Color trim panel

A vehicle door insert 10 comprises a decorative cover 20, an intermediate layer 22, a recyclate layer 24 and a fourth layer 26 constructed from the same material as layer 22. Cover 20 may comprise extruded or spun bond polypropylene, layers 22 and 24 may comprise a blend of natural fibres (sisal, hemp, flax, jute or kenaf for example) and polypropylene fibres and recyclate layer comprises granulated recycled material. The insert is manufactured by placing a preform for layer 26 in a mould, sprinkling recyclate over it, placing a second preform for layer 22 over the recyclate and tacking on cover 22. The resulting assembly is then compression moulded which bonds cover 20 to layer 22 and compresses the two preforms into a hard substrate layer. The preforms may include a binder in addition to the mixed fibres.

Color trim panel

Molded panels having a soft pad armrest

A method for forming a molded panel comprising a rigid substrate, a cover material, and a localized composite pad. The method comprises providing a molding tool having a first mold and a second mold, the first mold having a cavity; inserting a cover material between the first mold and the second mold; placing a composite pad comprising an impregnable layer and a non-impregnable layer in the cavity of the first mold, wherein the non-impregnable layer is facing the second mold and the impregnable layer is abutting the first mold; introducing resin into the molding tool; and solidifying the resin to form the molded panel whereby the non-impregnable layer of the composite pad is located adjacent the cover material.

Method of attaching thermoplastic attachments to a substrate

The present invention generally relates to interior trim parts such as door panels that are attached to an interior sheet in a motor vehicle. In accordance with the preferred embodiment of the present invention, a method of forming the trim part having an outer surface and an inner surface is disclosed. The method comprises providing a substrate having a first side and a second side and disposing the substrate in a molding tool, the molding tool has an upper mold and a lower mold. Engaging the first side of the substrate with the upper mold and the second side of the substrate with the lower mold. The first side is subject to compression molding such that the first side forms the outer surface of the trim part and injection molding an attachment surface to the second side of the substrate.