Trim panel assembly and method of manufacture

Abstract

A trim panel assembly and a method of manufacture. The trim panel assembly includes a trim panel and a backplate. The trim panel includes a speaker grill that allows sound to transmit from a speaker into the interior of a vehicle. The backplate is attached to the trim panel and includes a speaker mounting portion located adjacent to the speaker grill and a seal located adjacent to the speaker mounting portion that is configured to inhibit sound leakage.

1 . A method of manufacturing a trim panel assembly having an inner panel and a backplate, the backplate including a speaker aperture, a flange disposed around the aperture, and a recessed portion, the method comprising: 
 providing a multi-shot injection molding mold;    injection molding a first material to form the backplate in a first shot in the mold;    injection molding a second material to form a seal on the flange that extends around the aperture and a liner on a surface of the recessed portion in a second shot of the mold; and    assembling the backplate to the inner panel.    
     
     
         2 . The method of  claim 1  further comprising the step of actuating a portion of the injection molding mold after the first shot to create a relief cavity for receiving the liner.  
     
     
         3 . The method of  claim 1  further comprising the step of actuating a portion of the injection molding mold after the first shot to create a relief cavity for receiving the seal.  
     
     
         4 . The method of  claim 1  wherein the step of injection molding the second material further comprises injection molding the second material into a groove disposed on the flange to form the seal, the seal filling the groove and extending above the flange.  
     
     
         5 . The method of  claim 1  wherein the step of injection molding the second material further comprises injection molding the second material onto the flange to form the seal.  
     
     
         6 . The method of  claim 1  wherein the step of assembling the backplate to the inner panel further comprises positioning a speaker coaxially with the aperture and attaching the speaker to the backplate adjacent to the seal.  
     
     
         7 . The method of  claim 1  wherein the liner is disposed adjacent to an inner surface of the inner panel when the backplate is assembled to the inner panel.  
     
     
         8 . The method of  claim 1  wherein the inner panel further comprises a protruding portion disposed that cooperates with the recessed portion to define the storage compartment.  
     
     
         9 . The method of  claim 1  wherein the step of assembling the backplate to the inner panel further comprises removing the inner panel and the backplate from the mold before attaching the inner panel to an inner surface of a inner panel.  
     
     
         10 . A method of making a trim panel assembly, the method comprising: 
 forming a backplate having a speaker aperture and an inner panel having a speaker grill, the backplate and inner panel being made of a first material;    positioning the backplate and the inner panel adjacent to each other in a mold such that the backplate and the inner panel cooperate to define a storage compartment; and    injecting a second material into the mold to simultaneously form a seal disposed on the backplate and a liner disposed in the storage compartment;    
     
     
         11 . The method of  claim 10  wherein the liner extends along the backplate and the inner panel.  
     
     
         12 . The method of  claim 10  wherein the liner extends along the backplate and adjacent to the inner panel.  
     
     
         13 . The method of  claim 10  wherein the inner panel further comprises a protruding portion and the backplate further comprises a recessed portion, wherein the protruding portion and the recessed portion cooperate to define the storage compartment.  
     
     
         14 . The method of  claim 10  wherein the storage compartment further comprises a seam located where the backplate contacts the inner panel and wherein the liner extends along the backplate and the inner panel to conceal at least a portion of the seam.  
     
     
         15 . The method of  claim 10  further comprising the step of reconfiguring the mold to create a first and second relief cavities for accommodating the seal and the liner, respectively.  
     
     
         16 . The method of  claim 10  wherein the backplate and the inner panel are injection molded in different cavities of a common mold.  
     
     
         17 . The method of  claim 10  further comprising the step of positioning a speaker coaxially with the speaker aperture and attaching the speaker to the backplate.  
     
     
         18 . The method of  claim 17  wherein the seal is disposed between the speaker and the backplate.  
     
     
         19 . The method of  claim 17  wherein the backplate further comprises a groove and the seal is disposed at least partially in the groove.