Method of manufacturing a trim panel having a styling line

A method of manufacturing a trim panel having a soft cushion and a styling line combined with the soft cushion comprising the steps of:

• providing a facing layer of soft trim material adjacent a backing layer of flexible foam that has a gap,
• providing a heat sensitive adhesive barrier film adjacent the backing layer so that the gap exposes a back surface of the facing layer to the heat sensitive adhesive barrier film,
• laying the facing layer, the backing layer and the heat sensitive adhesive barrier film on a support surface in a mold, and
• injecting a foam precursor mixture into the mold to generate a structural substrate for the trim panel, the generation of the structural substrate creating sufficient pressure to crush the backing layer so that the substrate is in intimate contact with the heat sensitive adhesive barrier film and the facing layer, and
• creating sufficient heat to activate the heat sensitive adhesive barrier film to bond the structural substrate to the back surface of the facing layer that is exposed by the gap of the backing layer to create a styling line in the facing layer.

A method of manufacturing a trim panel having a soft cushion and a styling line combined with the soft cushion comprising the steps of:

• providing a facing layer of soft trim material adjacent a backing layer of flexible foam that has a gap,
• providing a heat sensitive adhesive barrier film adjacent the backing layer so that the gap exposes a back surface of the facing layer to the heat sensitive adhesive barrier film,
• laying the facing layer, the backing layer and the heat sensitive adhesive barrier film on a support surface in a mold, and
• injecting a structural plastic into the mold to generate a structural substrate for the trim panel and crush the backing layer so that the substrate is in intimate contact with the heat sensitive adhesive barrier film and the facing layer, and
• creating sufficient heat to activate the heat sensitive adhesive barrier film to bond the structural substrate to the back surface of the facing layer that is exposed by the gap of the backing layer to create a styling line in the facing layer.

A method of manufacturing a trim panel having a soft cushion and a styling line combined with the soft cushion comprising the steps of:

• providing a facing layer of soft trim material,
• providing a backing layer of flexible foam adjacent only a portion of the facing layer, the backing layer having a gap,
• providing a heat-sensitive adhesive barrier film adjacent the backing layer so that the gap exposes a back surface of the facing layer to the heat-sensitive adhesive barrier film,
• laying the facing layer, the backing layer and the heat-sensitive adhesive barrier film on a support surface in a mold,
• injecting a structural plastic into the mold to generate a structural substrate for the trim panel and crush the backing layer so that the substrate is in intimate contact with the heat-sensitive adhesive barrier film and the facing layer, and
• creating sufficient heat to activate the heat-sensitive adhesive barrier film to bond the structural substrate to the back surface of the facing layer that is exposed by the gap of the backing layer to create a styling line in the facing layer.