Method of producing automotive interior articles including frims

A method of producing an automotive interior vehicle part, the method comprising:

• forming a fiber reinforced thermoplastic polymer porous core layer by mixing reinforcing fibers, a thermoplastic polymer and a
• dispersing foam to provide a foam mixture of the reinforcing fibers and the thermoplastic polymer;
• disposing the foam mixture on a moving screen;
• evacuating the foam from the disposed foam mixture to form a web of open cell structures comprising the reinforcing fibers and the thermoplastic polymer;
• drying the web to form the fiber reinforced thermoplastic porous core layer, wherein the formed fiber reinforced thermoplastic polymer porous core layer comprises an areal density of 500 gsm to 3000 gsm;
• disposing a frim on a first surface of the formed fiber reinforced thermoplastic polymer porous core layer, wherein the frim comprises a film component coupled to a scrim component, and wherein the scrim is continuous from side to side of the film component, wherein the film component comprises a plurality of layers and a basis weight of 15 gsm to 75 gsm, wherein at least one of the plurality of layers of the film comprises a polyamide or polyethylene, and wherein the scrim comprises a basis weight of at least 15 gsm to prevent sag of the article during a forming operation;
• disposing a skin layer on a second surface of the formed fiber reinforced thermoplastic polymer porous core layer to form a thermoplastic composite article, wherein the formed fiber reinforced thermoplastic polymer porous core layer is positioned between the film component of the disposed frim and the disposed skin layer;
• and
• molding the formed thermoplastic composite article to form the automotive interior vehicle part, wherein the basis weight of the scrim of the formed thermoplastic composite article prevents sag of the formed thermoplastic composite article during the molding to form the automotive interior vehicle part.