| abstract |
The present invention provides a new and improved method for manufacturing vehicle interior trim panels such as door panels and instrument panels in which different regions of the trim panel have different colors or other aesthetic characteristics. Two pieces of sheet vinyl having the desired color or other aesthetic characteristic desired in the manufactured trim panel are cut to shape and then bonded together edge-to-edge to form a composite two-tone vinyl sheet. This composite vinyl sheet is draped over a mold having a blade projecting from the mold surface. A retainer is installed onto the backside of the composite vinyl sheet to attach the composite vinyl sheet to the blade and thereby hold the vinyl in place with the bond between the two sheets located at the apex of the blade. The mold is closed and urethane is poured against the backside of the composite vinyl sheet to encapsulate the retainer. Upon cure, the urethane adheres to the composite vinyl sheet and the retainers and provides a substantial rigid support for the vinyl sheet. The bond between the two vinyl sheets is concealed from view at the bottom of the crevice defined in the molded trim panel by the blade. |