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Vehicle interior trim panel component assembly and in-mold method of manufacturing same

  • US 20050140167A1
  • Filed: 12/30/2003
  • Published: 06/30/2005
  • Est. Priority Date: 12/30/2003
  • Status: Abandoned Application
First Claim
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1. A method of manufacturing a trim panel assembly for the interior of a vehicle having integrated trim panel components, said method comprising the steps of:

  • providing a die including a pair of die halves cooperating to define a mold cavity to form a interior trim panel, at least one of said die halves including a surface within said mold cavity defining an A-surface, one of said mold cavities including a plurality of recesses having a predetermined shape;

    placing at least one trim panel component into said corresponding recess within said mold cavity;

    closing said first and said second die halves;

    forming a rigid substrate having an A-side surface visible to the interior of a vehicle when secured to a vehicle door in said mold cavity by injecting a molten thermoplastic material having a predetermined pressure less than the maximum clamp pressure of said die into said mold cavity so as to fill said mold cavity; and

    bonding said molten thermoplastic material to at least one trim panel component within said mold cavity while said rigid substrate is formed.

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