Patent ID: 7431379

Claim:
An interior trim panel for a vehicle door, comprising: a bolster panel having a peripheral edge; a urethane skin layer covering one side of the bolster panel and having a portion extending outwardly from the peripheral edge of the bolster panel, wherein the portion extending outwardly from the bolster panel provides an exposed surface of the trim panel; an expanded polyurethane layer bonded to the opposite side of the urethane skin layer from the bolster panel; and a backing layer attached to the opposite side of the expanded polyurethane layer from the urethane skin layer wherein a bolster portion of the trim panel within the peripheral edge of the bolster panel is a multilayered structure comprised of the relatively rigid bolster panel, the urethane skin layer applied over the bolster panel, the expanded polyurethane layer that is sprayed over the urethane skin layer, and the backing layer that is attached over the expanded polyurethane layer and wherein the portion of the trim panel outboard of the peripheral edge of the bolster is a multilayered structure comprised of the urethane skin layer, the expanded polyurethane layer, and the fiber-reinforced urethane layer attached to the expanded polyurethane layer and the backing layer that is attached over the fiber-reinforced urethane layer.