Decorative automotive interior trim articles with cast integral light stable covering and process for making the same

An article comprising a panel structure mountable in a vehicle to form part of the interior thereof, the structure having an exterior surface, at least a portion of which is exposed to the vehicle interior, and an interior surface which is hidden from the vehicle interior when the panel structure is mounted in the vehicle, said panel structure comprising:

• a reinforcing substrate;
• a layered composition structure comprising an outer layer defining at least a portion of said exterior surface of the panel structure and an inner layer, said layered composite structure being united to a surface of said reinforcing substrate so that said reinforcing substrate serves to reinforce said outer layer;
• said outer layer comprising an at least substantially dried, light-stable, crosslinked polyurethane formulated from a water-dispersed composition comprising at least one coloring agent, at least one light-stable aliphatic thermoplastic polyurethane containing at least one pendent functional group selected from the group consisting of hydroxyl and carboxyl functional groups, and at least one heat-activated reactive crosslinking monomer or agent, said at least one light-stable aliphatic thermoplastic polyurethane being molded with and partially crosslinked by the heat-activated reactive crosslinking monomer or agent on a heated mold surface,
• said inner layer comprising poly(vinyl chloride), said poly(vinyl chloride) being formed directly on said outer layer by casting a composition comprising poly(vinyl chloride) containing at least one plasticizer onto an inner surface of said outer layer while on said mold surface such that unreacted functional groups of said at least one light-stable aliphatic thermoplastic polyurethane penetrates into said inner layer and reacts with said at least one plasticizer of said inner layer, thereby forming interfacial chemical bonding between said inner surface of said outer layer and an outer surface of said inner layer.