Skin-foam-substrate structure via induction heating

A method for making an automobile trim component having a skin-foam-substrate structure, the method comprising:

• supplying a skin material comprising a polyolefin elastomer having a density of 0.80 g/cc to 0.90 g/cc and a melting temperature in the range of 50° C. to 100° C.;
• supplying a substrate material;
• supplying a mixture of foamable polymer resin comprising crosslinked polypropylene having a gel content in the range of 15% to 85% and metal particles wherein the metal particles are present in the mixture at 5.0% by weight to 20.0% by weight;
• positioning the mixture of foamable polymer resin and metal particles between the skin and substrate material, wherein the foamable polymer resin includes a chemical foaming agent and said chemical foaming agent is present at a level of 5.0 wt. % to 15.0 wt. %;
• generating an electromagnetic induction field;
• inductively heating the metal particles of the mixture via the electromagnetic induction field;
• transferring the heat from the heated metal particles to the foamable polymer resin;
• heating the foamable polymer resin, including the chemical foaming agent, with the heat from the inductively heated metal particles to a temperature for foaming of the foamable polymer resin while maintaining the skin and substrate at room temperature plus no more than a 30° F. temperature rise;
• foaming the polymer resin with the chemical foaming agent to provide a foam layer between the skin and the substrate;
• wherein foaming is completed in less than or equal to 60 seconds;
• and
• adhering the polymer resin to the skin material and the substrate material, while foaming the polymer resin, to form the automobile trim component wherein the foam layer has a thickness of 0.2 mm to 5.0 mm, a density of 2.0 pcf to 4.0 pcf and said skin layer has a thickness of 0.5 mm to 1.5 mm.