Method of making a headliner and the like

DETAILED DESCRIPTION We claim: 1.
A process for making a flexible laminated sheet of foamed resin and fiber glass comprising, (a) providing layers of open celled polyurethane foam and non-woven scrim, said foam having a thickness in the range of about 0.
1 to 1.
1 inches, and ILD in the range of 10-80, a density in the range of 0.
7-2 pounds per ft.
sup.
3, and a permeability in the range 2-8 cfm, (b) providing a layer of material over said scrim layer, (c) chopping strands of fiber glass to a length in the range 1.
5-3 inches and depositing by gravity a first layer of fiber glass over said layer of material, said fiber glass being applied in a density in the range 4-16 gm/ft.
sup.
2, said layer of material between said first fiber glass layer and said scrim layer confining and supporting said first fiber glass layer.
(d) impregnating said layer of foam with a liquid polyurethane resin, said liquid resin comprising a mixture of about 40-50 volume percent aromatic isocyanate, about 50-60 volume percent polyether polyol, and about 0.
0-0.
2 volume percent of a catalyst, (e) running said impregnated foam layer between a first pair of rollers to provide a uniform non-saturating dispersion of said liquid resin in said foam layer, (f) depositing a second layer of fiber glass over said foam layer, said second fiber glass layer having similar physical characteristics as said first fiber glass layer and being chopped and deposited on said foam layer in the same way as said first fiber glass layer is deposited on said layer of material, (g) applying said impregnated foam layer and second fiber glass layer over said first fiber glass layer with the foam layer sandwiched between said two fiber glass layers, (h) compressing all layers together between a pair of calendar rollers to form a laminate with said liquid resin being squeezed from said foam layer into the adjoining fiber glass layers, (i) applying a cover layer over said second layer of fiber glass, said cover layer being selected from the group consisting of a woven fabric, a permeable vinyl sheet, and an impermeable vinyl sheet, (j) placing said laminate and cover layer between a pair of molds for a period of about 1/2-3 min