Abstract:
A method of marking a skin for a vehicle interior trim panel comprising providing a skin with a color and an outer skin surface. A laser is applied to the outer skin surface such that a portion of the skin surface contacted by the laser changes color relative to a portion of the outer skin surface not contacted by the laser to create a marking in the outer skin surface indicating the presence of a vehicle component or function.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a divisional application of U.S. patent application Ser. No. 09/625,117 filed Jul. 25, 2000. 
     
    
     
       TECHNICAL FIELD OF THE INVENTION  
         [0002]    This invention relates generally to the method of marking a skin for a vehicle interior trim panel.  
         BACKGROUND OF THE INVENTION  
         [0003]    U.S. Pat. No. 4,904,429 recites a method of producing an instrument panel of a motor vehicle or similar molding of foamed resin capable of fitting electrical parts thereon as desired. More particularly, the &#39;429 patent recites a method of producing a molding of foamed resin in which a flexible printed circuit (FPC), which is electrically connectable to electrical parts, is buried.  
           [0004]    The &#39;429 patent also recites that an instrument panel has customarily been implemented as a laminate having three layers, i.e., a covering made of soft resin, a base made of ABS resin or similar hard resin, and a padding made of foamed urethane or similar foaming resin and sandwiched between the covering and the base, and that an FPC and couplers are each mounted on the base by using adhesive or screws. Continuing, the &#39;429 patent recites that such a prior art three-layer instrument panel, however, is not satisfactory because the base and the padding have to be produced independently of each other and then bonded together, resulting in a disproportionate production cost.  
           [0005]    As an alternative to the prior art three-layer instrument panel described by the &#39;429 patent, the &#39;429 patent recites that the base may be formed from a foamed resin and molded integrally with the padding. However, when the base is formed from a foamed resin, the &#39;429 patent then discloses that the FPC and couplers may not be mounted with screws or adhesives. Consequently, the &#39;429 patent proposes a solution for mounting the FPC and couplers to this alternative structure by burying the FPC and couplers in the base when the latter is molded.  
           [0006]    In light of the &#39;429 patent, what is needed is a structure and method of combining a flat wire with a three-layer interior trim panel without the need for separate fasteners, such as screws, or adhesives.  
         SUMMARY OF THE INVENTION  
         [0007]    Accordingly, the present invention provides a structure and a method for combining a flat wire with a three-layer instrument panel without the need for separate fasteners, such as screws, or adhesives.  
           [0008]    According to one feature of the invention, a vehicle interior trim panel is provided comprising a skin, a substrate, a foam located between the skin and the substrate, and a flat wire at least partially surrounded by and embedded in the foam. The wire herein is therefore either physically placed within the foam, or, in the alternative, chemically bonded to the foam material.  
           [0009]    According to another feature of the invention the flat wire comprises a flexible printed circuit.  
           [0010]    According to another feature of the invention, a terminal end of the flat wire may include a connector.  
           [0011]    According to another feature of the invention, the foam comprises a density between 0.016 g/cm 3  to 0.288 g/cm 3 .  
           [0012]    According to another feature of the invention, the foam comprises an ultimate elongation greater than five percent.  
           [0013]    According to another feature of the invention, the substrate comprises a substrate aperture and the flat wire passes though the aperture.  
           [0014]    According to another feature of the invention, the substrate comprises at least a portion of a flat wire holder.  
           [0015]    According to another feature of the invention, the substrate portion of the flat wire holder is formed with the substrate and is adjacent the inner substrate surface.  
           [0016]    According to another feature of the invention, the flat wire holder at least partially confines movement of the flat wire.  
           [0017]    According to another feature of the invention, the flat wire holder comprises an elongated recess for holding or confining a terminal end of the flat wire with a smaller width dimension or a smaller length dimension than the terminal end of the flat wire.  
           [0018]    According to another feature of the invention, the flat wire holder comprises a pocket for holding or confining at least a portion of the flat wire, and at least a portion of the pocket comprises a recess formed in the substrate.  
           [0019]    According to another feature of the invention, the foam at least partially enters into the substrate aperture and the foam surrounds at least a portion of the flat wire.  
           [0020]    According to another feature of the invention, the foam entering into the substrate aperture is a buffer between the flat wire and a surface of the substrate aperture.  
           [0021]    According to another feature of the invention, the foam entering into the substrate aperture reduces contact, noise and wear between the flat wire and a surface of the substrate aperture.  
           [0022]    According to another feature of the invention, the foam exiting from the substrate aperture surrounds at least a portion of the flat wire, prevents the flat wire from being displaced from an embedded position and reduces contact between the flat wire and a corner of the substrate aperture.  
           [0023]    According to another feature of the invention, the terminal end of the flat wire is moved from a first position to a second position.  
           [0024]    According to another feature of the invention, a method of making a vehicle interior trim panel comprises providing a substrate, providing a skin, routing a flat wire along a surface of the substrate and through a substrate aperture, and providing a foam between the skin and the substrate such that the foam at least partially surrounds and embeds a portion of the flat wire.  
           [0025]    According to another feature of the invention, the method of making a vehicle interior trim panel further comprises the foam entering at least a portion of the substrate aperture between the flat wire and at least one substrate aperture surface.  
           [0026]    According to another feature of the invention, the method of making a vehicle interior trim panel further comprises the foam exiting the substrate aperture between the flat wire and at least one substrate aperture surface.  
           [0027]    According to another feature of the invention, the method of making a vehicle interior trim panel further comprises at least partially confining the flat wire in a pocket and adjacent the substrate inner surface.  
           [0028]    According to another feature of the invention, the method of making a vehicle interior trim panel further comprises at least partially confining the terminal end of the flat wire in an elongated recess and adjacent the substrate inner surface.  
           [0029]    According to another feature of the invention, a method of marking a skin for a vehicle interior trim panel comprises providing a skin with a color and an outer skin surface, and applying a laser to the outer skin surface such that a portion of the skin surface contacted by the laser changes color relative to a portion of the outer skin surface not contacted by the laser to create a marking in the outer skin surface indicating the presence of a vehicle component or function. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0030]    To better understand and appreciate the invention, refer to the following detailed description in connection with the accompanying drawings:  
         [0031]    [0031]FIG. 1 is a perspective view of an interior trim panel electrical switch assembly according to the present invention;  
         [0032]    [0032]FIG. 2 is a cross sectional view of the switch of the interior trim panel electrical switch assembly of FIG. 1 taken along section line  2 - 2 ;  
         [0033]    [0033]FIG. 3 is a cross sectional view of the wire of the interior trim panel electrical switch assembly of FIG. 1 taken along section line  3 - 3 ;  
         [0034]    [0034]FIG. 4 is a cross sectional view of the trim panel of FIG. 1 in a foam mold prior to introducing foam material taken along section line  4 - 4  according to a second embodiment of the present invention;  
         [0035]    [0035]FIG. 5 is a cross sectional view of the trim panel and electrical device of FIG. 1 taken along section line  4 - 4  according to the second embodiment of the present invention; 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0036]    An exemplary vehicle interior trim panel electrical switch assembly of the type for actuating various vehicle electrical devices is shown at  10  in FIG. 1 in connection with an armrest  12  for a vehicle trim panel  14 , such as a door panel. As shown in FIGS. 1 and 2, the armrest  12  is formed as a soft feel composite  15  which includes a switch panel portion  16  that has an outer surface  18  covering a switch array  20  including three electrical switches indicated at  20   a - 20   c . Two of the three electrical switches may be for locking and unlocking the doors of the vehicle while the remaining switch may be a multiposition switch for adjusting the position of the side view mirror. Other switches not shown may include, but are not limited to, switches for opening and closing windows, seat adjustment and for selecting either the left or the right side view mirror for adjustment.  
         [0037]    The armrest  12  is shown as a separate member from the trim panel  14 , but the armrest and trim panel  14  could be formed as one integral interior trim panel. Furthermore, the vehicle interior trim panel electrical switch assembly  10  can be employed on any interior surface of any trim panel in the vehicle. For example, it can be part of the instrument panel, headliner, overhead console, seats or any other part of a vehicle interior.  
         [0038]    Additionally, the switch array  20  can vary in number and location. For example, in another application a single switch can be provided to operate an overhead light, a power operated sunroof or other electrically switched accessory on a motor vehicle. Other arrangements will depend upon the system being controlled by the switch array  20  underlying the switch panel portion  16 .  
         [0039]    As shown in FIG. 2, the soft feel composite  15  and switch panel portion  16  of the interior trim panel electrical switch assembly  10  comprises a substrate layer  22 , a foam layer  24 , and a skin layer  26 . The outer surface  18  of skin layer  26  is the surface generally viewed by a vehicle occupant and is preferably continuous between the soft feel composite  15  and switch panel portion  16  of trim panel  14 . Generally, foam layer  24  is bonded directly to outer surface  23  of substrate layer  22  and to inner surface  28  of skin layer  26 .  
         [0040]    A switch  30  and a wire  48  are located beneath outer surface  18  within the switch panel portion  16  of the interior trim panel electrical switch assembly  10 . Preferably, the switch  30  has a low profile which allows it to be easily incorporated under outer surface  18  of skin layer  26  of the switch panel portion  16 . As used in this specification, a low profile switch has a thickness less than or equal to that of foam layer  24 . In other words, a thickness less than or equal to the distance as measured between the inner surface  28  of skin layer  26  and outer surface  23  of substrate layer  22 . More preferably, the switch  30  provides a substantially flat or arcuate surface region  32  in outer surface  18  of skin layer  26  without any bumps, ridges or other disruptions in outer surface  18 . However, it is recognized that certain disruptions in the outer surface  18  may be desirable as to provide assistance in locating switch panel portion  16  in an environment of reduced light or when it is unsafe for the driver to remove his vision from the road for the purposes of locating switch panel  16 .  
         [0041]    Switch  30  preferably comprises a switch arm  50  disposed within a housing portion  52 . Switch arm  50  functions as a conductor and preferably comprises a metal such as copper. In the illustrated exemplary embodiment, switch arm  50  is preferably U-shaped and comprises elongated member  54  connected to elongated member  58  by connecting member  56 . Preferably connecting member  56  is completely embedded in housing  52  which functions as an insulator while elongated member  54  and elongated member  58  are only partially embedded within housing portion  52  with contact portions  60  and  62  respectively thereof remaining exposed. Preferably, housing portion  52  comprises a polymer material and more preferably the polymer material comprises a silicone polymer.  
         [0042]    Preferably, housing  52  also comprises a recessed cavity  64  into which contact portions  60  and  62  of elongated members  54  and  58  project into. Recessed cavity  64  also preferably contains a wire  48 . Wire  48  comprises conductors  66  and  68  as well as an insulator  70  upon which conductors  66  and  68  are located. Outside the confines of recessed cavity  64 , wire  48  also includes an insulator  72  as shown in FIG. 3.  
         [0043]    Apart from operation, switch  30  exists more particularly as switch  30   a  in which the associated electrical circuit is in a normally open state. Then, during operation, switch  30  exists more particularly as switch  30   b  in which the associated electrical circuit is in a closed state. More specifically, during operation a force F is applied to outer surface  18  of skin layer  26 . Force F is ordinary applied by the vehicle occupant through the fingertips. Upon application, force F works on skin layer  26  and housing  52  such that they deform to enable contact portions  60  and  62  of elongated members  54  and  58  of switch arm  50  to contact conductors  66  and  68  of wire  48  and thus close the electrical circuit as created through connecting member  56  of switch arm  50 .  
         [0044]    As indicated above, within the confines of recessed cavity  64 , wire  48  comprises conductors  66  and  68  as well as an insulator  70  upon which conductors  66  and  68  are located. However, as also indicated above, outside the confines of recessed cavity  64 , wire  48  also includes an insulator  72  as shown in FIG. 3. It is noted that insulator  72  exists outside the confines to recessed cavity  64  generally to protect conductors  66  and  68  from undesirable short circuits outside the confines of recessed cavity  64 . More specifically, conductors  66  and  68  of wire  48  are protected from short circuit by virtue of being encapsulated between insulators  70  and  72 .  
         [0045]    As can best be seen from FIG. 3, conductors  66  and  68  preferably have a thin cross sectional thickness with a width Wc greater than thickness Tc. More particularly, conductors  66  and  68  comprise an electrically conductive metal, such as copper or similar metal, in the form of a thin foil. Insulators  70  and  72  comprise thin films, preferably polymer films and more preferably urethane polymer films which are laminated about their edges  74  and  78  as well as a central portion  76  located between conductors  66  and  68 . The use of one or more conductors with a rectangular shape sandwiched between two polymer films may be referred to as “flat” wire. The use of flat wire, as opposed to traditional round wire with a round conductor, is preferred for at least partially surrounding and embedding wire  48  in the foam layer  24  by virtue if its thinner cross-sectional thickness than traditional round wire.  
         [0046]    More particularly, the flat wire  48  may take the form of a flexible printed circuit (FPC). A FPC generally consists of a pair of polymer or resin films with one or more copper, or similar metal, foils sandwiched therebetween. Upon operation, the metal foil generally functions as an electrical circuit routing electric current between one or more connected electrical devices.  
         [0047]    In addition to switch  30  and wire  48  being located beneath the outer surface  18  of the switch panel portion  16  of the interior trim panel electrical switch assembly  10 , preferably they are at least partially surrounded by and embedded in the foam layer  24  of the soft feel composite  15 .  
         [0048]    Preferably, prior to being at least partially surrounded and embedded by the foam layer  24 , switch  30  is joined to the inner surface  28  of skin layer  26  or to the outer surface  23  of substrate layer  22 , but it is recognized that switch  30  may be positioned at any location therebetween. More preferably, switch  30  is joined to the inner surface  28  of skin layer  26  and/or to the outer surface  23  of substrate layer  22 , by a double-sided pressure sensitive adhesive tape located therebetween.  
         [0049]    As with switch  30 , prior to being at least partially surrounded and embedded by the foam layer  24 , wire  48  may also be joined to the inner surface  28  of skin layer  26  or to the outer surface  23  of substrate layer  22 , but it is recognized that wire  48  may be positioned at any location therebetween. More preferably, wire  48  is joined to the outer surface  23  of substrate layer  22  by a double-sided pressure sensitive adhesive tape located therebetween or mechanical type engagement clips.  
         [0050]    In order to at least partially surround and embed the switch  30  and/or wire  48  in foam layer  24 , the switch  30  and/or wire  48  are preferably placed in the cavity  40  created between the inner surface  28  of skin layer  26  and the outer surface  23  of substrate layer  22  as shown in FIG. 2 prior to the introduction of the foam layer  24 . Then, foam layer  24  is preferably formed by introducing a foam, or more preferably, a foam precursor material into cavity  40 . Preferably, the foam precursor is a urethane foam precursor which is introduced using a reaction injection molding process as known in the art. After the urethane foam precursor is introduced, the reactive constituents, a polyol and isocyanate, begin to react and the subsequently created foam material flows within the cavity  40  thus bonding skin layer  26  to substrate layer  22  while at the same time and flowing around and preferably bonding to the exposed surfaces of switch  30  and wire  48 .  
         [0051]    Alternatively, switch  30  and/or wire  48  may be located in the skin layer  26 . For example, the switch  30  may be held in place as skin-casting material is cast around it as more particularly shown in U.S. Pat. No. 5,269,559 assigned to the assignee of the present invention and incorporated herein by reference.  
         [0052]    In the embodiment shown in FIGS. 1, 2 and  3 , many types of adhesives, including urethanes, etc., may be used to bond the switch  30  or wire  48  to skin layer  26  or substrate  26  of trim panel  14 . The adhesives may be applied in any one of a number of forms to include pressure-sensitive backings, hot melts and spray coatings.  
         [0053]    While skin layer  26  is preferably formed by casting, skin layer  26  may also be formed by spray coating, blow molding, or thermoformed sheet and then incorporated into the subsequent foam forming process identified above. With regards to more specific skin materials, skin layer  26  may comprise thermoset or thermoplastic polymers. This group includes, but is not limited to, polymers containing vinyl (e.g. polyvinyl chloride (PVC)), urethane (e.g. thermoplastic urethane (TPU)), olefin (e.g. poylpropylene (PP), polyethyelene (PE), thermoplastic olefins (TPO)), and styrene (e.g. acrylonitrile-butadiene-styrene (ABS)). Also while foam layer  24  is preferably joined to skin layer  26  and substrate layer  22  simultaneously by the reaction injection molding process, foam layer  24  may also be joined to skin layer  26  prior to introduction of substrate layer  22  rather than simultaneously as identified above. For example, skin layer  26  and foam layer  24  may be provided as a multi-layer sheet which is subsequently heated and vacuum formed over substrate layer  22 .  
         [0054]    In the various embodiments, the foam layer preferably has certain molding conditions and physical properties. With regards to molding conditions, the foam layer  24  is preferably molded below 25 PSI (pounds per square inch) molding pressure and more preferably below 15 PSI molding pressure and even more preferably below 10 PSI molding pressure as to reduce any deformation of the FPC during the foam molding process. With regards to measuring the molding pressure, it is noted that molding pressure may be measured at any location within the trim panel  14 . With regards to physical properties, the foam layer  24  preferably exhibits the following:  
                                       Property   Test Method   Value                   Density   ASTM-3574-95   0.016-0.288 g/cm 3         Ultimate Elongation   ASTM-3574-95   Greater than 10%                  
 
         [0055]    With regards to measuring density, while any suitable test method may be used, the preferred test method is that of ASTM-3574-95, Test A—Density Test. With regards to range of density values, while the preferred value identified above is from 0.016 to 0.288 g/cm 3 , more preferably the value is from 0.06 to 0.15 g/cm 3 . With regards to the measured value, it is noted that the above values correspond to that of any single specimen (taken from any location within the trim panel  14 ), either an interior density specimen or a section density specimen as defined in ASTM-3574-95, and not the calculated median of more than one measured specimen. This is in accordance with ASTM-3574-95, paragraph 11.1 which calls for a single specimen to be tested.  
         [0056]    With regards to measuring ultimate elongation, while any suitable test method may be used, the preferred test method is that of ASTM-3574-95, Test E—Tension Test. With regards to the range of elongation values, the preferred value identified above is greater than or equal to five percent (5%), more preferably the value is greater than or equal to ten percent (10%), and even more preferably the value is greater than or equal to twenty-five percent (25%) ultimate elongation. With regards to the measured value, it is noted that the above values correspond to that of any single specimen (taken from any location within the trim panel  14 ), as defined in ASTM-3574-95, and not the calculated median of more than one measured specimen. This is in deviation with ASTM D-3574-95, paragraph 48.1 which calls for three specimens to be tested and the median value to be reported.  
         [0057]    Indicia  41  in the form of letters, numbers, or symbols may be printed, such as with silk screening, or molded on outer surface  18  of the skin layer  26  to indicate to vehicle occupants the position and/or function of each switch  30  or switch array  20  as shown in FIGS. 1 and 2. As an alternative to or used in combination with printing and/or molding, a laser, and more preferably a YAG laser, may be used to change the color (e.g. bleach or whiten) of the material, and preferably the pigments, of skin layer  26  as to create markings in the outer surface  18  which indicate to vehicle occupants the position and/or function of each switch  30  or switch array  20  as shown in FIGS. 1 and 2.  
         [0058]    A transparent protective coating may be applied to the outer surface  18  of the skin layer  26  and to the indicia  41 . The coating is preferably applied as a liquid and is then dried to form a thin durable protective film that keeps the indicia from rubbing off as is described in greater detail in U.S. Pat. No. 5,448,028 assigned to the assignee of the present invention and incorporated herein by reference.  
         [0059]    In a second embodiment of the invention, as illustrated in FIGS. 4 and 5, a structure is provided to enable wire  48  to enter and exit the confines of foam layer  24  of trim panel  14 . More specifically, prior to being at least partially surrounded and embedded by foam layer  24 , wire  48  is routed along outer surface  23  of substrate layer  22  and through aperture  80  to the inner surface  21  of substrate layer  22 . Upon placing and introducing skin layer  26  to the substrate layer  22  in a foam mold  83  (shown as first mold part  85  and second mold part  87 ) in a manner well known in the art, wire  48  now exists in cavity  40  and exits cavity  40  at aperture  80 . Aperture  80  is of such a geometry as to permit wire  48  to pass there through. Preferably, aperture  80  is of the geometry of an elongated slot of slightly larger dimension, in both width and thickness, than corresponding width Ww and thickness Tw of wire  48 .  
         [0060]    Upon passing through aperture  80 , terminal end  84  of wire  48  may included a connecter  82  attached thereto. Alternatively, connecter  82  may be attached to the terminal end  84  of wire  48  prior to wire  48  passing through aperture  80 , in which case the geometry of aperture  80  must be such as to permit connector  82  as well as wire  48  to pass there through.  
         [0061]    Terminal end  84  of wire  48 , with or without connector  82 , may then be placed into a holder  86  which holds, covers and/or protects from damage the wire  48  or terminal end  84  prior to its designated use. While holder  86  is preferably of temporary use, it is recognized that it may be used for permanent use as in the case where the electrical device  90  to which terminal end  84  of wire  48  is to attach is never installed, possibly due to differences in optional equipment between vehicles.  
         [0062]    Preferably holder  86  is formed integral with substrate  22  and is of a geometry, preferably that of an elongated recess  88 , of slightly smaller dimension, in either, or both, width and thickness, than terminal end  84  of wire  48 . In such a manner, terminal end  84  of wire  14  preferably interference fits with recess  88  of holder  86 . As a result, terminal end  84  of wire  48  is retained in recess  88  of holder  86  prior to designated use. In other embodiments, holder  86  may be any device which holds terminal end  84  and/or wire  48  in a confined, and preferably fixed, position prior to designated use. Example of such holders include, but are not limited to tape, adhesives, separate mechanical fasteners (e.g. screws, clips, etc.), or other structures designed integral with substrate  22  (e.g. rib structures, doghouses, etc.).  
         [0063]    With the introduction of substrate  22  to first mold part  85  of foam mold  83 , a pocket  89  must exist between the inner surface  21  of substrate  22  and the mold surface  91  of first mold part  85  for wire  48  and/or terminal end  84  to exist therein. The pocket  89  may be of any suitable geometry to contain wire  48  and/or terminal end  84  without their damage during the foaming process. As shown, pocket  89  comprises a recess in substrate  22  which includes a location for wire  48 , terminal end  84  and electrical device  90 . Pocket  89  also is shown to comprise a recess in first mold part  85 . It is recognized that any number of geometries may be employed to facilitate the presence of wire  48  and/or terminal end  84  adjacent the inner surface  21  of substrate  22  during the foaming process.  
         [0064]    The length of wire  48  required to extend wire  48  between aperture  80  and holder  86  may be different than is required to extend wire  48  between aperture  80  and receptacle  81  of electrical device  90 . In the case where the length of wire  48  required to extend between aperture  80  and holder  86  is less than the length of wire  48  required to extend wire  48  between aperture  80  and receptacle  81  of electrical device  90 , wire  48  may be comprise one or more rolls, bends, or folds  92  which exist while terminal end  84  of wire  48  is retained in holder  86 . These rolls, bends, or folds may then be reduced in size or number when terminal end  84  of wire  48  is attached to receptacle  81  of electrical device  90 . As used herein, an electrical device  90  is any electrical device, active or passive, electrical or electro-mechanical, which consumes, generates, or otherwise manipulates electrical power. This includes, but is not limited to, electrical motors, electro-mechanical motors, circuit boards, switches, power sources, couplers, sensors, junction boxes and fuse panels. As shown in FIG. 1, electrical device  90  is a seat switch.  
         [0065]    A second example of a holder  86  which holds terminal end  84  and wire  48  in a confined position prior to use is tape  93 . Tape  93  may cover the recess in substrate  22  such that, should the terminal end  84  become dislodged from recess  88  of holder  86  or folded wire  48  attempt to unfold from pocket  89  prior to use, the terminal end  84  and/or wire  48  will be prevented from exiting the confines of the recess in the substrate  22 .  
         [0066]    During the foam process in which foam material flows within cavity  40  thus bonding skin layer  26  to substrate layer  22 , preferably foam layer  24  extends into the confines of aperture  80  and exists between surfaces  94  and  96  of substrate  22  with wire  48  located therebetween. In this manner, foam layer  24  acts as a buffer between wire  48  and surfaces  94  and  96  of substrate  22  as to reduce, and preferably prevent, wire  48  from making contact with surfaces  94  and  96  of substrate  22 . As a result, the possibility of undesirable noise created by wire  48  rubbing against either surface  94  or  96  of substrate  22  during vehicle movement is substantially reduced. Further, the possibility of an undesirable short circuit caused by insulators  70  or  72  of wire  48  rubbing against either surface  94  or  96  of substrate  22  and wearing to expose the conductors located therebetween is also reduced.  
         [0067]    In order to reduce the amount of foam material exiting from aperture  80  as a result of the foam process, a layer of tape or other type of seal (not shown) may be applied to inner surface  21  of substrate  22  to partially close aperture  80 . Foam material which exits the aperture may do so in the form of a bun  98 . The bun  98  preferably at least partially surrounds and bonds to a portion of the wire  48  which has exited aperture  80 . In this manner, the foam bun  96  may act as a stay to help prevent wire  48  which has been at least partially surrounded and embedded by foam layer  24  from being inadvertently displaced from its embedded position by virtue of being partially or completely pulled out through aperture  80 , thus damaging the trim panel  14 . The bun  96  may also reduce, and preferably prevent, wire  48  from making contact with corners  95  and  97  of substrate  22  which may act to cut or otherwise damage the wire  48  depending on their sharpness.  
         [0068]    While bun  98  may be used for the above benefits, depending on the size of the bun  98 , it may be partially or completely removed from trim panel  14  after the foaming process. If aperture  80  is to large, the size of the resulting bun  98  may surround and embed a substantial portion of wire  48  such that at least a portion of the bun  98  must be removed. That portion of the bun  98  removed is generally preformed prior to attachment of wire  48  to receptacle  81  of electrical device  90  and often is preformed to facilitate extending wire  48  in order to attach wire  48  to receptacle  81  of electrical device  90 . Since the foam material is of a low density and generally flexible or semi-rigid by virtue of its cushion or padding effect, it ordinarily may be removed manually, with and/or without the use of hand operated tools. However, where removal of the bun  98  to the wire  48  or the inner surface  21  of substrate  22  is to be made easier, a mold release may be applied, generally by brush or spray, to wire  48  and inner surface  21  of substrate  22  after wire  48  has passed through aperture  80  and prior to the foaming process.  
         [0069]    After removal from the foam mold  83 , opening  99  is formed in trim panel  14  to facilitate that attachment of electrical device  90  to trim panel  14 . Preferably after electrical device  90  is attached to trim panel  14 , but possibly before, terminal end  84  of wire  48  is removed from its confined position (i.e. first position) and attached to receptacle  81  of electrical device  90  (i.e. second position).  
         [0070]    We intend the above description to illustrate embodiments of the present invention by using descriptive rather than limiting words. Obviously, there are many ways that one might modify these embodiments while remaining within the scope of the claims. In other words, there are many other ways that one may practice the present invention without exceeding the scope of the claims herein.