An article including a panel structure mountable in an automobile vehicle
to form a part of the vehicle interior thereof, and a process for making
the same are disclosed. According to this process, an outer layer
defining at least a portion of the exposed exterior surface of the
structure is prepared by applying a first composition containing a
thermoplastic polyurethane and a heat-activated crosslinking agent onto a
mold surface and thereafter drying the composition. Next, a second
composition comprising (i) a poly(vinyl chloride) resin and at least one
plasticizer and/or (ii) a thermoplastic polyurethane resin material is
gelled onto an inner surface of the outer layer while on the outer layer
is retained on the mold surface. The gelled composition is then fused to
form an inner layer interfacially chemically bonded to the outer layer.
The layered composite structure is united with the reinforcing substrate
so that the reinforcing substrate serves to reinforce the outer layer.
The exposed exterior surface of the panel structure simulates the
appearance and feel of authentic leather, while the inner layer and an
optional semi-rigid polyurethane cellular foam intermediate layer provide
a compressing feel to the exposed portion.