Abstract: An automotive assembly having an integrated spring mechanism. The assembly includes a first member and a second member pivotally coupled to the first member and moveable between a first and second position with respect to the first member. The assembly further includes a resilient element integrally molded with one of the first and second members. The resilient element includes an extension portion having a free end that is coupled to the other one of the first and second members. The extension portion imposes a force on the second member to bias the second member in at least one direction. A method of making the assembly includes a two shot molding process where the one of the first and second members is formed in a first shot of the molding operation and the resilient element is integrally molded thereto in the second shot of the molding operation.

Abstract: The present invention provides for an improved trim part, e.g. a bolster or trim plate, with integrated appliqué for use in a trim assembly, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, the trim part, i.e. a bolster, includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An appliqué is provided in a second shot mold cavity then a cover is formed between the substrate and appliqué by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The formed cover is integrally molded to at least a portion of the substrate and the appliqué to form a trim part with integrated appliqué.

Abstract: A door trim panel for a door frame of a motor vehicle. The door trim panel includes a main body portion adapted to be removably secured to the door frame and a bolster removably secured to the main body portion. The bolster covers an access opening in the main body portion. The bolster includes a substrate having a bolster portion integrally formed with an armrest portion. A cover is integrally molded with the substrate and includes a first portion overlying the bolster portion and having a first thickness, and a second portion overlying the armrest portion and having a second thickness greater than the first thickness to provide a softer feel. The bolster may be made in a two shot molding process with the substrate being formed in the first shot of the molding process and the multi-feel cover being formed in the second shot of the molding process.

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 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 armrest bun. The armrest bun inserts within an armrest to provide cushioning. The armrest bun includes a support substrate and a poured foam layer. The bun inserting within a cavity of the armrest. The foam layer shaped to match the armrest cavity to limit dead-spots. The bun can be manufactured by position a support substrate in a pouring tool. Foam is poured into a cavity of the pouring tool. The poured foam solidifies to bond to the support substrate. The bun can then be inserted into the armrest.

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 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 trim assembly comprises a substrate member forming at least a portion of the structural support of the trim assembly. A flexible skin overlies at least a portion of the substrate member and is coupled to the substrate. The substrate and flexible skin are configured to define a cavity having an opening. A back plate is mountable to the substrate and adapted to cover the cavity opening. A resilient foam pad contained within a pouch is positioned within the cavity to provide a soft feel to the trim assembly. The foam pad is inserted into the cavity using a tool that pulls a vacuum and compresses the foam pad. The foam pad is insertable into the cavity while in a compressed state and is adapted to expand so as to substantially fill the cavity.

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.