Patent Publication Number: US-2006012218-A1

Title: Sealing systems and related methods for automotive interior trim panels and the like

Description:
CROSS REFERENCE TO RELATED APPLICATION  
      The present application is a divisional application of U.S. Ser. No. 10/137,542 filed May 2, 2002, which claims the benefit of the filing date of U.S. Provisional Application No. 60/288,379 filed on May 3, 2001, the disclosures of which are hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates generally to sealing or gasketing and, more particularly, to systems and methods for sealing an interior compartment of a vehicle against entry of water, wind, noise, dust, or other environmental contamination. The system and method of the invention are particularly adapted for use in an automobile and will be described with particular reference thereto. However, it will be appreciated that the invention has broader applications and may be used to provide a water-tight seal in many different environments, such as other types of overland vehicles, watercraft, aircraft, washing machines, automatic dishwashers, and so forth.  
     BACKGROUND OF THE INVENTION  
      The metal inner panel of a vehicle door has a plurality of openings and holes therein for mounting certain accessories and mechanisms in the door and for providing access to such accessories and mechanisms. By way of example, the inner panel of a vehicle door may have openings and holes for mounting such items as window operating mechanisms, locks and lock switches, side-view mirror controllers, loudspeakers, and so forth.  
      A decorative interior trim panel and arm rest are conventionally applied over the inner panel of a vehicle door. Commonly, a water deflector or shield is applied between the inner door panel and interior door trim for preventing entry of water, dirt, and the like into the vehicle body or causing damage to the interior door trim itself. Heretofore, the normal practice has been to secure a water deflector over the inner door panel prior to installing the trim panel.  
      Therefore, as recognized by the present invention, there exists a need in the art for a combined trim panel and water deflector or shield which permits the water deflector to be installed simultaneously with the trim panel. As further recognized by the present invention, there exists a need in the art for a door trim sealing system which obviates the need for a separate water deflector or shield.  
     SUMMARY OF THE INVENTION  
      In a first aspect, a combined trim panel and water shield includes a water shield having opposite first and second surfaces, and which is of a size and shape to generally conform to a door panel and a trim panel to be protected. The trim panel is configured to cover a vehicle door panel and has a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface. A first sealing layer, applied in a predetermined pattern, engages the first surface of the water shield and the second surface of the trim panel. A second sealing layer, applied in a predetermined pattern, engages the second surface of the water shield.  
      In a second aspect, a method for the production of a combined water shield and trim panel structure is provided. The method comprises providing a trim panel which is configured to cover a door panel, and which has a first surface configured to face an interior compartment of a vehicle. A sealing member, which may be a flat or shaped sheet of material having opposite first and second surfaces is also provided. The sealing member is of a size and shape to generally conform to the trim panel and the door panel. A first sealing material is applied to the first surface of the sheet in a first predetermined pattern, and a second sealing material is applied to the second surface of the sheet in a second predetermined pattern. The sheet and the trim panel are aligned so that the first surface of the sheet is in facing relation with a second surface of the trim panel opposite the first surface thereof. The trim panel is contacted with the first sealing member to attach the trim panel to the water shield. In a more limited aspect, a protective liner of plastic or other material is removably attached to the second sealing layer and is removed when the combined water shield/trim panel is installed on the door.  
      In a third aspect, a sealing system for application to a vehicle interior trim panel for preventing the entry of water or dust from entering an interior compartment of the vehicle includes a trim panel configured for covering a vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface. The sealing system further includes at least one compressible sealing member engaging the trim panel and providing a sealing interference between the vehicle door panel and the trim panel when the trim panel is installed on the door panel.  
      In a fourth aspect, a method for sealing a vehicle door interior trim panel against entry of water or dust includes attaching at least one compressible sealing member to a trim panel such that the at least one sealing member is positioned to provide a sealing interference between the door panel and the trim panel when the trim panel is installed on the door panel. The trim panel retaining the at least one compressible sealing member is then installed onto the door panel.  
      In a fifth aspect, a combined trim panel and water shield assembly for a vehicle includes a trim panel configured for covering a vehicle door panel, the trim panel in facing relation to an interior compartment of the vehicle. A foam layer engages and is sandwiched between the trim panel layer and the door panel. Optionally, a sealing layer for providing a seal between the flat sheet and the inner door panel, such as an adhesive or a compressible seal, is provided.  
      In a sixth aspect, a stacked plurality of sealing systems is provided. The stacked plurality includes a first sealing system including a trim panel adapted to cover a vehicle door panel and a sealing member engaging the trim panel and providing a sealing interference between the vehicle door panel and the trim panel. The stacked plurality also includes a second sealing system positioned adjacent the first sealing system. The second sealing system includes a trim panel adapted to cover a vehicle door panel and a sealing member engaging the trim panel. The stacked plurality of sealing systems further comprises a releasable protective liner disposed between the first and second sealing systems.  
      In a seventh aspect, a combined trim panel and water shield assembly includes a trim panel configured for covering a vehicle door panel, a generally flat non-compressible water shield, and an adhesive layer engaging the flat sheet to the trim panel.  
      In an eighth aspect, a combined trim panel and water shield assembly includes a trim panel configured for covering a vehicle door panel, a generally flat non-compressible water shield, and an adhesive layer engaging the flat sheet and adapted to engage the vehicle door panel.  
      One advantage of the present invention is found in that combining the water shield and trim panel or, alternatively, eliminating the water shield, reduces the number of parts needed to make the automobile and simplifies assembly of the automobile.  
      Further advantages of the present invention reside in its ease, accuracy, and repeatability of installation.  
      Another advantage is that many add-on parts used in door trim can be eliminated, thereby reducing noise, vibration, and harshness (NVH) and buzz, squeak, and rattle (BSR) issues.  
      Yet another advantage resides in the fact that by eliminating a separate water shield component, additional door components can be packaged to the trim panel.  
      Still a further advantage is found in that the door sealing system is self-locating and eliminates the need for part application in the assembly plant.  
      Another advantage is found in that rework, repair, and service are made easier.  
      Another advantage of the invention resides in its ease of disassembly, recycling, and the like, e.g., at the end of vehicle life.  
      Yet another advantage resides in that the number of parts can be reduced by adding them to the module.  
      Still further benefits and advantages of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.  
      It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The following detailed description may be best understood when read in reference to the accompanying drawings wherein similar reference characters denote similar elements throughout the several views.  
       FIG. 1  shows an automobile door employing the combined water deflector and trim panel formed according to a first embodiment of the present invention.  
       FIGS. 2A-2F  are cross-sectional views of six different embodiments of the combined water shield and trim panel taken along line  2 - 2  of  FIG. 1 .  
       FIG. 3  is a cross-sectional view of an embodiment similar to that shown in  FIG. 2D , illustrating a plurality of adhesive-coated water shields layered between successive carrier sheets.  
       FIG. 4  is an exploded view of an automobile door employing the sealing system formed according to a second embodiment of the invention.  
       FIG. 5A  is a cross-sectional view taken along line  5 - 5  of  FIG. 4 .  
       FIGS. 5B-5F  illustrate alternative embodiments to that shown in  FIG. 5A .  
       FIGS. 6-9  are fragmentary cross-sectional views of some sound-absorbing combined trim panel/water deflectors contemplated by the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       FIG. 1  and  FIGS. 2A-2F  show a typical vehicle door  10  incorporating a combined trim panel and water shield construction  18  in accordance with the subject invention. The door  10  includes inner and outer door panels  12  and  14 , respectively, secured together with a space therebetween for accommodating various mechanisms. A window  16  is shown for door  10  and moves into the space defined between the inner and outer door panels in a known manner.  
      Referring now to  FIG. 2A , a fragmentary cross-sectional view is shown of a combined interior trim panel and water shield  18   a  of the present invention. The combined unit is peripherally shaped to substantially cover the inner door panel  12 . The combined trim panel and water deflector  18   a  includes decorative trim panel layer  20  and compressible water shield layer  24  disposed between the sheet metal  12  and the decorative trim panel  20 . Optionally, the compressible shield  24  can be placed on or secured to the trim panel  20  at a centralized location and installed onto the door as a single unit. At least a portion of the water shield  24  has a cross-sectional thickness, which may be varied or uniform, which is greater than the width of the space to be sealed, such that the material is compressed when the trim panel is installed on the door, the compression providing a sealing pressure between the door panel  12  and the trim panel shell  20 . Preferably, the compressed areas form a seal about the door panel periphery or other areas where prevention of water entry is desired.  
      Referring now to  FIG. 2B , combined trim panel and water deflector  18   b  includes decorative trim panel layer  20  and a compressible water shield layer  24 . A sealing layer or coating  26  is disposed between the compressible shield member  24  and the door panel  12 . The sealing layer  26  preferably forms a continuous ribbon or bead about the periphery of the water shield layer  24 , although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding or sealing the middle area of the deflector layer  24  with respect to the inner door panel  12 . The sealing material  26  may comprise an adhesive or a compression-type gasket or seal formed of a compressible or resilient material, such as a formed-in-place (FIP) gasket.  
      Optionally, the combined unit  18   b  can be assembled at a centralized location and installed onto the door as a single unit. A protective sheet of material (not shown) can be removably attached over the layer  26  for handling and is removed prior to installing the unit. Again, the sealing materials  24  and  26  are of a size and configuration such that they are compressed to form a sealing engagement when the unit is installed on the door, e.g., at the door panel periphery or other areas where prevention of water entry is desired.  
      Referring now to  FIG. 2C , combined trim panel and water deflector  18   c  includes decorative trim panel layer  20  and a compressible water shield layer  24 . A sealing layer or coating  22  is disposed between the compressible shield member  24  and the trim panel shell  20 . The sealing layer  22  preferably forms a continuous ribbon or bead about the periphery of the water shield layer  24 , although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding or sealing the middle area of the deflector layer  24  with respect to the trim panel  20 . The sealing material  22  may comprise an adhesive or a compression-type gasket or seal formed of a compressible or resilient material, such as a formed-in-place (FIP) gasket.  
      Again, the combined unit  18   c  can optionally be assembled at a centralized location and installed onto the door as a single unit. Again, the sealing materials  24  and  22  are of a size and configuration such that they are compressed to form a sealing engagement when the unit is installed on the door, e.g., at the door panel periphery or other areas where prevention of water entry is desired.  
      Referring now to  FIG. 2D , a combined trim panel and water deflector  18   d  includes a decorative trim panel layer  20  and a water shield layer  24  which are adhesively bonded by a first seal layer  22 . The combined trim panel and water shield  18   d  further includes a second sealing layer  26  which affixes water shield layer  24  to the inner door panel  12 . The sealing layers  22  and  26 , which may be the same or different, preferably each form a continuous ribbon or bead about the periphery of the water shield layer  24 , although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding the middle area of the deflector layer  24  to the inner door panel  12  and/or trim panel layer  20 .  
      The combined unit  18   d  can optionally be assembled at a centralized location for installation as a single unit. A protective sheet of material (not shown) can be removably attached over the layer  26  for handling and is removed prior to installing the unit. The sealing materials  22 ,  24 , and  26  are of a size and configuration such that they are compressed to form a sealing engagement when the unit is installed on the door, e.g., at the door panel periphery or other areas where prevention of water entry is desired.  
      Referring now to  FIG. 2E , a combined trim panel and water deflector  18   e  includes decorative trim panel layer  20  and a rigid, non-compressible water shield layer  24 ′, e.g., formed of a rigid plastic or other material. A sealing layer or coating  26  is disposed between the rigid shield member  24 ′ and the door panel  12 . The sealing layer  26  preferably forms a continuous ribbon or bead about the periphery of the water shield layer  24 , although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding or sealing the middle area of the deflector layer  24  with respect to the inner door panel  12 . The sealing material  26  may comprise an adhesive or a compression-type gasket or seal formed of a compressible or resilient material, such as a formed-in-place (FIP) gasket.  
      Optionally, the combined unit  18   e  can be assembled at a centralized location and installed onto the door as a single unit. A protective sheet of material (not shown) can be removably attached over the layer  26  for handling and is removed prior to installing the unit. Again, the sealing material  26  is of a size and configuration such it is compressed to form a sealing engagement between the door panel  12  and the rigid shield  24 ′ when the unit  18   e  is installed on the door, e.g., at the door panel periphery or other areas where prevention of water entry is desired.  
      Referring now to  FIG. 2F , a combined trim panel and water deflector  18   f  includes a decorative trim panel layer  20  and a water shield layer  24 ″ which are adhesively bonded by a first seal layer  22 . The combined unit  18   f  further includes a second sealing layer  26  which affixes water shield layer  24 ″ to the inner door panel  12 . The sealing layers  22  and  26 , which may be the same or different, preferably each form a continuous ribbon or bead about the periphery of the water shield layer  24 ″, although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding the middle area of the deflector layer  24 ″ to the inner door panel  12  and/or trim panel layer  20 .  
      The combined unit  18   f  can optionally be assembled at a centralized location for installation as a single unit. A protective sheet of material (not shown) can be removably attached over the layer  26  for handling and is removed prior to installing the unit. Again, the sealing materials  22  and  26  are of a size and configuration such that they are compressed to form a sealing engagement when the unit is installed on the door, e.g., at the door panel periphery or other areas where prevention of water entry is desired.  
      In reference now to  FIGS. 2A-2F , the combined trim panel and water shield of each of the above-described embodiments  18   a - 18   f  functions to deflect water entering the space between the inner and outer door panels. The water is thus kept within the door assembly for drainage out through conventional bottom drain openings instead of wetting the inner door trim panel layer  20  or entering the interior compartment of the vehicle.  
      The trim panel layer  20  generally comprises a structural material, such as a plastic, metal, composite, laminate, or other material generally used in the construction of automotive interior trim panels, which is molded or otherwise formed to the needed functional and aesthetic shape. The trim panel layer may further include decorative materials, such as cloth, leather, plastic, foam, vinyl, or other material generally used in the construction of automotive interior trim panels.  
      In the depicted embodiments of  FIGS. 2A-2D , the water shield layer  24  comprises a foam material, such as open- or closed-cell polyurethane, polypropylene, polyethylene, and so forth. In the embodiment depicted in  FIG. 2E , the water shield layer  24 ′ comprises a non-compressible and generally nonflexible or rigid plastic material. In  FIG. 2F , the deflector layer  24 ″ is a polymer film, such as polyethylene film, corona surface-treated polyethylene film, and the like.  
      In the embodiments of  FIGS. 2B-2F , having one or both of the sealing coatings or bands  22  and  26 , such layers are form of an adhesive or a compression-type gasket or seal. The adhesive may be, for example, a temporary or removable pressure-sensitive adhesive, or a generally permanent pressure-sensitive adhesive. In the embodiments of  FIGS. 2D and 2F , wherein both of the layers  22  and  26  are present, the composition, pattern, thickness, and/or orientation of the layers may be the same or different.  
      When a compression type seal is employed as the layer  22  and/or  26 , it may have sufficient tack to adhere to the water shield layer or, alternatively, it may be adhesively bonded to the water shield layer by, for example, using an adhesive, such as a pressure-sensitive adhesive.  
      A compression-type seal employed in conjunction with the present invention comprises a flexible, resilient, or compressible material. Such materials include flexible plastic, rubber, elastomers, silicone, foam rubber, synthetic foam materials, gels, and the like. Such seals or gaskets can be formed separately, or more preferably, can be dispensed directly onto the water deflector in an uncured state and allowed to cure. A preferred compression seal comprises a polyurethane foam.  
      As illustrated in  FIGS. 2A-2D , the water deflector substrate  24  comprises a compressible or resilient material, such as a foam or the like, and one or both of the sealing layers  22  and  26  can optionally be omitted. Finally, when a rigid, non-compressible water shield substrate  24 ″ is employed ( FIG. 2F ), the first and second sealing layers  22  and  26  are selected from adhesives and compression-type seal or gasket materials, and may the same or different. When the flexible, non-compressible substrate  24 ′ is used ( FIG. 2E ), sealing layer  22  on the trim panel side is omitted and sealing layer  26  on the door panel side is either an adhesive or a compression-type sealing layer. The combinations of sealing layers for compressible, rigid non-compressible, and flexible non-compressible substrates are listed in TABLE 1 below.  
                           TABLE 1                                   Coating on Trim   Coating on Door           Panel Side   Panel Side                                                Compressible   None   None       Water Shield   None   Adhesive       Substrate   None   Compression Seal           Adhesive   None           Adhesive   Adhesive           Adhesive   Compression Seal           Compression Seal   None           Compression Seal   Adhesive           Compression Seal   Compression Seal       Flexible,   Adhesive   Adhesive       Non-compressible   Adhesive   Compression Seal       Water Shield   Compression Seal   Adhesive       Substrate   Compression Seal   Compression Seal       Rigid,   None   Adhesive       Non-compressible Water   None   Compression Seal       Shield Substrate                      
 
      In one preferred embodiment, the layer  22  is a permanent pressure-sensitive adhesive and the layer  26  is a compression-type seal. This embodiment provides the advantage of allowing easy removal and replacement for door access and repair. In another preferred embodiment, the layer  22  comprises a first adhesive, such as a non-permanent or removable pressure-sensitive adhesive, and layer  26  comprises a second adhesive having a greater tenacity or tack than the first adhesive, which may be, for example, a nonpermanent adhesive having a higher tack or tenacity than the first or a substantially permanent adhesive. Both of these embodiments allow the trim panel and water shield to be applied as a single unit, thus eliminating the need for separate water shield application during assembly.  
      In construction, one or both of the first and second sealing layers, if present, are applied to the respective side of the water shield substrate, each in a preselected pattern corresponding to a desired configuration, and serve as means of attachment to aligned or mating surfaces of the trim panel layer  20  and the inner door panel sheet metal  12 , respectively.  
      The water shields can be attached to the trim panel at a central location and the combined article  18  then applied to the door  10  as a single unit at the assembly plant. In embodiments  2 B and  2 D- 2 F, which have a layer  26  on the side of the substrate intended to face the sheet metal door panel, a protective liner, such as a release coated sheet or film, is preferably removably applied over the layer  26  for protection during processing and handling. The protective liner is a polyethylene or other plastic sheet, preferably release coated with a release agent, such as a silicone-based release material. The protective sheet is then removed prior to installation at the assembly plant. The trim panel shell  20  serves as a protection for the layer  22  if present. If the water deflectors are not preattached to the trim panel, the layer  22  can be lined with a protective sheet in like manner.  
      Alternately, the units can be stacked into pads, with protective liners removably placed over the adhesive or sealing layers as necessary to separate adjacent units. As shown in  FIG. 3 , the water shields  24  with oppositely disposed first and second sealing layers are removably sandwiched between protective liners  28  to form a stack or pad of a desired number of water deflectors for processing, shipping, handling, and storage until use.  
      Referring now to  FIGS. 4 and 5 A- 5 F, there is shown an exploded view of a vehicle door  40  employing a sealing system formed in accordance with a second aspect of the subject invention in which a door panel  42  is sealed with a substrate  44  which uses sealing elements  70  and  76  formed on the door and trim panel parts.  
      The door  40  generally comprises an outer panel  44  and an inner panel  42  suitably secured to the outer panel  44 , such as by welding along the peripheral edge of panel  42 , the panels defining an internal chamber for accommodating various internal door mechanisms.  
      A trim panel  50  is installed over the inner panel to form the interior surface of the door  40  and to overlie the various door-mounted components. The trim panel is attached to the inner door panel using clips, screws, snap-type fasteners, and the like, in a known manner. A water shield  54 , which may be a flat or shaped sheet of material, is located between the door panel  42  and the trim panel layer  50 . Various openings, e.g., openings  60 ,  62  and  64 , may be provided in the substrate  54  for loudspeaker, wire, door handle, lock rod, and other attachment and pass-through points. In the embodiment of  FIGS. 4 and 5 A, a first sealing material  52 , which may be an adhesive or a compression-type gasket material, is disposed between the deflector  54  and the trim panel  50 . A second sealing layer  56  which is also an adhesive or a compression-type gasket material, and which may be the same as or different than the layer  52  is located between the panel  42  and the substrate  54 .  
      The compression seal or adhesive layers  52  and  56  are applied in a predetermined pattern which is in aligned relationship with respect to certain design features or sealing elements of the inner door panel and the trim panel when the trim panel and door panel are placed in facing relation. In the illustrated embodiment, inner panel  42  includes a flat region  70  generally following the peripheral edge thereof. In this manner, the inner door panel can be formed with a functionally needed shape as determined by the particular door configuration and which can be generally uneven so long as at least track  70  is generally flat for sealingly engaging the sealing system of the present invention.  
      Referring to  FIG. 5A , the sealing system includes a flexible substrate  54 , e.g., a flexible plastic film, having a first sealing layer  52  facing the trim panel  50  and a second sealing layer  56  disposed on the opposite side of the substrate  54  and facing the track  70  of the door panel. The trim panel  50  further includes a raised pressure rib  76  molded thereinto for retaining and further compressing the sealing member  52 .  
      Referring now to  FIG. 5B , the sealing system includes a compressible substrate  54 ′, e.g., a compressible foam material. The substrate  54 ′ is disposed between the trim panel  50  and the track  70  of the door panel. The trim panel  50  further includes a raised pressure rib  76  molded thereinto for retaining and further compressing the substrate  54 ′.  
      Referring now to  FIG. 5C , the sealing system includes a compressible substrate  54 ′ engaging trim panel  50  which includes a raised pressure rib  76  molded thereinto for retaining and further compressing the substrate  54 ′. A sealing layer  56 , such as an adhesive or compression-type seal, engages the opposite side of the substrate  54 ′ and the track  70  of the inner door panel  42 .  
      Referring to  FIG. 5D , the sealing system includes a compressible substrate  54 ′ having a first sealing layer  52  facing the trim panel  50  and a second sealing layer  56  disposed on the opposite side of the substrate  54 ′ and facing the track  70  of the door panel. The trim panel  50  further includes a raised pressure rib  76  molded thereinto for retaining and further compressing the sealing member  52 .  
      Referring to  FIG. 5E , the sealing system includes a compressible substrate  54 ′ having a sealing layer  52  facing the trim panel  50 , a raised pressure rib  76  formed in the trim panel surface retaining and further compressing the sealing member  52 . The opposite surface of the substrate  54 ′ sealingly engages the track  70  of the door panel.  
      Referring now to  FIG. 5F , the sealing system includes a rigid, non-compressible substrate  54 ″ facing the trim panel  50  and a sealing member  56  engaging the raised portion  70  of the door panel  42 .  
      In each of the embodiments shown in  FIGS. 5A-5F , the trim panel and the appropriate sealing elements  52 ,  54 ,  54 ′,  54 ″, and  56  can be assembled at a centralized location to provide a combined trim panel and water shield to be installed as a single unit onto the door at the assembly plant. In a preferred embodiment, clips or other mechanical fasteners which are used fasten the trim panel to the door panel also fasten the sealing members to the trim panel.  
      Of course, in each of the embodiments shown in  FIGS. 5A-5F , the track region  70  can be omitted where the door panel itself otherwise provides an adequate sealing surface.  
      Although a door and sealing system of given configuration are illustrated in the depicted exemplary embodiment, the present invention is not limited to any particular configuration. It will be recognized that other geometric shapes, patterns, and spatial orientations can be used to accommodate different applications or installations without in any way departing from the overall intent or scope of the invention. Likewise, continuous gaskets or beads of material need not be used, and the seals may instead comprise one or more discontinuous strips.  
      When a compression-type seal is used as a sealing member  52  and/or  56 , the cross-sectional shape of the gasket can be modified to accommodate the particular surface to be sealed. Likewise, the resiliency of the gasket material can be selected to obtain a desired degree of sealing force. Instead of a generally solid gasket as shown in the illustrated embodiment, a hollow or tubular compression seal, e.g., having a flexible sealing portion and compressible walls, may be used.  
      A fragmentary cross-sectional view of a combined trim panel/water deflector system  80  formed in accordance with another embodiment of the development is illustrated in  FIG. 6 . The combined trim panel and water deflector  80  includes a trim panel layer  20 , the outward surface  82  of which faces an interior compartment of a vehicle and is peripherally shaped to substantially cover an inner door panel  12 . A foam layer  86  is sandwiched between the trim panel  20  and a substrate  88 . The foam layer  86  is preferably an open-cell foam material, most preferably a polyurethane foam material, and provides a sound-absorbing function to reduce wind noise and other noise from entering the interior compartment of the vehicle. Since the water deflector  88  is attached directly to the trim panel, fewer holes in the part are required, thus improving air, dust, and sound sealing than conventional water deflectors. The foam material is adhesively bonded to the substrate  88  and the trim panel  20 .  
      The foam layer  86  is advantageously compression cut to provide a nonplaniform surface which is complimentary to and mating with the inward surface  84  of the trim panel  20 . The thickness of the foam layer is thus varied so as to provide a surface which matches the inward surface  84  of the trim panel  20 , i.e., the foam surface has raised areas which engage complimentary recesses or depressions in the trim panel and vice versa.  
      The variable thickness in the foam layer  86  can be formed using a compression cutting technique. In this manner, the foam thickness can be varied in any configuration from full thickness down to near zero. The sheet is compressed between a smooth roller and a profiled roller or plate to selectively compress the foam different amounts in different regions. A cutting blade is positioned to cut the foam just as it exits the nip. In this manner, the regions that are compressed are not cut or are minimally cut and the uncompressed areas are cut more deeply.  
      A sealing layer  90  engages substrate  88  and inner door panel  12 . In one embodiment, the sealing layer is a pressure sensitive adhesive, preferably forming a continuous ribbon or bead about the periphery of the combined trim panel and water shield  80 . The use of discontinuous bands is also contemplated, and the sealing material  90  may be provided to additional areas within the peripheral bands.  
      In a second embodiment, sealing layer  90  comprises a compression-type seal or gasket, preferably forming a continuous seal about the periphery of the combined trim panel and water shield  80 . The use of discontinuous sealing portions is also contemplated, however. The sealing material  90  may be provided to additional areas within the periphery of the area to be sealed. Preferably, the gasket is a formed-in-place (FIP) type of gasket, such as polyurethane foam or other material which is dispensed as a bead of material in its uncured state and then allowed to cure.  
      Irrespective of the material comprising the sealing layer  90 , the trim panel is fastened to the inner door panel  12  using mechanical fasteners, such as conventional trim panel clips or the like (not shown). The thickness of the foam layer  86  is such that it will be compressed when the combined unit  80  is installed on the door, the compression providing a sufficient degree of pressurization to effect a seal.  
      Although the sealing layer  90  can be formed in situ at the assembly plant, it is preferable to apply the layer  90  at a centralized location. When the sealing layer  90  is preapplied, it is preferable to removably attach a protective sheet of material. When sealing layer  90  is a pressure sensitive adhesive, including both nonpermanent and substantially permanent pressure sensitive type adhesives, a release coated sheet of plastic material can advantageously be employed as the protective sheet.  
      Since the mechanical attachments found on the trim panel portion  20  are used to locate the sealing system, operator sensitivity and variation in part installation is eliminated.  
      In a preferred embodiment, a first adhesive is used between the foam layer  86  and the substrate  88 , and a second adhesive having a higher tack or tenacity than the first is used between the foam layer  86  and the trim panel  20 . The foam layer  86  and trim panel  20  are thus easily removable from the substrate  88 , e.g., for servicing, replacement, and so forth. When an adhesive is used as the sealing layer  90 , the tack or tenacity of the adhesive  90  is likewise higher than the first adhesive.  
      In an alternate embodiment, an adhesive is used as the sealing layer  90  which has a lower tack or tenacity than the adhesive bonding the foam layer  86  to the trim panel shell  20  as well as the adhesive bonding the foam layer  86  to the substrate  88 . In this manner, the combined trim panel and water shield  80  is removable as a single unit for servicing, repair, or replacement.  
      In  FIG. 7 , there is illustrated an embodiment substantially as described in reference to  FIG. 6 , but wherein the sealing layer  90  is eliminated. In the embodiment of  FIG. 7 , the compression of the foam material  86  that results when the unit is installed on the door effects a sealing engagement between sheet metal layer  12  and substrate layer  88 .  
      In  FIGS. 8 and 9 , there are shown embodiments which are as described above in reference to  FIGS. 6 and 7 , respectively, except that the substrate  88  is omitted.  
      The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. The forms hereinbefore described are merely explanatory and exemplary and it is intended that the invention be construed as including all such modifications and alterations.