Patent ID: 7195725

Claim:
A method of making an integrated inner trim panel of a door for a vehicle comprising: providing an open mold that defines a facing surface of the inner panel of the door, wherein the mold further defines an armrest cavity; spraying a skin layer on the facing surface and into the armrest cavity with a spray tool that sprays a reactant mixture of polyurethane; spraying a padding layer onto the opposite side of the skin layer from the facing surface and the armrest cavity, the armrest cavity being sprayed to a first thickness in a first portion of the armrest cavity and to a second thickness in a second portion of the armrest cavity that is thinner than the first portion with the spray tool that sprays a reactant mixture comprising a polyurethane reactant mixture and a blowing agent, inserting and supporting a core in a void in the padding layer before filling the void in the armrest cavity, and leaving the void in the padding layer within the armrest cavity; and applying a structural layer onto the padding layer on the opposite side of the padding layer from the skin layer, filling the void in the armrest cavity and covering the padding layer opposite the facing surface, the structural layer comprising a reaction mixture of a polyurethane reactant mixture and a glass fiber reinforcement material.