Method of manufacturing a trim panel having a styling line

DETAILED DESCRIPTION The object of this invention is to provide a unique method for making a trim panel such as an automotive door panel that has an area where a soft cushion is combined with style lines.
A feature and advantage of the method of the invention is that the method uses a low density substrate so that the resulting trim panel is lighter.
Another feature and advantage of the method of the invention is that method uses a substrate that is typically used for automotive door panels so that the entire door trim panel can be made in the same molding process.
Still another feature and advantage of the method of the invention is that method uses a low density reaction injection molded (RIM) substrate so that the soft styled area is not only lighter but also can be integrated into a single process for producing the entire door trim panel.
Yet another feature and advantage of the method of this invention is that a reaction injection molded substrate may be used that automatically compresses the foam cushion for creation of the desired style lines.
Still yet another feature and advantage of the method of this invention is that a reaction injection molded substrate may be used that automatically creates the heat required to bond the cover material to the substrate by the exothermic chemical reaction of the substrate components.
Still yet another feature and advantage of the method of this invention is that the semi-rigid urethane foam which inherently has good adhesive qualities for bonding to cover materials, particularly cloth, may be used as the substrate.
Still yet another feature and advantage of this invention is that styling lines can be incorporated into a trim panel that has a structural urethane foam substrate.