US Patent 7976659 Zero gap integration of switching modules with negative vacuum process

A process for assembling a composite piece for use in the interior of an automobile. An outward facing skin of the composite piece is connected to a substrate by a foaming material, and at least one switch item is integrated seamlessly into the composite piece. Part of the process includes wrapping a visible portion of each switch item with the outward facing skin. A spare piece is placed against the surface of the visible area of each item opposite the surface located on the visible surface of the composite piece. A foaming material is injected between the skin and the substrate, and then each spare piece is removed. A control component is placed at each cavity left where the removed spare pieces blocked expansion of the foaming material.