All synthetic fiber interior trim substrate

DETAILED DESCRIPTION An object of the present invention is to provide a headliner substrate which is made entirely or predominantly of synthetic fibers such as polyester or polypropylene, so that the substrate can be recycled or be made recyclable.
The headliner of the invention is also cost effective, lightweight and has similar advantageous characteristics of strength and acoustic absorption to its fibrous counterparts and better sound absorption characteristics as other substrates that are not made from fibrous material.
A further object of the present invention is to provide a method for manufacturing the all synthetic fiber substrate into various interior trim components such as a headliner.
Another object is to provide a 100% synthetic fiber interior trim headliner substrate that does not require a thick mat of fibers with a high percentage of the more costly binder fibers in order to pass the testing requirements of the automotive industry and to maintain low weight.
If a thick mat is necessary for additionally enhanced acoustical performance, less fibers would be required compared to other synthetic fiber substrate constructions on the market.
This construction will greatly reduce both cost and weight from the product.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure.
For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.