Abstract: A vehicle interior panel includes a decorative skin and a polymer coating provided to increase material thickness at a desired portion of the decorative skin The polymer coating may be formed by a thermal spraying process in which a polymeric material is heated and deposited along an inner side of the decorative skin The decorative skin may be thermoformed from a uniformly thick sheet of thermoplastic material so that it includes a reduced thickness portion after forming. The polymeric material can be deposited along the reduced thickness portion to form the polymer coating, thereby restoring integrity or providing enhanced integrity to the decorative skin to aid subsequent material processes such as sewing or foam backfilling.

Abstract: A vehicle interior panel includes stitching sewn through a decorative skin layer of the panel. The associated sewing needle holes are sealed by an elastomeric material before a foam layer is formed on the non-visible side of the skin layer to prevent the expanding foam from leaking through the needle holes and becoming visible at the visible side of the panel. The elastomeric material is initially applied as a viscous liquid formulated to solidify and can be applied by spraying, enabling lines of stitching to be located along complex contours of the panel. A latex emulsion is one suitable type of viscous liquid.

Abstract: A vehicle interior panel includes a decorative skin and a polymer coating provided to increase material thickness at a desired portion of the decorative skin The polymer coating may be formed by a thermal spraying process in which a polymeric material is heated and deposited along an inner side of the decorative skin The decorative skin may be thermoformed from a uniformly thick sheet of thermoplastic material so that it includes a reduced thickness portion after forming. The polymeric material can be deposited along the reduced thickness portion to form the polymer coating, thereby restoring integrity or providing enhanced integrity to the decorative skin to aid subsequent material processes such as sewing or foam backfilling.

Abstract: A vehicle interior panel includes stitching sewn through a decorative skin layer of the panel. The associated sewing needle holes are sealed by an elastomeric material before a foam layer is formed on the non-visible side of the skin layer to prevent the expanding foam from leaking through the needle holes and becoming visible at the visible side of the panel. The elastomeric material is initially applied as a viscous liquid formulated to solidify and can be applied by spraying, enabling lines of stitching to be located along complex contours of the panel. A latex emulsion is one suitable type of viscous liquid.

Abstract: A vehicle interior component including decorative stitching along a stitch path includes a seam filler located between a component substrate and an overlying decorative covering. The seam filler lies along the stitch path and supports the decorative covering directly beneath at least a portion of a line of decorative stitching, where the covering may include a reduced thickness portion. The seam filler can have any number of configurations to prevent visual defects along the stitch path and/or to cause the appearance of simulated seams to be more realistic. The seam filler may be deposited along the stitch path as a curable filler material that cures, or it may be provided as a pre-formed piece for attachment to the decorative covering.

Abstract: A vehicle interior component includes a decorative covering with one or more lines of decorative stitching sewn therethrough. Together with one or more ridge features, the decorative stitching can be part of a simulated seam formed in the decorative covering. A densified portion and/or a reduced thickness portion can be formed in the decorative covering along the intended stitch path and prior to addition of the decorative stitching to help reduce the effect of the stitching on the overall appearance of the simulated seam, such as the shape of the ridge feature(s). The decorative covering can be compressed along the intended stitch path in a thermoforming process, such as an in-mold graining process.

Abstract: A vehicle interior component includes a decorative covering with one or more lines of decorative stitching sewn therethrough. Together with one or more ridge features, the decorative stitching can be part of a simulated seam formed in the decorative covering. A densified portion and/or a reduced thickness portion can be formed in the decorative covering along the intended stitch path and prior to addition of the decorative stitching to help reduce the effect of the stitching on the overall appearance of the simulated seam, such as the shape of the ridge feature(s). The decorative covering can be compressed along the intended stitch path in a thermoforming process, such as an in-mold graining process.

Abstract: A vehicle interior component including decorative stitching along a stitch path includes a seam spacer located between a component substrate and an overlying decorative covering. At least a portion of the seam spacer lies along the stitch path and supports the decorative covering therealong, where the covering may include a reduced thickness portion due to the decorative stitching. The seam spacer can have any number of configurations to prevent visual defects along the stitch path and/or to cause the appearance of simulated seams to be more realistic. The seam spacer may be attached to the covering at the same time the decorative stitching is sewn through the covering.

Abstract: A vehicle interior component including decorative stitching along a stitch path includes a seam filler located between a component substrate and an overlying decorative covering. The seam filler lies along the stitch path and supports the decorative covering directly beneath at least a portion of a line of decorative stitching, where the covering may include a reduced thickness portion. The seam filler can have any number of configurations to prevent visual defects along the stitch path and/or to cause the appearance of simulated seams to be more realistic. The seam filler may be deposited along the stitch path as a curable filler material that cures, or it may be provided as a pre-formed piece for attachment to the decorative covering.

Abstract: A vehicle interior component including decorative stitching along a stitch path includes a seam spacer located between a component substrate and an overlying decorative covering. At least a portion of the seam spacer lies along the stitch path and supports the decorative covering therealong, where the covering may include a reduced thickness portion due to the decorative stitching. The seam spacer can have any number of configurations to prevent visual defects along the stitch path and/or to cause the appearance of simulated seams to be more realistic. The seam spacer may be attached to the covering at the same time the decorative stitching is sewn through the covering.

Abstract: A mold assembly, a method of molding, and a molded component for an interior of a vehicle using two shots of material. The mold assembly includes first and second mold halves cooperating to define a cavity. One of the mold halves includes a retractable core. The second mold half defines a divider for engaging the retractable core, when the retractable core is extended, so as to divide the mold cavity into first and second chambers. Portions of the core cooperate to define a sloped surface on the first shot that aids in inhibiting flash forming as the second shot is introduced into the mold assembly.