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filingDate 2004-08-04-04:00^^<http://www.w3.org/2001/XMLSchema#date>
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publicationDate 2007-03-27-04:00^^<http://www.w3.org/2001/XMLSchema#date>
publicationNumber US-7195725-B2
titleOfInvention Method of making an integrated door inner panel and an article made thereby
abstract A method of making an integrated inner trim panel for a vehicle door and an inner trim panel made thereby are disclosed. The method includes sequentially spraying a skin layer, a padding layer, and applying a structural layer in an open mold that defines the facing surface of the inner panel of a door. The integrated inner trim panel may be provided with areas of greater and lesser padding. The skin layer may be formed from a reactant mixture of polyurethane. The padding layer may be a foam polyurethane composition. The structural layer may be a glass-reinforced polyurethane reactant mixture. The inner door panel is an integrated layered structure including a skin layer, a padding layer, and a structural layer. The padding layer may be varied in thickness to provide selectively variable padding in predetermined areas.
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