Ford Motor Company Limited

Thomas Junior Luckett

Michael T Vecchio

A method and apparatus (10) for molding a multilayered automotive trim component (12) having a covered edge portion (60). A flexible covering (32) is positioned between opposable molds (14, 16) that are continuously operable between an open position and a closed position. First and second article shaping surfaces (18, 20) on the molds (14, 16) form the article surfaces. An extendable slide (22, 23) having a cover receiving surface (24, 25) is positioned between the molds (14, 16) such that the cover receiving surface (24, 25) is positioned inwardly of a perimeter portion (26) of the first article shaping surface (18). The slide (22, 23) is extended and a polymeric resin (48) is injected onto the second article-shaping surface (20). The molds (14, 16) are closed such that the first and second article-shaping surfaces (18, 20) and the cover-receiving surface (24, 25) together define a cavity (52). The resin (48) is compressed within the cavity (52) and urges the covering (32) against the first article-shaping surface (18) and the cover-receiving surface (24, 25) to form a substrate layer (56) having a first covered surface (58) conforming to the first article-shaping surface (18) and a second covered surface (60) conforming to the cover-receiving surface (24, 25). The second covered surface (60) is generally opposite of the first covered surface (58). The slide (22, 23) is retracted sufficiently to remove the component (12) from the molds (14, 16).

Method for molding a multilayered trim component

An automotive door interior assembly has an interior door trim panel with a plurality of bosses extending therefrom having sections of varying wall thickness for allowing energy absorption through columnar deformation of the bosses. The bosses comprise conically shaped, hollow pedestals having a first end attached to the trim panel, a second truncated end opposite the first end, a wall connecting the first end and the second end, and an inner surface on the wall having at least one groove thereon. Connectors on the second truncated end of the bosses attach the trim panel to receiving apertures in the inner door panel.

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Westland, MI, United States of America

Thomas Junior Luckett