US20050275134A1 - Trim panel assembly having an integrated door bumper and method of manufacture - Google Patents
Trim panel assembly having an integrated door bumper and method of manufacture Download PDFInfo
- Publication number
- US20050275134A1 US20050275134A1 US11/162,010 US16201005A US2005275134A1 US 20050275134 A1 US20050275134 A1 US 20050275134A1 US 16201005 A US16201005 A US 16201005A US 2005275134 A1 US2005275134 A1 US 2005275134A1
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- United States
- Prior art keywords
- door
- housing
- panel
- bumper
- skin
- Prior art date
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- Abandoned
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R7/00—Stowing or holding appliances inside vehicle primarily intended for personal property smaller than suit-cases, e.g. travelling articles, or maps
- B60R7/04—Stowing or holding appliances inside vehicle primarily intended for personal property smaller than suit-cases, e.g. travelling articles, or maps in driver or passenger space, e.g. using racks
- B60R7/06—Stowing or holding appliances inside vehicle primarily intended for personal property smaller than suit-cases, e.g. travelling articles, or maps in driver or passenger space, e.g. using racks mounted on or below dashboards
Definitions
- the present invention relates to trim panel assembly having an integrated door bumper and a method of manufacturing the same.
- Trim panel doors have been used to close openings in vehicles. For instance, trim panel doors have been used to close openings in vehicle storage compartments, ash trays, and cup holders.
- a quite common example of such a use is the use of a trim panel door, such as a glove box door, to close a glove box opening.
- a glove box door is typically connected with a housing having an opening. The opening provides access to a glove box compartment. The door when in an open position provides access to the compartment and when closed covers the opening preventing access to the compartment.
- elastomeric bumpers have been provided, typically placed on the housing perimeter forming the opening. These bumpers are typically separately manufactured and are press-fit into a small opening in the perimeter of the housing. This press fitting provides an extra step and an extra part during the manufacturing process, thus increasing cost and complexity of manufacture.
- the present invention relates to a method for making trim panel assembly.
- the method comprises providing a housing comprising a housing panel having a perimeter portion defining an opening and a housing skin covering at least a portion of the housing panel.
- the method further comprises providing a door connectable with the housing which is moveable between a first position wherein the door closes the opening to a second position wherein the door provides access to the opening.
- the door comprises a door panel and a door skin covering at least a portion of the door panel.
- the method further comprises providing a bumper disposed between the housing and the door. The bumper and at least one of the skins are made during the same injection molding step.
- the bumper may be located on the door.
- the bumper may be located on the housing perimeter portion.
- an extension portion may extend between and connect the bumper and either the door skin or the housing skin.
- the extension portion may extend through the door panel or the housing panel.
- the extension portion may extend around an edge of the door panel.
- the bumper may comprise a first portion on the door and a second portion facing the first portion and being located on the housing.
- the door may be a glove box door and the housing may be a glove box compartment.
- FIG. 1 illustrates a perspective view of one embodiment of an instrument panel for a motor vehicle in accordance with the present invention
- FIG. 2 illustrates a view along line 2 - 2 of FIG. 1 with the door in a first position
- FIG. 3 is a view similar to FIG. 2 showing the door in a second position
- FIG. 4 illustrates a front view of a portion of the instrument panel of FIG. 1 with the door removed;
- FIG. 5 is a view similar to FIG. 2 illustrating a second embodiment of the present invention.
- FIG. 6 is a view similar to FIG. 2 illustrating a third embodiment of the present invention.
- FIG. 7 is a view similar to FIG. 2 illustrating a fourth embodiment of the present invention.
- FIG. 8 is a view similar to FIG. 2 illustrating a fifth embodiment of the present invention.
- a motor vehicle trim panel 10 such as an instrument panel, that is located essentially between a windshield (not shown) and an occupant compartment 12 . While the trim panel is being illustrated as an instrument panel 10 , it should be understood that other trim panels, such as those used to close vehicle compartments, such as ash trays and cup holders, can enjoy the benefits of the present invention.
- the panel 10 generally comprises a substrate 14 having a first surface 15 and a second surface 17 . The first surface 15 of the substrate 14 faces the occupant compartment 12 and is covered at least in part by a cover skin 16 .
- the substrate 14 can be made of any suitable material such as a relatively hard, relatively rigid material like polypropylene, polyethylene, TPO, PC (Polycarbonate), PC/ABS, ABS and SMA.
- the cover skin 16 may also be made of any suitable relatively non-rigid relatively soft material such as TPE, TEE, EPDM and any other suitable elastomeric materials.
- the instrument panel 10 includes a glove box, generally indicated at 20 .
- the glove box 20 comprises a glove box door 22 connected, preferably hingedly connected in at least one embodiment, to a glove box compartment 24 .
- the glove box compartment 24 has a housing portion 23 made of the substrate material (i.e. the housing portion 23 is part of the substrate 14 ).
- the housing portion 23 comprises four side walls 23 a and a back wall 23 b, as best shown in FIG. 4 , that forms a storage unit 25 of the glove box compartment 24 .
- suitable storage unit configurations could be used, such as a substrate unit formed on the door 22 that pivots open when the door is opened.
- the glove box compartment 24 has a perimeter portion 32 , shown in the FIG. 4 to be a flange.
- the flange 32 defines an opening 34 .
- the glove box opening 34 provides access to the storage unit 25 of the glove box compartment 24 .
- the glove box door 22 comprises a door panel 26 having a first surface 27 and a back surface 29 .
- the first surface 27 of the door panel 26 faces the occupant compartment 12 and is covered, at least in part, by a door skin 28 .
- the door panel 26 also includes an upper edge surface 31 that extends between and connects the surfaces 27 and 29 of the door panel 26 .
- the door panel 26 is made of the same material as the housing portion 23 , ie., the substrate.
- the door skin 28 in at least one embodiment, is made of the same material as the cover skin 16 . It should be understood however that the door skin 28 and the cover skin 16 could be made of different materials.
- the instrument panel 10 includes at least one bumper 30 .
- the bumper 30 provide a biasing effect between the glove box door 22 and the glove box compartment 24 .
- the bumper 30 urges the door 22 away from the compartment 24 to prevent unwanted and unnecessary noise and rattling during vehicle operation. While only two bumpers 30 are shown, it should be understood that more or fewer bumpers 30 could be provided, as desired.
- the bumpers 30 are made of the same material as either, or both, of the cover skin 16 and/or the door skin 28 .
- the bumpers 30 can be made simultaneously with one of the skins 16 or 28 during a two-shot injection molding process, as will be described further below.
- the bumpers 30 are provided on the face of the flange 32 and face towards the door 22 .
- Extension portions 36 extend between and connect the cover skin 16 and the bumpers 30 .
- the extension portions 36 are made of the same material, and are made during the same molding process, as the bumpers 30 and the cover skin 16 .
- the extension portions 26 are located on the perimeter portion, i.e., flange 32 , of the glove box compartment 24 facing the occupant compartment 12 .
- the extension portions 36 can extend through the flange 32 of the glove box compartment 24 at a first location and then extend along a back surface 40 of the flange 32 , facing away from the occupant compartment, and then back through a second location of the flange 32 .
- the second location is below the first location.
- the bumpers 30 are made of the same material as the skin 16 .
- the bumpers 30 and the skin 16 are made simultaneously during a two-shot injection molding process, as will be described further below.
- the bumpers 30 could be placed on the door 22 instead of on the glove box compartment 24 .
- the extension portion 36 extend around the top edge 31 of the door panel 26 and down a back surface 29 of the door panel 26 .
- the extension portions 36 could extend through the door pane 26 , from the front surface 27 to the back surface 29 , so that the extension portions 36 are not visible to the eye.
- the bumpers 30 are made of the same material as the door skin 28 . The bumpers 30 and the door skin 28 are made simultaneously during a two-shot injection molding process, as will be described further below.
- the bumpers 30 have a first portion 30 a located on the door 22 and a second portion 30 b located on the housing 24 .
- the bumpers 30 a and 30 b are able to be made in a smaller dimension then the bumpers 30 in the other embodiments.
- the bumpers 30 in this embodiment can have average heights of 0.1 to 1.5 mm and average widths of 0.5 to 4.0 mm, whereas the bumpers 30 in the other embodiments have average heights of 0.2 to 3.0 mm and average widths of 0.5 to 4.0. While the extension portions 36 are shown in FIG.
- the extension portions 36 could extend either around the upper edge surface 37 on the door panel 26 , on the face of the flange 32 , or both and not through the door panel and/or flange 32 .
- the bumper 30 a is made of the same material as the door skin 28 and the bumper 30 b is made of the same material as skin 16 .
- the bumper 30 b and the skin 16 are made simultaneously during a two-shot injection molding process, as will be described further below.
- the bumper 30 a and the door skin 26 a are made simultaneously during a two-shot injection molding process, as will be described further below.
- a method of forming the bumpers 30 , 30 a and/or 30 b using a multi-shot or two-shot injection molding process will now be described. Such a process is generally described in U.S. patent application Ser. No. 10/131,015, assigned to Lear Corporation, is incorporated by reference herein in its entirety. The process allows the manufacture of assembly of at least one bumper to be integrated with the manufacturer and/or assembly of a trim component to improve quality, reduce manufacturing complexity, and reduce costs.
- a first type of material is injected into an injection molded mold to form either the door panel 26 or the instrument panel 10 with the glove box compartment 24 .
- a second type material is injected into the injection molding mold to form one of the cover skin 16 or door skin 28 , along with the bumpers 30 , 30 a and/or 30 b and the extension portions 36 .
- the mold may include one or more cams or slides that are actuated to create relief cavities to which the second material flows.
- different mold cavities may be employed for the first and second shots. For instance, a portion of the mold having material from the first shot may be indexed to a second position and made into another mold portion having appropriate relief cavities before injecting the second type material.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
Description
- This application is a division of U.S. application Ser. No. 10/852,276, filed May 24, 2004 and entitled “Trim Panel Assembly Having an Integrated Door Bumper and Method of Manufacture.”
- 1. Field of the Invention
- The present invention relates to trim panel assembly having an integrated door bumper and a method of manufacturing the same.
- 2. Background Art
- Trim panel doors have been used to close openings in vehicles. For instance, trim panel doors have been used to close openings in vehicle storage compartments, ash trays, and cup holders. A quite common example of such a use is the use of a trim panel door, such as a glove box door, to close a glove box opening. A glove box door is typically connected with a housing having an opening. The opening provides access to a glove box compartment. The door when in an open position provides access to the compartment and when closed covers the opening preventing access to the compartment.
- To prevent rattling and undesirable noises associated therewith, elastomeric bumpers have been provided, typically placed on the housing perimeter forming the opening. These bumpers are typically separately manufactured and are press-fit into a small opening in the perimeter of the housing. This press fitting provides an extra step and an extra part during the manufacturing process, thus increasing cost and complexity of manufacture.
- It would be desirable to provide a trim panel assembly having a door wherein the operability of a bumper is provided without having to provide an added part, such as a press-fit bumper.
- In at least one embodiment, the present invention relates to a method for making trim panel assembly. The method comprises providing a housing comprising a housing panel having a perimeter portion defining an opening and a housing skin covering at least a portion of the housing panel. The method further comprises providing a door connectable with the housing which is moveable between a first position wherein the door closes the opening to a second position wherein the door provides access to the opening. The door comprises a door panel and a door skin covering at least a portion of the door panel. The method further comprises providing a bumper disposed between the housing and the door. The bumper and at least one of the skins are made during the same injection molding step.
- In at least one embodiment, the bumper may be located on the door.
- In at least another embodiment, the bumper may be located on the housing perimeter portion.
- In at least another embodiment, an extension portion may extend between and connect the bumper and either the door skin or the housing skin.
- In at least another embodiment, the extension portion may extend through the door panel or the housing panel.
- In at least another embodiment, the extension portion may extend around an edge of the door panel.
- In at least one embodiment, the bumper may comprise a first portion on the door and a second portion facing the first portion and being located on the housing.
- In at least another embodiment, the door may be a glove box door and the housing may be a glove box compartment.
-
FIG. 1 illustrates a perspective view of one embodiment of an instrument panel for a motor vehicle in accordance with the present invention; -
FIG. 2 illustrates a view along line 2-2 ofFIG. 1 with the door in a first position; -
FIG. 3 is a view similar toFIG. 2 showing the door in a second position; -
FIG. 4 illustrates a front view of a portion of the instrument panel ofFIG. 1 with the door removed; -
FIG. 5 is a view similar toFIG. 2 illustrating a second embodiment of the present invention; -
FIG. 6 is a view similar toFIG. 2 illustrating a third embodiment of the present invention; -
FIG. 7 is a view similar toFIG. 2 illustrating a fourth embodiment of the present invention; and -
FIG. 8 is a view similar toFIG. 2 illustrating a fifth embodiment of the present invention. - As required, detailed embodiments of the present invention are disclosed herein. However, it is to be understood that disclosed embodiments are merely exemplary of the invention that may be embodied in various alternative forms. The Figures are not necessarily to scale, some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural or functional details disclosed herein are not be interpreted as limiting, but merely as a representative basis for the claims and/or a representative basis for teaching one skilled in the art to variously employ the present invention.
- Moreover, except for otherwise expressly indicated, all numeral quantities in this description and in the claims indicating amounts or conditions are to be understood as modified by the work (about) in describing the broader scope of the invention. Practice within the numerical limits as stated is generally preferred. Also, unless expressly stated to the contrary, percents, “parts of,” and ratio values are by weight and the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more members of the group or class may be equally suitable or preferred.
- Referring to
FIGS. 1 and 2 , there is illustrated a motorvehicle trim panel 10, such as an instrument panel, that is located essentially between a windshield (not shown) and anoccupant compartment 12. While the trim panel is being illustrated as aninstrument panel 10, it should be understood that other trim panels, such as those used to close vehicle compartments, such as ash trays and cup holders, can enjoy the benefits of the present invention. Thepanel 10 generally comprises asubstrate 14 having afirst surface 15 and asecond surface 17. Thefirst surface 15 of thesubstrate 14 faces theoccupant compartment 12 and is covered at least in part by acover skin 16. Thesubstrate 14 can be made of any suitable material such as a relatively hard, relatively rigid material like polypropylene, polyethylene, TPO, PC (Polycarbonate), PC/ABS, ABS and SMA. Thecover skin 16 may also be made of any suitable relatively non-rigid relatively soft material such as TPE, TEE, EPDM and any other suitable elastomeric materials. - The
instrument panel 10 includes a glove box, generally indicated at 20. Theglove box 20 comprises aglove box door 22 connected, preferably hingedly connected in at least one embodiment, to aglove box compartment 24. Theglove box compartment 24 has ahousing portion 23 made of the substrate material (i.e. thehousing portion 23 is part of the substrate 14). In at least one embodiment, thehousing portion 23 comprises fourside walls 23a and aback wall 23b, as best shown inFIG. 4 , that forms astorage unit 25 of theglove box compartment 24. It should be readily understood that other suitable storage unit configurations could be used, such as a substrate unit formed on thedoor 22 that pivots open when the door is opened. - The
glove box compartment 24 has aperimeter portion 32, shown in theFIG. 4 to be a flange. Theflange 32 defines anopening 34. Theglove box opening 34 provides access to thestorage unit 25 of theglove box compartment 24. - As best seen in
FIG. 2 , theglove box compartment 24 and the glove box opening 34 are closeable and coverable by theglove box door 22. When thedoor 22 is opened, as shown inFIG. 3 , theopening 34 andstorage unit 25 are accessible by the vehicle occupants. Referring again toFIG. 2 , theglove box door 22 comprises adoor panel 26 having afirst surface 27 and aback surface 29. Thefirst surface 27 of thedoor panel 26 faces theoccupant compartment 12 and is covered, at least in part, by adoor skin 28. Thedoor panel 26 also includes anupper edge surface 31 that extends between and connects thesurfaces door panel 26. In at least one embodiment, thedoor panel 26 is made of the same material as thehousing portion 23, ie., the substrate. It should be understood however that thedoor panel 26 and thehousing portion 23 could be made of different materials. Thedoor skin 28, in at least one embodiment, is made of the same material as thecover skin 16. It should be understood however that thedoor skin 28 and thecover skin 16 could be made of different materials. - The
instrument panel 10 includes at least onebumper 30. Thebumper 30 provide a biasing effect between theglove box door 22 and theglove box compartment 24. Thebumper 30 urges thedoor 22 away from thecompartment 24 to prevent unwanted and unnecessary noise and rattling during vehicle operation. While only twobumpers 30 are shown, it should be understood that more orfewer bumpers 30 could be provided, as desired. As will be described further below, thebumpers 30 are made of the same material as either, or both, of thecover skin 16 and/or thedoor skin 28. Thebumpers 30 can be made simultaneously with one of theskins - As shown in
FIGS. 2-4 , thebumpers 30, or bumper as the case may be, are provided on the face of theflange 32 and face towards thedoor 22.Extension portions 36 extend between and connect thecover skin 16 and thebumpers 30. In the embodiment, theextension portions 36 are made of the same material, and are made during the same molding process, as thebumpers 30 and thecover skin 16. In this embodiment, theextension portions 26 are located on the perimeter portion, i.e.,flange 32, of theglove box compartment 24 facing theoccupant compartment 12. - In another embodiment, as illustrated in
FIG. 5 , if it desirable to hide theextension portions 36, theextension portions 36 can extend through theflange 32 of theglove box compartment 24 at a first location and then extend along aback surface 40 of theflange 32, facing away from the occupant compartment, and then back through a second location of theflange 32. In this embodiment, the second location is below the first location. - In the embodiments illustrated in
FIGS. 2-5 , thebumpers 30 are made of the same material as theskin 16. Thebumpers 30 and theskin 16 are made simultaneously during a two-shot injection molding process, as will be described further below. - In another embodiment, the
bumpers 30 could be placed on thedoor 22 instead of on theglove box compartment 24. In one of these embodiments, as shown inFIG. 6 , theextension portion 36 extend around thetop edge 31 of thedoor panel 26 and down aback surface 29 of thedoor panel 26. In an alternative embodiment, as shown inFIG. 7 , theextension portions 36 could extend through thedoor pane 26, from thefront surface 27 to theback surface 29, so that theextension portions 36 are not visible to the eye. In the embodiments illustrated inFIGS. 6 and 7 , thebumpers 30 are made of the same material as thedoor skin 28. Thebumpers 30 and thedoor skin 28 are made simultaneously during a two-shot injection molding process, as will be described further below. - In yet another embodiment, as illustrated in
FIG. 8 , thebumpers 30 have afirst portion 30 a located on thedoor 22 and asecond portion 30 b located on thehousing 24. In this embodiment, thebumpers bumpers 30 in the other embodiments. For instance, thebumpers 30 in this embodiment can have average heights of 0.1 to 1.5 mm and average widths of 0.5 to 4.0 mm, whereas thebumpers 30 in the other embodiments have average heights of 0.2 to 3.0 mm and average widths of 0.5 to 4.0. While theextension portions 36 are shown inFIG. 8 to be hidden from view, theextension portions 36 could extend either around the upper edge surface 37 on thedoor panel 26, on the face of theflange 32, or both and not through the door panel and/orflange 32. In this embodiment, thebumper 30 a is made of the same material as thedoor skin 28 and thebumper 30 b is made of the same material asskin 16. Thebumper 30 b and theskin 16 are made simultaneously during a two-shot injection molding process, as will be described further below. Thebumper 30 a and the door skin 26 a are made simultaneously during a two-shot injection molding process, as will be described further below. - A method of forming the
bumpers - In a two-shot injection molding process, a first type of material is injected into an injection molded mold to form either the
door panel 26 or theinstrument panel 10 with theglove box compartment 24. And a second type material is injected into the injection molding mold to form one of thecover skin 16 ordoor skin 28, along with thebumpers extension portions 36. The mold may include one or more cams or slides that are actuated to create relief cavities to which the second material flows. Alternatively, different mold cavities may be employed for the first and second shots. For instance, a portion of the mold having material from the first shot may be indexed to a second position and made into another mold portion having appropriate relief cavities before injecting the second type material. - While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.
Claims (18)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/162,010 US20050275134A1 (en) | 2004-05-24 | 2005-08-25 | Trim panel assembly having an integrated door bumper and method of manufacture |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US10/852,276 US6945583B1 (en) | 2004-05-24 | 2004-05-24 | Trim panel assembly having an integrated door bumper and method of manufacture |
US11/162,010 US20050275134A1 (en) | 2004-05-24 | 2005-08-25 | Trim panel assembly having an integrated door bumper and method of manufacture |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US10/852,276 Division US6945583B1 (en) | 2004-05-24 | 2004-05-24 | Trim panel assembly having an integrated door bumper and method of manufacture |
Publications (1)
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US20050275134A1 true US20050275134A1 (en) | 2005-12-15 |
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US10/852,276 Expired - Fee Related US6945583B1 (en) | 2004-05-24 | 2004-05-24 | Trim panel assembly having an integrated door bumper and method of manufacture |
US11/162,010 Abandoned US20050275134A1 (en) | 2004-05-24 | 2005-08-25 | Trim panel assembly having an integrated door bumper and method of manufacture |
Family Applications Before (1)
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US10/852,276 Expired - Fee Related US6945583B1 (en) | 2004-05-24 | 2004-05-24 | Trim panel assembly having an integrated door bumper and method of manufacture |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US20090305000A1 (en) * | 2008-06-04 | 2009-12-10 | International Automotive Components Group North America, Inc. | Integrated seal for two-shot assembly and method of manufacture |
JP2019099072A (en) * | 2017-12-07 | 2019-06-24 | しげる工業株式会社 | Interior component for vehicle and center console |
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JP2006153083A (en) * | 2004-11-26 | 2006-06-15 | Daiwa Kasei Ind Co Ltd | Cushioning clip |
US7784844B2 (en) * | 2005-09-21 | 2010-08-31 | Komatsu Ltd. | Interior trim member of work vehicle and method of manufacturing the same |
US7597371B2 (en) * | 2007-05-01 | 2009-10-06 | Toyota Motor Engineering & Manufacturing North America, Inc. | Lead-in for trim assembly |
US10246912B2 (en) | 2016-11-18 | 2019-04-02 | Ford Global Technologies Llc | Locator feature for automotive interior doors |
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US6475576B1 (en) * | 1999-12-30 | 2002-11-05 | Delphi Technologies, Inc. | Reinforced interior trim panel assembly and method |
US20010030438A1 (en) * | 2000-03-14 | 2001-10-18 | Fuminori Kamemizu | Article storing structure for scooter type vehicle |
US20030180498A1 (en) * | 2000-08-01 | 2003-09-25 | Hugo De Winter | Method for manufacturing an automotive trim part |
US20030201571A1 (en) * | 2002-04-24 | 2003-10-30 | Davis Joseph J. | Method for manufacturing cockpit-type instrument panels |
US20040000737A1 (en) * | 2002-06-28 | 2004-01-01 | Nicole Durr | Method of manufacturing energy absorbent vehicle components |
US20050183897A1 (en) * | 2004-02-24 | 2005-08-25 | Lear Corporation | Two-shot co-injected automotive interior trim assembly and method |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090305000A1 (en) * | 2008-06-04 | 2009-12-10 | International Automotive Components Group North America, Inc. | Integrated seal for two-shot assembly and method of manufacture |
JP2019099072A (en) * | 2017-12-07 | 2019-06-24 | しげる工業株式会社 | Interior component for vehicle and center console |
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