Patent ID: 7033660
Filing Date: 2006-04-25
Classification: B29C,B29L,B32B,B60R,Y10T

Abstract:
1. Method of making an interior trim panel for a vehicle door, comprising: forming a bolster having a raised portion defining a bolster cavity; inserting the bolster into a mold; spraying polyurethane onto the mold and over one side of the bolster to form a skin/bolster assembly; inserting the skin/bolster assembly and a glass fiber mat into a reaction injection mold; closing the reaction injection mold against the raised portion to seal the bolster cavity; injecting polyurethane into the reaction injection mold that bonds to the skin/bolster assembly and the portions of the glass fiber mat that extend outside of the bolster cavity to form a glass fiber reinforced portion; removing the glass fiber mat from the bolster cavity; inserting a foam pad into the bolster cavity; and attaching a cover layer over the glass fiber reinforced portion and the foam pad to provide the interior trim panel with a padded bolster area.