Abstract: An automotive interior trim panel has an outer flexible skin that overlies a rigid backing panel formed with a foam entry hole through which foam precursors are poured into a space between the skin and panel and they react and expand to generate a foam layer within the space. Tab projections are carried by the panel and extend into the foam space to at least partially cover the opening and provide rigid backing support for foam expanding in the region of the entry hole to control the density of the foam in this entry hole region such that it conforms more closely with the density of the immediate surrounding foam.

Abstract: An automotive interior trim panel has an outer flexible skin that overlies a rigid backing panel formed with a foam entry hole through which foam precursors are poured into a space between the skin and panel and they react and expand to generate a foam layer within the space. Tab projections are carried by the panel and extend into the foam space to at least partially cover the opening and provide rigid backing support for foam expanding in the region of the entry hole to control the density of the foam in this entry hole region such that it conforms more closely with the density of the immediate surrounding foam.

Abstract: A door cover assembly for concealing a supplemental inflatable restraint (SIR) system of an automotive interior trim component includes a substrate having a door section in which formed depressions are provided to strengthen the door. The depressed regions are filled with a secondary foam insert to level the outer surface of the substrate. A primary foam layer overlies the substrate and is covered by an outer vinyl shell. The leveling of the substrate by the secondary foam insert eliminates "show through" of the depressed regions on the outer Class A surface of the vinyl shell.