Headliner having integrated energy absorbing foam

Details Headliner having integrated energy absorbing foam Headliner having integrated energy absorbing foam

2007-08-28

2007-08-28

Kuhns, Allan R. (Department: 1732)

Stock material or miscellaneous articles

Structurally defined web or sheet

Including variation in thickness

C296S214000, C428S141000, C428S158000, C428S160000, C428S317900

Reexamination Certificate

active

10262735

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.

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