Vehicle door interior panels and methods of making same

摘要

An interior trim panel (12) for a vehicle door (10)(figure 1-not shown) is provided according to alternative methods. The interior trim panel (12) includes a bolster (16) to which a polyurethane skin (28) is molded by a spraying operation. Expanded polyurethane foam (32) is sprayed over the polyurethane skin (28) and a backing panel (50, 56) is either integrally formed or assembled to the polyurethane foam layer (32). The bolster may be vacuum formed before being inserted into a mould in which the spraying steps are performed to form the bolster/skin/foam assembly. The substrate may be assembled by applying an adhesive layer between the foam layer and the substrate, or by placing the substrate on the foam layer whilst it is curing or by placing the assembly in a reaction injection mould and injecting polyurethane in the presence of chopped glass fibre or glass fibre mat 42.