The present invention relates to a crash pad for a vehicle and a manufacturing method thereof. In one embodiment, the method for manufacturing the crash pad for the vehicle comprises a step of injecting a skin foam-forming composition between a lower mold having a color coating layer formed thereon and an upper mold having a core layer formed thereon, foaming the injected skin foam-forming composition to form a skin foam layer, wherein the color coating layer is formed by applying the color coating composition to the inside surface of the lower mold and curing the applied color coating composition.

Provided is a cooling tank comprising a tank body in which a water accommodation space is formed, a foaming case for encompassing the outer peripheral surface of the tank body, and a foam insulating material formed by a foaming agent flowing into the foaming space between the outer peripheral surface of the tank body and the foaming case, and then foaming, wherein the foam insulating material is integrated with the tank body and the case through foaming, and the case has an air outlet through which air of the foaming space is discharged during a foaming process.

A foaming die device for forming a headrest is provided, which comprises a lower die having a first protrusion and an upper die having a second protrusion. The lower and upper dies are used for accommodating a trim cover assembly with a headrest stay portion extending outwardly through a stay passage hole formed in the trim cover assembly. The first and second protrusions are adapted to press and turn over a projected area created about the stay passage hole into the inside of that trim cover assembly. Also, a foaming process for forming the headrest, using this foaming die device, is provided, in which the projected area is turned over by the first and second protrusions into the trim cover assembly when placing the trim cover assembly in the dies. Hence, conventional preliminary steps using cylindrical stick to turn over the projected area into the trim cover assembly are eliminated.

The disclosure discloses a vehicle interior panel for covering an airbag and a method of fabricating a vehicle interior panel for covering an airbag. The vehicle interior panel includes a substrate with an opening, a chute channel assembly inserted into the opening, a surface skin, and a foam layer disposed between the surface skin and the substrate. The chute channel assembly includes a wall section surrounding a chute channel for the airbag and a cover plate covering the chute channel and closing the opening. The cover plate includes an airbag door, wherein an outer surface of the cover plate is in contact with the foam layer. The outer surface of the cover plate has a rough surface structure, the outer surface having a surface roughness parameter R.sub.a of at least 4 m.

An apparatus includes a first mold having an injection cavity at a side thereof, for molding of a substrate, a second mold having two injection cores and two skin shaping plugs, and a third mold having a foaming section where a foaming material is injected between a substrate and a skin, and a skin shaping section where embossing is carried out on a skin, wherein, under the condition that the first mold, second mold and third mold are simultaneously closed to one another, a substrate is molded by the injection cavity and a first injection core, embossing is carried out on a skin by one skin shaping plug and the skin shaping section, and, at a same time, the foaming material is injected between a previously molded substrate and a previously embossed skin by a second injection core and foaming section.

A cushion pad of a vehicle seat including: a cushion member including a soft pad and a hard pad which is harder than the soft pad, the soft pad being integrated with the hard pad so as to wrap the hard pad without covering a mounting side surface of the hard pad, wherein a groove, which is opened to the mounting side and having a size large enough to receive an exuding piece generated during molding of the soft pad, is provided in a periphery of the mounting side surface of the hard pad.

A method of providing interior trim for a motor vehicle comprising forming a first interior trim article providing a first interior trim level, wherein the first article comprises a first article decorative covering overlying a first article cushion member and a first article substrate; and forming a second interior trim article having a base structure comprising the first interior trim article; wherein the second interior trim article provides a second interior trim level different from the first interior trim level; wherein the second interior trim article comprises a second article decorative covering and a second article cushion member overlying the base structure; wherein the first article decorative covering includes an elongated channel; wherein the second article decorative covering comprises a plurality of decorative covering segments joined at a joining seam; and wherein the joining seam is located in the elongated channel.

An open core crash pad includes a core and a skin abutting the core to include a forming space therebetween. A foaming layer is foam-formed by injecting a foam liquid into the forming space. A foam tape prevents an overflow of the foam liquid. The skin includes a body portion and a distal end which extends from the body portion in parallel with the core. The core comprises a protrusion protruding toward the skin and formed at which the core and the distal end contact.

A trim component for vehicle interior is disclosed. A method for forming the trim component is also disclosed. The trim component comprises a cover material, a base layer, a foamed plastic, and a support element. The base layer is intended to prevent foamed plastic from penetrating into the pores of the cover material. Foamed plastic is injected between the base layer and the support element to form the trim component. The method comprises the steps of producing a base layer, applying and fixing at least part of the cover material to the base layer to form a pre-laminate, introducing the pre-laminate into a foaming mold with the base layer between the cover material and a foam chamber (between the pre-laminate and the support element) within a foaming mold and introducing foamed plastic into the foam chamber to form the trim component.

A physically crosslinked foamable particle comprises a polyolefin resin and a chemical foaming agent, the foamable particle having a volume of at least about 0.002 mm.sup.3.