Method for making a vehicle panel
View Patent ↗A method of forming a panel is disclosed. The method includes forming a flexible skin ( 22 ); coupling a compressible material ( 24 ) to the skin ( 22 ); positioning the skin ( 22 ) and compressible material ( 24 ) in a mold; and forming a rigid substrate ( 20 ) around the skin ( 22 ) and compressible material ( 24 ) providing a first soft region ( 12 ) wherein the compressible material ( 24 ) is disposed between the skin ( 22 ) and the substrate ( 20 ) so that a first soft region ( 12 ) is defined by the compressible material ( 24 ).
1. A component for a vehicle interior comprising:
a flexible skin having a flange that extends substantially entirely about the periphery of the skin;
a compressible material coupled to the skin;
a rigid substrate having grooves that define an area;
wherein the flange of the skin is coupled to and embedded in the grooves of the substrate which provides a visual boundary between the skin and the substrate defined by the groove and extends substantially entirely about the periphery of the area over which the skin is provided;
wherein the area over which the skin is provided comprises a first soft region and a second soft region, the first soft region and the second soft region each defining an exposed surface of the component that is configured to be interfaced by a vehicle occupant;
wherein the compressible material is located between the skin and the substrate to provide the first soft region;
wherein a portion of the skin is in direct contact with the substrate to provide the second soft region; and
wherein the skin extends continuously between the first soft region and the second soft region.
2. The component of claim 1 wherein the flange comprises a folded back configuration that forms a protrusion.
3. The component of claim 2 wherein the substrate comprises a molded polymer material.
4. The component of claim 3 wherein the skin is a vacuum formed and trimmed sheet of a thermoplastic olefin material.
5. The component of claim 4 wherein the compressible material is a foam material.
6. The component of claim 5 wherein the foam material is a closed cell foam.
7. The component of claim 5 wherein the foam is bonded to the skin.
8. The component of claim 1 wherein the component is a vehicle door trim panel.
9. The component of claim 1 wherein the boundary is filled in to provide the appearance of a seamless transition between the skin and the substrate.