Note: Descriptions are shown in the official language in which they were submitted.
CA 02535166 2002-11-05
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention concerns a method for using the same injection molding
apparatus to
manufacture at least two and up to four different levels of automobile trim
pieces. This invention
also concerns a strong third trim level piece that is comprised of a thin
decorative metal layer and
a thin resin layer. This invention further includes trim level pieces
manufactured from a stable
injected molding resin. Another aspect of this invention are molded plastic
and metal parts that
include a through feature on their face through which a transparent, semi-
transparent or opaque
resin or plastic is injected.
(2) Description of the Art
Automobiles include various "trim levels" depending primarily upon the cost
and luxury
level of the automobile in which the trim is being installed. The trim pieces
are interior and
exterior trim features and molding that are applied to the automobiles in
various locations such as
dashboards, door handle trim, glove compartment trim, console trim and so
forth. The first and
lowest trim level is typically painted molded resin trim pieces. A second trim
level consists of a
pre-formed polymer skin to which a resin backing is applied to give the pre-
decorated skin
structural integrity. A third trim level consists of decorated metal sheets
that are preformed and
then united with a premolded resin backing. The fourth and highest trim level
consists of real
laminated wood to which is applied a metal or premolded resin backing.
Each trim level piece includes tabs, connectors, an adhesive on the backing or
some
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equivalent means for attaching each trim level piece to an automobile
structure.
Presently, each level type of trim piece is manufactured using different
processes,
machines and molding apparatuses. This means that tools, dies, stamping
machines, injection
molds and so forth must be individually purchased to manufacture each piece
for each trim level.
Further, employees must be hired to manufacture the various trim level pieces,
and each trim
level piece must be separately designed and engineered. All of this equipment
and labor
increases the cost to manufacture each trim level trim piece.
Moreover some of the trim levels pieces require post molding manufacturing
steps. For
example third trim level pieces are made by uniting a premolded resin backing
with a prestamped
decorative metal piece. After the parts are united, further stamping and
crimping steps are
required to secure the decorative metal piece to the resin backing. These
manufacturing steps
also add significant costs to each manufactured trim piece.
There is a need therefore to reduce the design, machining and manufacturing
costs of
automobile trim level pieces. Furthermore, there is a need to produce third
trim pieces that use
significantly less materials.
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SUMMARY OF THE INVENTION
It is an object of this invention to provide a method for manufacturing at
least two and
preferably three or four levels of automobile trim pieces using the same
injection molding
apparatus. The methods of this invention significantly reduce the tooling cost
and labor
associated with the production of automobile trim level.
It is another object of this invention to provide third trim level pieces
including a
decorative metal surface and a resin backing that is manufactured of very thin
layers of material.
Yet another object of this invention is a plastic or metal part including
through features
that are filled with a transparent or semi-transparent or opaque plastic or
resin.
One aspect of this invention includes methods for manufacturing at least two
types of
trim level pieces using the same injection mold. The method includes the steps
of (a) preparing
a mold having a first piece including a first surface, a second piece
including a second surface,
and at least one injection port located in the second piece wherein the
injection port has an outlet
associated with the second surface wherein the mold first piece and second
piece unite to form an
internal cavity; and (b) manufacturing at least two different trim level
pieces using the mold. The
trim level piece are selected from the group including; (i) a first trim level
piece prepared by
injecting a resin into the mold and thereafter removing the cured first level
trim piece from the
mold and painting at least one surface of the molded trim piece; (ii) a second
trim level piece that
is prepared by the further steps comprising: preparing a preformed skin having
a (decorated) first
surface and a second surface wherein the preformed skin first surface has a
shape complementary
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to the mold first surface; placing the preformed skin into the mold such that
the preformed skin
first surface contacts the mold first surface; closing the mold and injecting
resin into the mold
through the at least one injection port and into contact with the preformed
piece second surface
until the internal cavity is filled with resin to form a second trim level
piece; and removing the
second trim level piece from the mold; (iii) a third trim level trim piece
that is prepared by the
:further steps comprising: preparing a predecorated shaped metal piece from
flat metal stock
wherein the shaped metal piece has a first surface and a second surface and
wherein the shaped
metal piece first surface has a shape complementary to the shape of the mold
first surface;
placing the shaped metal piece into the mold such that the metal sheet first
surface is in "contact"
with the mold first surface; closing the mold and injecting resin into the
mold through the at least
one injection port until the mold cavity is "filled with resin" to form a
third trim level piece; and
removing the third trim level piece from the mold; and (iv) a fourth trim
level piece that is
prepared by the further steps comprising; preparing a wooden trim piece having
a first surface
and a second surface wherein the wooden trim piece first surface has a shape
that is
complementary to the shape of the mold first surface; placing the wooden trim
piece into the
mold such that the wooden trim piece first surface is in contact with the mold
first surface;
closing the mold and injecting a resin into the mold through the at least one
injection port and
into contact with the wood trim piece second surface until the mold cavity is
filled with resin to
form a forth trim level piece; and removing the fourth trim level piece from
the mold.
Another aspect of this invention includes decorative automobile trim piece
comprising:
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a formed metal sheet having decorated first surface and a second surface
wherein the metal sheet
has a thickness of no greater than about 0.025 inches; and a resin layer
applied to the formed
metal sheet second surface wherein the resin layer has a thickness of no
greater than 2.5 mm.
Yet another aspect of this invention is a second trim level piece that is
prepared by the
further steps comprising: adhesively laminating cloth to a plastic skin and
then performing the
cloth covered plastic skin to form a preformed skin having a cloth covered
first surface wherein
the preformed skin first surface has a shape complementary to a mold first
surface; placing the
preformed skin into a mold so that the preformed skin first surface contacts
the mold first
surface; closing the mold and injecting resin into the mold through at least
one injection port and
into contact with a second surface of the preformed skin until the mold
internal cavity is filled
with resin to form a second trim level piece; and removing the second trim
level piece from the
mold.
Still another aspect of this invention is a trim level piece comprising an
insert having at
least one through hole and further including a decorative surface, and a
backing; a resin backing
associated with the insert backing; and at least on resin feature located on
the insert decorative
surface.
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DESCRIPTION OF THE FIGURES
Figure 1 is a cross-section of a mold useful in the methods of this invention
including a
mold cavity (14);
Figure 2 is a first level trim piece manufactured by the methods of this
invention;
Figure 3 is a second level trim piece manufactured by the methods of this
invention;
Figure 4A is a third level trim piece manufactured by the methods of this
invention;
Figure 4B is a blow-up view of a cross section of the third level trim piece
of Figure 4A;
Figure SA is a fourth level trim piece manufactured by the methods of this
invention;
Figure SB is a blow-up view of a cross section of the fourth trim level piece
of Figure SA;
Figures 6, 7, 8 and 9 are a cross-section views of a mold of this invention
holding first,
second, third and fourth level trim pieces;
Figures 10A and lOB are front and side cutaway views of a metal piece
including a
through hole in which resin has been injected using methods of this invention.
Figure 11A is a cross section of a mold useful for making a trim piece of this
invention
and Figures 11B and 11C are side and front views of the trim piece
manufactured using the mold
of Figure 11A;
Figure 12A is a cross section of a mold useful for making a trim piece of this
invention
including a preformed skin 22 and Figures 12B and 12C are side and front views
of the trim
piece manufactured using the mold of Figure 12A;
Figure 13A is a cross section of a mold useful for making a trim piece of this
invention
CA 02535166 2002-11-05
including a pre-shaped metal piece, and Figures 13B and 13C are side and front
views of a trim
piece manufactured using the mold of Figure 13A; and
Figures 14A and 14B are side and front views of a trim piece 60(d) includes a
metal skin
80, an adhesive layer 36, a preformed skin layer 22, a second optional
adhesive layer 77 and a
resin backing 72.
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DESCRIPTION OF THE CURRENT EMBODIMENT
The present invention relates to methods for using the. same resin injection
molding
equipment to manufacture multiple automobile trim level pieces. In another
aspect of this
invention is a third trim piece level including a very thin metal layer and a
very thin resin layer
that has good strength and that is highly dent-resistant.
By "multiple automobile trim levels pieces," it is meant that an injection
mold having the
same cavity dimensions is used in the process of this invention to manufacture
at least two,
preferably three and most preferably four different levels of automobile trim
pieces. Preferably,
the same mold is used to manufacture at least two and preferably three or more
levels of
automobile trim pieces.
In the specification and claims certain mold inserts will be described as
being in "contact"
with the mold cavity surface. The word contact is used in its broadest sense
to mean that the
insert is associated with the mold surface in a manner that inhibits resin
from contacting the
surface of the insert that is associated with the mold surface except in
situations where the insert
includes a through hole that expressly allows resin to flow between the insert
and the mold cavity
wall.
The four levels of automobile trim that are manufactured using a single
injection mold by
the methods of this invention are described below as "first trim level
pieces," "second trim level
pieces," "third trim level pieces," and "fourth trim level pieces." Each of
the trim level pieces is
manufactured using an injection mold such as the injection mold of Figure 1.
Injection mold 10
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of Figure 1 includes a first piece 13 including a first surface 12 associated
with cavity 14 and a
second piece 17 including a second surface 16. Injection mold IO further
includes at Least one
and preferably a plurality of resin injection ports 19. When mold first piece
13 is united with
mold second piece 17, a cavity 14, in the shape of a desired trim level piece
is formed.
First Trim Level Pieces
First trim level piece 18, shown in Figure 2 is made of an injected molded
resin that may
be painted or unpainted. First trim level piece 18 is manufactured by
injecting a molten resin
into injection mold cavity 14 and thereafter removing the molded part from
injection mold 10
once the part is sufficiently cooled. Therea$er, first trim level piece 18 may
be painted or may
remain unpainted to form a first level trim piece 18. First trim level piece
18 will generally be
made entirely of resin and will have a thickness ranging from about 0.040 to
about 0.156 inches.
Second Trim Level Pieces
A second trim level piece 20 is shown in Figure 3. Second trim level piece 20
comprises
a prefornied skin 22 that is colored, decorated, or that is a laminate.
Preformed skin 22 is
typically prefonned by thennalfonning. In one optional embodiment, preformed
skin 22 is a
laminate of a cloth layer and a plastic skin Layer. In this embodiment, a
piece of cloth is
adhesively laminated to a plastic.skin and the laminated cloth covered plastic
piece is formed into
preformed skin 22. In this alternative embodiment, the cloth may be located on
prefonned skin
first surface 24 or second surface 26.
Preformed skin 22 has a first surface 24 and a second surface 26. The skin
first surface
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24 is complementary to a first surface 12 of injection mold 10. Second trim
level piece 20 is
manufactured by placing preformed skin piece 22 into mold cavity 14 such that
first surface 24 of
the precoated preformed skin rests against the first surface 12 of injection
mold cavity 14. Next,
a resin is injected into the mold such that the resin enters the mold through
mold second surface
16, fills cavity 14, and becomes adhered to the second surface 26 of preformed
skin 22 to form a
second trim level piece 20. After cooling, second trim level piece 20
including preformed skin
22 and resin layer 25 is removed from injection mold 10. The second trim level
piece will have a
total thickness of from about 0.040" to about 0.156" with the plastic inmolded
preformed skin 22
having a thickness of from about 0.048 to about 0.030 inches.
Third Trim Level Pieces
A third trim level piece 30, shown in Figures 4A and 4B includes a pre-shaped
metal
piece 32 and a resin backing layer 34. A close up cross-section view of third
trim level piece 30
in Figure 4B shows that third tzim level piece 30 further includes an adhesive
36 located between
pre-shaped metal piece 32 and the resin backing 34. Third trim level piece 30
is manufactured by
first shaping a sheet of metal having a thickness of from about 0.005 to about
0.025 inches, and
preferably a sheet of aluminum that is decorated on one surface in stamping
and die cutting
processes to produce pre-shaped metal piece 32 having a first surface 37 and a
second surface 38.
First surface 37 will have a shape that is complimentary to the shape of the
first surface 12 of
mold 10.
Prior to or following shaping of pre-shaped metal piece 32, an adhesive
material is
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applied in a thin layer to the second surface 38 of the metal sheet or pre-
shaped metal piece 32.
The adhesive layer will have a thickness sufficient to bind the resin to pre-
shaped metal piece 32.
The purpose of the adhesive is to aid in bonding the resin to a pre-shaped
metal piece 32. Useful
adhesives include thermoplastic adhesives and thermoset adhesives with
thermoset adhesives
such as acrylics, polyeurethanes and combinations thereof being preferred. A
preferred adhesive
is a hot melt adhesive such as Ashland Prelam manufactured by Ashland
Chemical.
1
Shaped metal piece 32 is then placed in mold cavity 14 suc that shaped metal
piece first
surface 37 abuts first surface 12 of mold cavity 14. The mold is closed and
resin is injected into
the mold and against second surface 38 of shaped metal piece 32. During resin
injection, the
adhesive layer facilitates the bonding of the resin to second surface 38 of
shaped metal piece 32
to form a third trim level piece 30 including a resin backing 34. After
cooling, the third trim
level piece 30 is removed from mold 10. Third trim level piece 30 will have a
total thickness of
from about 0.040 to about 0.156 inches.
Fourth Trim Level Pieces
A fourth trim level piece 40 is shown in Figure 5. Fourth trim level piece 40
includes a
decorative wooden piece 42 and a resin backing 44. Fourth trim level piece 40
is manufactured
by first preparing decorative wooden piece 42 having a first surface 45 and a
second surface 46
as shown in Figure SB. Decorative wooden piece first surface 45 is
complimentary in shape to
the shaped first surface 12 of mold cavity 14. Decorative wooden piece 42
typically consists of
one or more layers of wood with a very thin wooden veneer on exposed first
surface 45. The
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wood veneer surface is typically covered with one or more layers of a
protective polymer coating
such as a urethane, polyester, or acrylic coating.
Fourth trim level piece 40 is manufactured by placing decorative wooden piece
42 into
mold cavity 14 so that the decorative wooden piece first surface 45 is
complimentary to and abuts
mold cavity first surface 12. Mold 10 is closed and resin is inj ected into
the mold whereupon the
resin adheres to the second surface 46 of decorative wooden piece 42. The
second surface 46 of
decorative wooden piece 42 may include an adhesive or mechanical structure
such as a metal
frame or foundation to facilitate the adherence of resin to second surface 46
of decorative
wooden piece 42. Fourth trim level piece is removed from mold 10 after the
resin has cooled.
Fourth level trim piece 40 will have a total thickness of from about 0.040
inches to about 0.156
inches with veneer portion having a thickness of from about 0.008 to about
0.100 inches.
The methods of this invention allow for the manufacture of first, second,
third and fourth
trim level pieces all having essentially the same overall thickness. Thus,
even though the trim
pieces may include decorative metal, wood, or preformed plastic layers of
varying thickness, the
overall trim piece thicknesses are made uniform because the amount of resin
that can be added to
the piece is limited by the injection mold cavity dimensions which is the same
for all trim levels.
In addition, the methods of the invention allow for the manufacture of a
variety of trim level
pieces all including the same installation tabs and construction thereby
facilitating the assembly
of automobiles with different trim levels using the same assembly techniques.
A benefit of manufacturing third trim level pieces 30 using the methods of
this invention
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is that the resulting third trim level pieces 30 are unexpectedly very strong.
Therefore, it is
possible to decrease the thickness of the resin and/or metal layers in the
third trim level pieces in
comparison to prior art metal clad trim level pieces thereby reducing the cost
of manufacturing
third trim level pieces 30 while maintaining its strength and dent resistant
properties. The metal
used in third trim level piece may be any metal that is used to manufacture
any thin sheet of
metal that used to manufacture automobile trim. Examples of useful metals
include stainless
steel, copper, bronze, aluminum, alloys thereof, nickel and so forth. Further,
the exposed metal
surface may be burnished or polished to form a decorative metal surface. A
preferred metal is
aluminum. The metal thickness and preferably aluminum thickness is less than
0.025 inches and
even more preferably ranges between 0.012 and 0.018 inches. T'he resin layer
can be as little as
1.0 mm thick and preferably ranges between 1.0 and 2.5 mm in thickness.
The selection of the resin is important in order to maintain the strength of
the trim level
pieces manufactured according to this invention. It is preferred that the
resin material have a
coefficient of expansion that is similar if not equal to the coefficient of
expansion of the material
to which it is associated. Examples of useful resins include, but are not
limited to thermoplastic
resins such as nylon, polycarbonate, ABS, PC/ABS, and combinations thereof. A
preferred resin
used in the manufacture of third trim level piece 30 is a glass filled
thermoplastic resin such a
glass filled nylon or glass filled PC/ABS wherein the resin includes from
about 10 to about 30 wt
glass fibers and preferably about 25 wt % glass fibers. A preferred
thermoplastic material is a
nylon resin manufactured by Bayer and sold under the trade name Durethan BKV-
125.
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The methods of this invention use standard injection molding processes and
techniques to
manufacture the trim level pieces of this invention. Figures 6-10 are side
cross section views a of
a mold 10 that is used to manufacture a first trim level piece (Figure 6), a
second trim level piece
(Figure 7), a third trim level piece (Figure 8), and a fourth trim level piece
(Figure 9). In Figures
6-9, injection mold 10 is typically a two-piece mold that includes a first
piece 13 having a first
surface 12 and a second piece 17 having a second surface 16. Mold 10 further
includes at least
one and preferably a plurality of resin injection ports 19 in second piece 17
that unite the outside
of second piece 17 with second surface 16.
In addition to the trim level pieces described above, the methods of invention
are useful
for manufacturing automobile buttons, switches, knob covers and so forth that
may optionally
include a through hole as a resin feature associated with the exposed surface
of the trim level
piece. An example of such a trim level piece is shown, is side and front view
in Figures 10A and
10B. The button 50 shown in Figures 10A and lOB includes an insert 51 that
includes a
decorative surface 52, a backing 54 and a through hole 62. When the insert is
placed in injection
mold 10, resin 55 is applied to backing 54 but some of the resin passes
through through hole 62
and fills a feature in the mold having a shape corresponding to decorative
resin feature 56 of
button 50. Buttons and trim pieces including a variety of decorative resin
features can be made
according to the methods of this invention. Decorative resin features can
include designs, words,
emblems, and they can be made using opaque, transparent, and semi-transparent
resins that have
any color.
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Another aspect of this invention is, therefore, a resin is injected~into a
through hole in a
substrate to form a design on the surface of the substrate or a design that
can be back-lit.
Referring to Figures 11A-11C, 12A-12C and 13A-13C, there is shown trim pieces
60(a), 60(b),
and 60(c) that can be made of any material such as plastic, wood or metal to
which a resin
backing can be applied. Trim pieces 60(b) and 60(c) include and optional
through hole 62.
Referring now to Figures 11A-11C, there is shown an injection mold 10
including a first
piece 13 and a second piece 17 that is combined to form a mold cavity 14. A
resin injection port
19 provides a path for injecting resin into mold cavity 14 from outside mold
10. Mold cavity 14,
as shown in Figure 11A, is in the shape of a button or knob that is useful as
an automobile trim
piece. Mold cavity 14 further includes a plurality of features 68. Feature 68
may be an
indentation, knob, buttons, writings, decorations and so forth. Figure 11B
shows trim piece 60(a)
that is manufactured from injection mold 10 shown in Figure 11A. Trim piece
60(a) is made
entirely of a resin material 70. Trim piece 60(a) includes an exposed surface
67(a) that includes a
plurality of feature 68(a). Expose surface 67(a) and/or feature 68(a) may be
painted or printed as
desired to form a decorated trim piece 60(a). Figure 11 C is a front view of a
decorated trim piece
60(a) including a plurality of features 68(a) wherein numerals have been
printed onto feature
68(a). Trim piece 60(a) corresponds to first level trim pieces described
above.
Figures 12A-12C depict an alternative trim piece 60(b) that may be
manufactured by the
methods of this invention. Injection mold 10 used to manufacture trim piece
60(b) includes a
mold cavity 14 that is identical in geometry to the mold cavity used to
manufacture trim piece
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60(a). However, in Figure 12A, a pre-formed skin 22 is placed in injection
mold 10 such that
first surface 24 of pre-formed skin 22 is associated with first surface 12 of
injection mold 10.
Pre-formed skin 22 as shown in Figure 12A includes a through hole 62
associated with a feature
68. The pre-formed skin 22 covers the remaining features 68. Injecting resin
into mold 10 of
Figure 12B, produces trim piece 60(b) shown in Figures 12B and 12C. Trim piece
60(b)
includes a pre-formed skin layer 22 and a resin backing 72. First surface 24
of pre-formed skin
22 may be decorated with numerals, writings, patterns, it may be made of a
colored material, or is
may included any known type of decoration that is used to decorate trim piece
60(b).- When resin
is injected into the mold of Figure 12A, the hot resin heats and forces pre-
formed skin 22 into
features 68 thereby forming pre-formed skin covered features 74. In areas
where a through hole
62 is associated with a mold feature 68, the resin fills the feature to form a
resin feature 76. It
may be desirable to form resin feature 76 for a variety of reasons. The resin
used to manufacture
resin feature 76 may be clear or semi-opaque thus allowing light to be
transmitted from behind
trim piece 60(b) to illuminate resin feature 76. Alternatively, the resin
material used to
manufacture trim piece 60(b) may be a colored resin that has a color that is
different than the
color of pre-formed skin 22 thereby providing contrasting colors on the
surface of trim piece
60(b). Trim piece 60(b) is essentially identical in structure to the second
level trim pieces
described above.
Figure I3A depicts a mold that is useful for manufacturing trim piece 60(c)
while Figures
13B and 13C depict side and front views of trim pieces 60(c) manufactured
using the mold of
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CA 02535166 2002-11-05
Figure 13A. The injection mold 10 shown in Figure 13A is essentially identical
to the injection
mold shown in Figures 12A and 11A. In addition, mold cavity 14 has the same
dimensions as
the mold cavity 14 of Figures 11A and 12A. In Figure 13A, a pre-shaped metal
piece 32 is
placed in injection mold cavity 14 such that first surface 37 of pre-shaped
metal piece 32 abuts
first surface 12 of injection mold 10. Pre-shaped metal piece 32 does not have
to conform
identically to the shape of first surface 12 which includes a plurality of
features 68. In Figure
13A, pre-shaped metal piece 32 includes an indentation 78 that corresponds to
the shape of a
feature 68. Additionally, pre-shaped metal piece 32 includes a through hole 62
that is- located
adjacent to a feature 68. .Finally, pre-shaped metal piece 32 includes a
portion that covers but
does riot conform to a feature 68(c). Once injection mold of Figure 13A is
closed, a heated resin
is injected into mold 10 through resin injection port 19 until cavity 14 is
essentially filled with
resin to form trim piece 60(c) shown in Figures 13B and 13C. Trim piece 60(c)
includes a metal
skin 80 and a resin backing 72. In Figures 13B. and 13C, two of the features
are formed metal
features 82. Formed metal features 82 may be formed as described above by
shaping pry-shaped
metal piece 32 to conform with the mold features or formed metal feature 82
may be formed
when pressure applied by the injected resin forces pre-shaped metal piece 32
into feature 68(c) of
Figure 13A. In addition, trim piece 60(c) includes a resin feature 76 formed
when the injected
resin passed through through hole 62 in pre-shaped metal piece 32 to fill
feature 68 in mold first
surface I2. Trim piece 60(c) is essentially identical to the third level trim
piece described above:
Figures 14A and 14B are side and front views of yet another embodiment of a
trim piece
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60(d) that can be manufactured by the methods of this invention: Trim piece
60(d) is
manufactured using the same mold depicted in Figures 11A, 12A and 13A by
placing a pre-
shaped metal piece 32 including an adhesive layer 36 in injection mold cavity
14 such that first
surface 37 of pre-shaped metal piece 32 abuts first surface 12 of injection
mold 10. Pre-shaped
metal piece 32 includes a plurality of through holes 62 that correspond to
features 68 in the final
trim piece 60(d). After placing preshaped metal piece 32 into the mold, a
preformed and
optionally predecorated skin 22 including a first surface 24 having one or
more features 68 is
located in mold 10 so that features 68 protrude through through holes 62 and
contact first surface
12 of injection mold 10. Second surface 26 of preformed skin 22 may include an
adhesive layer
77. Mold 10 is closed and heated resin is injected into mold 10, through resin
injection port 19
until cavity 14 is essentially filled with resin to form trim piece 60(b)
shown in Figures 14A and
14B. Trim piece 60(d) includes a metal layer 32, an adhesive layer 36, a
preformed skin layer 22,
a second optional adhesive layer 77 and a resin backing 72. In Figures 14A and
14B, each of the
features 68 are part of the preformed skin layer 22. Further, as shown in
Figure 14B, skin layer
22 is predecorated so that the final trim piece features 68(d) are printed
with numerals.
The four levels of trim pieces described above, and trim pieces 60(a), 60(b),
60(c), and
60(d) may all be produced using a single injection mold having a mold cavity
14 of identical
dimensions. One of the primary differences between the four trim piece levels
described above
and trim pieces 60(a), 60(b), 60(c), and 60(d) is the presence of features on
the exposed surface
of the trim piece and in particular a feature consisting partially or entirely
of resin material.
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The preceding description of this invention is intended to be illustrative in
nature and is not
to be considered as limiting the scope of the invention.
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