International Automotive Components Group North America, Inc.

Lear Corporation

Kenneth W Shaner

Glenn A Cowelchuk

John David Youngs

Robert J Adams

Nelson E Williams, Jr

Randy S Reed

Michael P Schoemann

David Dooley

Mark Heinze

Joseph T Donatti

Raymond K Cummins

Matthew S Brummer

Andrew P Mellentine

Ian S Williams

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

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

An interior trim panel for a vehicle door is provided according to alternative methods. The interior trim panel includes a bolster to which a polyurethane skin is molded by a spraying operation. Expanded polyurethane foam is sprayed over the polyurethane skin and a backing panel is either integrally formed or assembled to the polyurethane foam layer.

Method of making an interior panel for a door and an article made thereby

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.

Interior vehicle trim panel having a sprayed expanded polyurethane layer and method and system of making same

A method of making an integrated inner trim panel for a vehicle door and an inner trim panel made thereby are disclosed. The method includes sequentially spraying a skin layer, a padding layer, and applying a structural layer in an open mold that defines the facing surface of the inner panel of a door. The integrated inner trim panel may be provided with areas of greater and lesser padding. The skin layer may be formed from a reactant mixture of polyurethane. The padding layer may be a foam polyurethane composition. The structural layer may be a glass-reinforced polyurethane reactant mixture. The inner door panel is an integrated layered structure including a skin layer, a padding layer, and a structural layer. The padding layer may be varied in thickness to provide selectively variable padding in predetermined areas.

Method of making an integrated door inner panel and an article made thereby

A method of making a vehicle part includes spraying material proximate a surface of a tool to form a skin layer, and spraying material onto the skin layer to form a resilient layer. The method further includes removing the skin layer and the resilient layer from the tool and positioning the layers in a mold. Next, the method involves applying material onto the resilient layer to form a rigid substrate on the resilient layer.

Vehicle part with integrated impact management feature and method of making same

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.

Method of making an interior trim panel for a door and an article made thereby

A spray applicator for dispensing a multiple component reactant mixture and for also dispensing purge materials. The applicator has a valve plate with a plurality of valve seats for cylindrical valve elements that are arcuately shifted by a control air circuit.

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Howell, MI, United States of America

Kenneth W Shaner