A vehicle panel basically includes a skin layer, a substrate layer and a foam material. The skin layer includes an inbound facing side and an outbound facing side. The substrate layer includes an inbound facing side and an outbound facing side, with the inbound facing side of the substrate layer overlying and spaced from the outbound facing side of the skin layer to form a space therebetween. The foam material includes a first foam layer disposed in the space between the skin layer and the substrate layer and a second foam layer overlying the outbound facing side of the substrate layer, with the first and second foam layers being interconnected as a unitary member through at least one opening in the substrate layer.
1. A vehicle panel comprising:
a skin layer including an inbound facing side and an outbound facing side;
a substrate layer including an inbound facing side and an outbound facing side, with the inbound facing side of the substrate layer overlying and spaced from the outbound facing side of the skin layer to form a space therebetween; and
a foam material including a first foam layer disposed in the space between the skin layer and the substrate layer and a second foam layer overlying the outbound facing side of the substrate layer as a unitary member over a plurality of openings in the substrate layer, with the first and second foam layers being interconnected as a unitary member through the plurality of openings in the substrate layer, and the second foam layer having an exposed surface that faces away from the outbound facing side of the substrate layer and defines an outbound facing surface of the vehicle panel.
2. The vehicle panel according to claim 1 , wherein
the outbound facing side of the substrate layer includes at least one retaining member protruding outwardly from the outbound facing side of the substrate layer and being embedded in the second foam layer.
3. The vehicle panel according to claim 2 , wherein
the at least one retaining member includes a plurality of retaining members of protruding outwardly from the outbound facing side of the substrate layer and being embedded in the second foam layer.
4. The vehicle panel according to claim 2 , wherein
the substrate layer and the at least one retaining member are integrally formed as a one-piece member.
5. The vehicle panel according to claim 2 , wherein
the at least one retaining member includes a barbed portion.
6. The vehicle panel according to claim 1 , wherein
the exposed surface includes a plurality of projections.
7. The vehicle panel according to claim 6 , wherein
the projections of the exposed surface are generally cone-shaped members.
8. The vehicle panel according to claim 6 , wherein
the outbound facing side of the substrate layer includes a plurality of retaining members protruding outwardly from the outbound facing side of the substrate layer with each of the retaining members being embedded in one of the projections of the second foam layer.
9. The vehicle panel according to claim 6 , wherein
at least one of the projections of the exposed surface is positioned entirely over a portion of the substrate layer without one of the openings therein.