US20010037854A1 - Method for making composite headliner - Google Patents
Method for making composite headliner Download PDFInfo
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- US20010037854A1 US20010037854A1 US09/027,702 US2770298A US2001037854A1 US 20010037854 A1 US20010037854 A1 US 20010037854A1 US 2770298 A US2770298 A US 2770298A US 2001037854 A1 US2001037854 A1 US 2001037854A1
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- United States
- Prior art keywords
- layers
- headliner
- cover member
- polyester
- vehicle
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0036—Heat treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B2037/148—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers whereby layers material is selected in order to facilitate recycling of the laminate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R13/0212—Roof or head liners
- B60R13/0225—Roof or head liners self supporting head liners
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
- Y10T156/1092—All laminae planar and face to face
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
- Y10T156/1092—All laminae planar and face to face
- Y10T156/1093—All laminae planar and face to face with covering of discrete laminae with additional lamina
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
- Y10T428/31681—Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
- Y10T428/3179—Next to cellulosic
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/25—Coating or impregnation absorbs sound
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3382—Including a free metal or alloy constituent
- Y10T442/3415—Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the woven fabric]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3707—Woven fabric including a nonwoven fabric layer other than paper
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3854—Woven fabric with a preformed polymeric film or sheet
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/654—Including a free metal or alloy constituent
- Y10T442/656—Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the nonwoven fabric]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet
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- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
A unitary composite headliner adapted to be installed adjacent a motor vehicle roof comprises at least two reinforcing layers of recyclable polyester fibers configured to provide sufficient flexibility to the headliner to facilitate installation in the vehicle, while also providing sufficient rigidity to the headliner to enable the headliner to be self-supporting once installed in the vehicle. The headliner further comprises at least one inner layer of recyclable polyester fibers sandwiched between at least two of the reinforcing layers and configured to absorb sound and vibrations, and a cover member of polyester bonded to one of the reinforcing layers with a polyester adhesive. The inner and reinforcing layers are bonded together by differentially heating each layer to a predetermined temperature and compressing the layers together. Furthermore, the headliner is recyclable as a unit. A method of making the headliner is also disclosed.
Description
- The invention relates to headliners for motor vehicles.
- Prior headliners for motor vehicles include a batt of fiberglass impregnated with a thermosetting resin. The headliner is typically compression molded in a heated mold, and then cooled to attain the desired shape. Such headliners are self supporting, but are also relatively inflexible and brittle. As a result, they are easily broken or damaged during shipment and installation.
- Other headliners have been proposed which are more flexible and resilient than fiberglass headliners. U.S. Pat. No. 4,840,832, for example, shows a headliner which is formed from a layer of polymeric fibers combined with a foam layer and a fabric surface layer. The layers are preheated together in an oven and then molded into a predetermined shape. Because the layers are simultaneously heated to approximately the same temperature, however, optimal compression of the different layers is difficult to achieve.
- U.S. Pat. No. 4,828,910 shows a thermoformed laminate which is useful in headliners, and the laminate includes a layer of resilient sound absorbing material sandwiched between two layers of reinforcing materials. The method of making such laminates includes introducing the layers into a heated mold and thermoforming the layers together to achieve a desired shape. As with the previous example, however, optimal compression of the different layers is difficult to achieve because the layers are all heated to approximately the same temperature. Furthermore, because the reinforcing materials are different in composition than the sound absorbing material, the laminate is not recyclable as a unit.
- The invention is a unitary composite headliner adapted to be installed adjacent a motor vehicle roof. The headliner comprises at least two layers of polymeric material, one of the layers being configured to absorb sound and vibrations, and the other of the layers being configured to provide sufficient flexibility to the headliner to facilitate installation in the vehicle, while also providing sufficient rigidity to the headliner to enable the headliner to be self-supporting once installed in the vehicle. The layers are bonded together by differentially heating each layer to a predetermined temperature and compressing the layers together.
- A method for making the headliner is also disclosed. The method comprises providing at least two layers of polymeric material, one of the layers being configured to absorb sound and vibrations, and the other of the layers being configured to provide flexibility and rigidity to the headliner; differentially heating the layers to predetermined temperatures; inserting the layers into a mold; and compressing the layers together to bond the layers and form the headliner.
- Accordingly, it is an object of the invention to provide an improved composite headliner which optimizes sound absorbing properties in combination with flexibility and structural rigidity.
- It is another object of the invention to provide an improved composite headliner which is entirely recyclable as a unit.
- It is yet another object of the invention to provide a method of making the composite headliner which includes differentially heating multiple layers of recyclable polymeric material and then compression molding the layers together to obtain optimal compression and bonding of the layers.
- These and other objects, features and advantages of the invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in conjunction with the accompanying drawings.
- FIG. 1 is a perspective view of a composite headliner according to the present invention as installed in a motor vehicle;
- FIG. 2 is a cross-sectional view taken along line2-2 of FIG. 1;
- FIG. 3 is a cross-sectional view similar to FIG. 2 and showing a second embodiment of the composite headliner according to the invention;
- FIG. 4 is a schematic illustration of steps of a method according to the invention; and
- FIG. 5 is a diagrammatic view of an apparatus for practicing the method.
- With reference to the drawings, the preferred embodiments of the invention will be described. FIG. 1 shows a
composite headliner 10 according to the invention mounted to the underside of a roof of amotor vehicle 12 using hook-and-loop fastener strips 13 and interior trim strips (not shown) mounted along opposite sides of the headliner. Theheadliner 10 may include anopening 14 for a dome light andopenings 15 for receiving the mounting hardware for a pair of sun visors. Depending on the application, theheadliner 10 may include various other openings as necessary. Alternatively, it may be desirable to pre-install such components as dome lights, sun visors, coat hooks, wire harnesses and the like on theheadliner 10 prior to mounting the headliner in thevehicle 12. As shown in FIG. 2, theheadliner 10 comprises a laminate or composite construction including aninner layer 16 sandwiched between two outer or reinforcinglayers cover member 22 is attached to reinforcinglayer 20, and provides an aesthetically pleasing finished surface on the underside of the vehicle roof. - The
inner layer 16 comprises a blend of nonwoven fibers, including fine denier fibers, regular denier fibers and binder fibers which contain a relatively low melting temperature component. The fibers range from 0.8 to 15 denier, and theinner layer 16 preferably contains 20-50% of fine fibers in the range of 0.8 to 3 denier, 0-70% of fibers in the range of 4 to 15 denier and 10-50% of binder fibers. The fibers are preferably formed of a recyclable thermoplastic polymer, including polyester, nylon, polyethylene and/or polypropylene, which enables theheadliner 10 to be recycled as a unit. Presently preferred are polyester fibers, including bi-component polyester fibers having a relatively low melting temperature binder component and a higher melting temperature strength component. Alternatively, the fibers may be formed of any suitable polymeric material. The thickness of theinner layer 16 ranges from 0.5 to 20 millimeters (mm), and is preferably in the range of 0.5 to 15 mm. Theinner layer 16 preferably has a relatively low density with a basis weight in the range of 200 to 800 grams/meter2 (g/m2), and preferably in the range of 400 to 500 g/m2. Theinner layer 16 with the blend of fibers described above and its relatively low density provides for excellent sound absorption properties while maintaining a relatively low mass. Alternatively, theheadliner 10 may have a plurality of inner layers, each of which is configured to absorb sound and vibrations. - Binder materials can be mixed with the fibers to provide the
inner layer 16 with additional dimensional stability when exposed to extreme temperatures, humidity, or mechanical strain. Suitable binder materials include co-polymeric binder fibers, thermosetting binder powders, or fully or partially crystallized bi-component or staple fibers, such as Hoechst J58, Wellman T0196, or Unitika 7080 polyester bi-component fibers. - The reinforcing
layers layers headliner 10 to be recycled as a unit. Presently preferred are fibers and binder material formed of polyester. Alternatively, the fibers and binder material may be formed of any other suitable polymeric material. Each of thelayers layers layers headliner 10 with structural rigidity in combination with flexibility and resiliency. Alternatively, theheadliner 10 may have more than two reinforcing layers. - The
cover member 22 is preferably made of nonwoven polyester which enables theheadliner 10 to be recycled as a unit, but it may be made of any other suitable polymeric material. An adhesive preferably made of polyester may be used to aid in the bonding of thecover member 22 to the reinforcinglayer 20. It is also possible to eliminate thecover member 22 if the characteristics of the reinforcinglayer 20 are aesthetically satisfactory. - FIG. 3 shows a
second embodiment 110 of the headliner including astiffening layer 112 and ascrim layer 114 overlaying the reinforcinglayer 18. Thestiffening layer 112 provides additional rigidity to theheadliner 110 and may comprise such materials as fiberglass, a metal mesh, metal fibers or natural fibers such as jute, knaff, or hemp. Any of these materials may also be imbedded in a polymeric matrix. Alternatively, one or more stiffening layers 112 may be sandwiched between any of thelayers layer 20 and thecover member 22. Thescrim layer 114 provides a finished surface for mounting against the vehicle roof, and may be eliminated from theheadliner 110 depending on the application. Additionally, thescrim layer 114 may be used to provide additional rigidity to theheadliner 110 and/or to assist in holding thestiffening layer 112 together. Furthermore, adhesives may be used to bond the stiffening layer or layers 112 and thescrim layer 114, if used, to theheadliner 110. - FIG. 4 schematically illustrates steps of a method according to the invention of making the
headliner 10. By this method, theinner layer 16 and the reinforcinglayers oven 24 configured to individually receive and heat each of the layers, as shown in FIG. 5. Theinner layer 16, the reinforcinglayer 18 and the reinforcinglayer 20 are preferably heated to 185° C., 215° C. and 210° C., respectively. Alternatively, theinner layer 16, the reinforcinglayers cover member 22 may be individually heated or simultaneously heated to the same or different temperatures in any manner known to those skilled in the art, or preheating one or more of the layers and/or the cover member may be eliminated. - The
inner layer 16, the reinforcinglayers cover member 22, if used, are then inserted into acompression mold 26 where they are compressed and simultaneously thermoformed, thereby bonding the layers and the cover member together and forming theheadliner 10. During the thermoforming process, fibers within each of thelayers compression mold 26 can include thermally regulated cold, warm or hot mold halves. The mold halves can also be provided with varying mold surfaces so that portions of the headliner can be compressed to different thicknesses within a range of 3 to 40 mm, and preferably within a range of 3 to 25 mm. For example, it may be desirable to compress certain portions of theheadliner 10 to a greater extent to increase structural rigidity, or to create recesses in the headliner that conform to projections on the underside of the vehicle roof. Depending on the application, adhesives can also be used between two or more of thelayers layer 20 and thecover member 22. Such adhesives are preferably made of polyester so that theheadliner 10 can be recycled as a unit, but the adhesives may be made of any other suitable material. Alternatively, thecover member 22 can be molded or otherwise attached to a previously formed substrate including theinner layer 16 and reinforcinglayers - Differentially heating the
inner layer 16 and the reinforcinglayers headliner 10 depend largely on the density of theinner layer 16, it may be desirable to minimize heating of the inner layer, as compared with the reinforcinglayers - The
headliner 10 formed by the above method has improved sound absorbing properties in combination with structural rigidity and flexibility. Because the compression of theinner layer 16 is minimized, the sound absorption properties of the inner layer are maximized. Because the reinforcinglayers headliner 10 is also optimized. As a result, theheadliner 10 does not substantially bow or sag when exposed to heat or humidity, and the headliner easily supports its own weight, as well as the weight of components mounted to the headliner, such as a dome light or coat hooks. The reinforcing layers 18 and 20, however, should also remain highly flexible and resilient so that theheadliner 10 can be installed in thevehicle 12 easily and without fracturing or breaking. - Furthermore, the invention provides a headliner that is preferably recyclable as a unit, so there is no need to separate components prior to recycling. In particular, the thermoplastic layers of the headliner can be easily reground or shredded together, and the ground or shredded material can be used to preferably form a new headliner or other thermoplastic parts.
- The
headliner 110 can be manufactured by the process previously described. Thestiffening layer 112 and thescrim layer 114, if used, may be preheated to a predetermined temperature either individually or simultaneously with any one or more of thelayers cover member 22, if used. Alternatively, preheating of thestiffening layer 112 and thescrim layer 114 may be eliminated. In either case, thestiffening layer 112 and thescrim layer 114 are then inserted into themold 26 with theother layers cover member 22, where they are thermoformed with the other layers and the cover member to form theheadliner 110. - The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
Claims (17)
1. A unitary composite headliner adapted to be installed adjacent a motor vehicle roof, the headliner comprising at least two layers of polymeric material, one of the layers being configured to absorb sound and vibrations, and another of the layers being configured to provide sufficient flexibility to the headliner to facilitate installation in the vehicle, while also providing sufficient rigidity to the headliner to enable the headliner to be self-supporting once installed in the vehicle, the layers being bonded together by differentially heating each layer to a predetermined temperature and compressing the layers together.
2. The headliner of further including at least one stiffening layer bonded to at least one of the layers of polymeric material.
claim 1
3. The headliner of wherein each of the layers comprises a recyclable polymeric material which enables the headliner to be recycled as a unit.
claim 1
4. The headliner of wherein the layers comprise polyester fibers.
claim 1
5. The headliner of further including a cover member comprising polyester bonded to one of the layers.
claim 4
6. The headliner of wherein the cover member is bonded to one of the layers using a polyester adhesive.
claim 5
7. A unitary composite headliner adapted to be installed adjacent a motor vehicle roof, the headliner comprising:
at least two reinforcing layers of recyclable polyester fibers configured to provide sufficient flexibility to the headliner to facilitate installation in the vehicle, while also providing sufficient rigidity to the headliner to enable the headliner to be self-supporting once installed in the vehicle;
at least one inner layer of recyclable polyester fibers sandwiched between at least two of the reinforcing layers and configured to absorb sound and vibrations; and
a cover member of polyester bonded to one of the reinforcing layers with a polyester adhesive;
the inner and reinforcing layers being bonded together by differentially heating each layer to a predetermined temperature and compressing the layers together, wherein the headliner is recyclable as a unit.
8. A method for making a unitary composite headliner adapted to be installed in a motor vehicle, the method comprising:
providing at least two layers of polymeric material, one of the layers being configured to absorb sound and vibrations, and another of the layers being configured to provide sufficient flexibility to the headliner to facilitate installation in the vehicle, while also providing sufficient rigidity to the headliner to enable the headliner to be self-supporting once installed in the vehicle;
differentially heating the layers to predetermined temperatures;
inserting the layers into a mold; and
compressing the layers together to bond the layers and form the headliner.
9. The method of further including at least one stiffening layer bonded to at least one of the layers of polymeric material.
claim 8
10. The method of wherein each of the layers comprises a recyclable polymeric material which enables the headliner to be recycled as a unit.
claim 8
11. The method of wherein the layers comprise polyester fibers.
claim 8
12. The method of further including providing a cover member of polyester and inserting the cover member into the mold before inserting the layers into the mold.
claim 11
13. The method of further including providing a cover member of polyester and inserting the cover member into the mold with the layers.
claim 11
14. The method of further including heating the cover member to a predetermined temperature before inserting the cover member into the mold with the layers.
claim 13
15. The method of further including applying a polyester adhesive to the cover member before inserting the cover member into the mold with the layers.
claim 13
16. The method of further including providing an adhesive layer comprising polyester and inserting the adhesive layer into the mold with the layers and the cover member, the adhesive layer being positioned between the cover member and one of the layers.
claim 13
17. A method for making a unitary composite headliner adapted to be installed in a motor vehicle, the method comprising:
providing at least one inner layer, at least two reinforcing layers, and a cover member, each of which comprises a recyclable polyester material, the inner layer being configured to absorb sound and vibrations, and the reinforcing layers being configured to provide sufficient flexibility to the headliner to facilitate installation in the vehicle, while also providing sufficient rigidity to the headliner to enable the headliner to be self-supporting once installed in the vehicle;
applying a polyester adhesive to the cover member;
differentially heating the inner and reinforcing layers to predetermined temperatures;
inserting the layers and the cover member into a mold with the inner layer being sandwiched between at least two of the reinforcing layers, and the cover member being adjacent one of the reinforcing layers; and
compressing the layers and the cover member together to bond the layers and the cover member together and to form the headliner, wherein the headliner is recyclable as a unit.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/027,702 US6322658B1 (en) | 1998-02-23 | 1998-02-23 | Method for making a composite headliner |
PCT/US1999/002885 WO1999042330A1 (en) | 1998-02-23 | 1999-02-11 | Composite headliner and method for making same |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/027,702 US6322658B1 (en) | 1998-02-23 | 1998-02-23 | Method for making a composite headliner |
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US20010037854A1 true US20010037854A1 (en) | 2001-11-08 |
US6322658B1 US6322658B1 (en) | 2001-11-27 |
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US09/027,702 Expired - Fee Related US6322658B1 (en) | 1998-02-23 | 1998-02-23 | Method for making a composite headliner |
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WO (1) | WO1999042330A1 (en) |
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US6322658B1 (en) | 2001-11-27 |
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