Patent ID: 7686992

Claim:
A method of forming an interior member for a cab of a work vehicle, the method comprising: forming a foundation body panel having a predetermined shape from a polyurethane resin by reaction injection molding using a first mold; forming an outer layer material into a predetermined shape using a thermoforming process; installing the outer layer material formed by the thermoforming process and the foundation body panel formed by the reaction injection molding in a second mold such that a gap is formed between the outer layer material and the foundation body panel; forming an interior member main structure comprising the foundation body panel, the outer layer material and a sound absorbing member by, after the outer layer material and the foundation body panel have been installed in the second mold, injecting a sound absorbing material into the gap so that the sound absorbing material reacts, foams and is cured to form the sound absorbing member between the outer layer material and the foundation body panel by reaction injection molding; placing and installing at least one fastener on an outer surface of the foundation body panel of the interior member main structure; connecting the interior member main structure and an outer plate using the at least one fastener such that the outer plate faces the outer surface of the foundation body panel of the interior member main structure and at least one space is formed between the outer plate and the interior member main structure; providing a hole in the interior member main structure which extends from the outer surface of the outer layer material through the outer layer material and the foundation body panel to the at least one space; and injecting a sound absorbing foaming material in liquid form through the hole into the at least one space between the outer plate and the interior member main structure; wherein the injected sound absorbing foaming material reacts and is cured so as to form a sound absorbing foaming member.