Method of making a headliner having integrated energy absorbing foam

US6500369B1 · kind B1 · utility

Inventors

• Janusz P. Gorowicz · Pinckney, US
• Alan D. Picken · Pontiac, US
• Roland Heiberger · Northville, US
• Normand Marceau · Linden, US

Key dates

• Filing date: Oct 16, 2000
• Grant date: Dec 31, 2002
• Expiry date: Dec 26, 2020

Classification

• Technology area (CPC Y): Emerging Cross-Sectional Technologies
• CPC primary: Y10T428/249986
• WIPO field: Transport
• WIPO sector: Mechanical engineering

Abstract

A method of manufacturing a headliner assembly for use in the interior compartment of an automotive vehicle comprising the steps of: placing a mold release film onto a concave mold surface of a lower mold assembly for providing a barrier against the mold surface; placing a fiber mat on the mold release film; applying a foamable material directly onto the fiber mat; expanding the foamable material around the fiber mat to embed the fiber mat therein; placing an adhesive film onto a convex mold surface of an upper mold assembly; positioning the lower mold assembly directly beneath the upper mold assembly; moving the upper mold assembly in mating engagement with the lower mold assembly to define a mold cavity between the convex mold surface and concave mold surface; curing the foamable material within the mold cavity; and bonding the mold release film and adhesive film to the foamable material with the fiber mat embedded therebetween. A layer of scrim is then adhered to the mold release film and a layer of fabric is adhered to the adhesive film for providing a decorative cover to the headliner assembly.