the automobile interior door panel is made by providing a bolster within a first mold cavity, introducing a first resin into the first mold cavity to form a door panel sub assembly comprising a door panel portion secured to the bolster, with the door panel portion having a first upper door panel portion above the bolster and a lower door panel portion below the bolster, providing the door panel sub assembly within a second mold cavity, and introducing a second resin less rigid that the first material into the second mold cavity to form a second upper door panel portion over and secured to the first upper door panel portion.

Abstract: A method of sewing a decorative seam includes providing a material suitable for receiving stitches, folding a first portion of the material onto a second portion of the material to form a bend, sewing a first stitch to join the first portion to the second portion, the stitch being substantially parallel to the bend and spaced apart therefrom, the first stitch forming a seam, unfolding the material and sewing a second and third stitch into the material such that the second and third stitches are substantially parallel to the seam and arranged such that the second and third stitches are on opposite sides of the seam.

Abstract: The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Abstract: The present invention provides for an improved trim part, such as an automotive handle, with a soft feel, for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, an automotive handle includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. A handle cover is molded to at least a portion of the substrate by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the handle with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the handle.

Abstract: An automotive trim assembly adapted to have an airbag deploy through the trim assembly includes a substrate with a deployment door integrally molded with the substrate and having a front surface adapted to face the interior of the automobile and a back surface opposite the front surface. The airbag is adapted to be stored behind the deployment door, which is adapted to open when the airbag is deployed. A cover is molded onto at least a portion of the substrate and deployment door and includes an inner and outer layer of a polymer material having a substantially non-cellular structure and an inner core having a cellular structure positioned between the inner and outer layers. The cover is adapted to keep the door attached to the trim assembly when the airbag is deployed.

Abstract: The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Abstract: In one advantageous embodiment of the claimed invention, an integral cushioned trim panel (14a-14c) for a vehicle passenger cabin (10) is provided. The integral cushioned trim panel (14a-14c) includes a substrate (22) for attachment to a predetermined portion (12a-12c) of the vehicle. The substrate (22) has a cover member (24) coupled thereto for substantially covering the substrate (22). In addition, the substrate (22) and the cover member (24) have a cushioning member (16) disposed therebetween. The cushioning member (16) is injection molded between the substrate (22) and the cover member (24) for forming an integral construction, minimizing the manufacturing cycle time, and decreasing the costs associated therewith.

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 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: 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 trim panel assembly includes a first trim panel and a second trim panel. The first trim panel has an attachment portion, and the second trim panel has an attachment portion that cooperates with the attachment portion of the first trim panel to connect the first and second trim panels together to provide a trim panel assembly that allows relatively sliding movement between the first and second trim panels. The first trim panel can have a single attachment portion that extends continuously throughout the length thereof, while the second trim panel can have a plurality of discrete portions that extends along the length thereof, or vice versa. The attachment portion of the second trim panel can be molded either about or within the attachment portion of the first trim panel.

Abstract: A vacuum-forming system (10) for manufacture of a component includes a vacuum-forming mold (18, 20). The vacuum-forming mold (18, 20) may be heated. One or more wrapping arms (60, 62, 64) are in operative coupling with the vacuum-forming mold (18, 20). One or more cutting elements (196, 207, 262) are mechanically coupled to the vacuum-forming mold (18, 20), the wrapping arms (60, 62, 64), or a substrate (40). A controller (42) may be coupled to and adjust the temperature of the cutting elements (196, 207, 262). A controller (42) may also or as an alternative be coupled to and control the operation of the wrapping arms (60, 62, 64) to wrap a compliant cover stock object (22) on the substrate (40) and to simultaneously trim the object (22) via the cutting elements (196, 207, 262).

Abstract: A method of forming a trim panel is provided comprising molding an interior panel substrate including a main body portion, a lock portion molded as a portion of the interior panel substrate and having a locking element, a first living hinge positioned between the lock portion and the main body portion, a lock engagement portion, and a second living hinge positioned between the lock engagement portion and the main line portion. The method molds an exterior cover stock, including a belt line skin portion, onto an outer surface of the interior panel substrate. The lock portion is rotated about the first living hinge to trap the belt line skin portion between the lock portion and the lock engagement portion in order to create a mechanical skin lock. The lock engagement portion is then rotated about the second living hinge towards an inner surface of the interior panel substrate.

Abstract: A method of dielectrically embossing material comprising the steps of providing a dielectric embossing machine having a dielectric tool, providing a coloring agent, providing a material, applying the coloring agent to the dielectric tool, placing the material in the dielectric embossing machine, bringing the dielectric tool into contact with the material, energizing the dielectric tool, dielectrically embossing the material, de-energizing the dielectric tool, allowing the material and the coloring agent to cool, and backing the dielectric tool away from the material.

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 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.