International Automotive Components Group North America, Inc.

Lear Corporation

David Dooley

Glenn A Cowelchuk

Todd DePue

Randy S Reed

Michael J Hier

Mark Heinze

Alan George Dry

John David Youngs

Bogdan Radu

Michael P Schoemann

Kenneth W Shaner

Raymond K Cummins

Matthew S Brummer

Thomas Bush

Robert J Adams

Charles A Haba

Mark Fero

Richard David George

James Gregory

Thomas W Spanos

Matthey S Brummer

Dick George

Mike P Schoemann

Leyang Lu

A method is provided for forming a welt in a single sheet of coverstock by folding and sewing. A second method is provided for forming a welt adjacent a seam formed by sewing two sheets of coverstock together, the method requiring less selvage from one of the sheets.

Deck seam with reduced selvage

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.

Method of making a trim panel having a narrow transition radius and apparatus

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.

Method of sewing a decorative seam and trim component made by that method

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.

Insert molded bolster in two-shot door panel

A pocketed panel assembly for a vehicle door is disclosed herein. The pocketed panel assembly includes a trim panel, a partial pocket structure, and a living hinge. The trim panel has a pivotal edge, and the partial pocket structure also has a pivotal edge. The living hinge integrally joins the pivotal edge of the trim panel to the pivotal edge of the partial pocket structure. In such a configuration, the partial pocket structure can be rotated about the living hinge and substantially abutted against the trim panel so as to form an open pocket on the trim panel.

Pocketed panel assembly

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.

Automotive handle with soft feel and method of making the same

Apparatus for molding a trim panel assembly having a narrow transition radius

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.

Automotive armrest with soft feel and method of making the same

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.

Automotive trim assembly having an integrated airbag door

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

Integral cushioned trim panel for a vehicle

A trim part for use with a vehicle includes a substrate and a trim cover overlaying the substrate. The trim cover has first and second portions that are folded together to form a flexible edge seal that is engageable with the vehicle. A method of making such a trim part is also disclosed.

Trim panel with edge seal

A trim system configured to be received by a vehicle door substrate is provided. Some embodiments of the trim system include a locator and a feature. The feature is moveable relative to the locator after the locator is assembled with the substrate. Some embodiments of the trim system include a first and second feature. The second feature is moveable relative to the first feature after the first feature is assembled with the substrate.

Trim system for a vehicle door

An energy absorbing countermeasure for motor vehicle doors comprises a body having at least a first zone and a second zone. Each zone has at least one surface with recesses in the surface and portions between recesses. The portions are broken upon impact and enter into the recess to exhibit energy absorbing efficiency. The recesses in the first zone are arranged or configured to absorb a first desired peak load during impact and the recesses in the second zone are arranged or configured to absorb a second desired peak load during impact. The first desired peak load is different from the second desired peak load.

Tunable geometry for energy absorbing foam to lower peak load during side impact

A door trim speaker grille with an electroluminescent lamp for use with an audio speaker of a vehicle. The electroluminescent lamp is positioned for emitting visible light through sound passages in the speaker grille. In certain embodiments of the invention, the electroluminescent lamp may be integrally molded with the speaker grille. One method of forming the door trim speaker grille is by an injection molding process that places the electroluminescent lamp as an insert in the mold cavity.

Door trim speaker grille with electroluminescent lamp and injection molding method of making same

An injection molding system () includes a first mold half () and a second mold half (), which forms a cavity () with the first mold half (). A cavity intrusion element () is displaceable to extend within the cavity (). A displacement mechanism () is coupled to the cavity intrusion element (). A controller () is coupled to the displacement mechanism () and controls the intrusion depth (D) of the cavity intrusion element () during an injection molding process. A method of forming an article includes the pressurizing of the cavity () within a mold () via a gas. A material having a blowing agent is injected into the cavity (). The gas pressure within the cavity () is released. The cavity intrusion element () is backed out from within the cavity (). The material is cured.

Growing community of inventors

Troy, MI, United States of America

David Dooley