Patent ID: 7005091

Claim:
A method for forming an integrated trim component within a mold having an upper section and a lower section, the mold having a mold cavity defined by said upper section and lower section; the method comprising: reversibly coupling an appliqué section to an outer surface of the lower section of the mold; coupling at least one tab to an exterior surface of said appliqué section, said at least one tab aiding in sealing a layer of a two-component liquid resin to said appliqué section when said layer is cured; introducing said layer of a two-component liquid resin at a first thickness to one side of said appliqué section and to said outer surface; curing said layer to said appliqué section to form a thermoplastic sealed appliqué section; coupling a substrate to the upper section surface of the mold; introducing a foam material onto said thermoplastic sealed appliqué section; and closing said mold such that said upper section seals to said lower section such that said substrate is located within the mold cavity in spaced relationship to said thermoplastic sealed appliqué section; wherein said foam material reacts to fill the mold cavity with a foam structure between said substrate and said thermoplastic sealed appliqué section.