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.

Abstract: A method of thermoforming a thin flexible film comprising a series of steps. A thin flexible film capable of being thermoformed is heated until it is pliable. A mold having first and second surfaces on different planes forms a thermoformed article having a contoured surface. A first portion of the pliable film is contacted with the first surface. A first vacuum is applied through the first surface to draw the first portion against the first surface. After the first portion of the film is drawn against the first surface, a second portion of the film contacts the second surface. A second vacuum is applied through the second surface to draw the second portion of the film against the second surface. Air trapped between the mold and the film is first removed between the first surface and the first portion of the film and then removed from between the second surface and the second portion of said film so that the thermoformed article is substantially defect-free.