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| Method and apparatus for producing a curly puff extrudate |
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| Polyester film composites |
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| Polyester film for thermal lamination |
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| Heat-sealable polyester film |
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Method for making a composite headliner
| Details |
Inventors: Byma, George B.; Gabrysiak, John J.;
Assignee: Lear Corporation (Southfield, MI)
Primary Examiner: Chen; Vivian
Assistant Examiner:
Attorney, Agent or Firm:
A method for making a unitary composite headliner adapted to be installed in a motor vehicle includes providing an inner layer and two reinforcing layers, each of which comprises polymeric 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; differentially heating the layers such that each reinforcing layer is heated to a respective predetermined reinforcing layer temperature, and the inner layer is heated to a predetermined inner layer temperature less than either respective reinforcing layer temperature; inserting the layers into a mold such that the inner layer is disposed between the reinforcing layers; and compressing the layers together to bond the layers and form the headliner. |
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DETAILED DESCRIPTION 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.
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