Method for producing a foamed panel

A method of manufacturing an article having a substructure with a wall having first and second wall surfaces, a molded layer along said first wall surface, and a finishing layer, comprising the following steps:

• supporting said substructure in a tool having first and second die surfaces on either side of said wall, said first die surface being spaced apart from said first wall surface and said second die surface being spaced apart from said second wall surface;
• supporting said finishing layer on said first die surface with said finishing layer being spaced apart from said first wall surface;
• injecting an expandable foamable material into the space between said first wall surface and said finishing layer under conditions causing said foamable material to exert a force on said wall;
• and
• contacting said second wall surface with a fluid under sufficient pressure to create a force on said wall that offsets the force exerted by said material whereby said wall is supported against deformation.

A method of manufacturing an article having a rigid substructure with a hollow section, a finishing layer, and a molded foam layer therebetween, said section having and a wall with first and second wall surfaces, comprising the following steps:

• supporting said substructure in a tool having first and second die surfaces on either side of said wall, said first die surface being spaced apart from said first wall surface and said second die surface being spaced apart from said second wall surface;
• supporting said finishing layer on said first die surface with said finishing layer being spaced apart from said first wall surface;
• closing said tool and forming a fluid-tight chamber between said second die surface and said second wall surface;
• injecting an expandable foamable material into the space between said first wall surface and said finishing layer under conditions causing said foamable material to exert a force on said wall;
• and
• injecting a fluid into said chamber under sufficient pressure to create a force on said wall that offsets the force exerted by said material whereby said wall is supported against deformation.