Lear Corporation

Lear Donnelly Overhead Systems, L.l.c.

George B Byma

Brian Cristea

Richard M&uuml;hlbacher

Jack M Van Ert

Richard Mühlbacher

Thomas Greiner

The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the substrate.

Multiple density interior trim substrate and method and system for making same

This invention relates to a flexible headliner for an automotive vehicle. The headliner includes a flexible foam core layer having a nominal thickness of greater than 5 millimeters. A cover layer is bonded to a first side of the core layer. A backing layer is bonded to a second side of the core layer opposite the first side. The headliner is sized and shaped to conform to an interior roof of the vehicle. The invention also relates to particular methods of forming the headliner in a mold.

Flexible headliner for automotive vehicle

The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Tool for forming a multiple foam substrate for impact energy absorption

Multiple foam energy absorbing substrate assembly

Method of making a multiple foam interior trim substrate

The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The multiple density substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the multiple density substrate.

Multiple density interior trim substrate and method of making same

An apparatus for forming an article from at least one layer of formable material includes a mold for receiving the at least one layer of formable material. The mold has first and second thin mold sections and a seal associated with at least one of the mold sections for effecting a sufficiently sealed relationship between the mold sections. Each mold section has a non-planar configuration, and one mold section has at least one aperture. A vacuum source is in fluid communication with the at least one aperture for applying a vacuum pressure to the at least one aperture when the mold sections are sufficiently sealed together in order to reduce air pressure within the mold. As a result, ambient air pressure is used to forcefully bias the mold sections sufficiently together so as to form the at least one layer of formable material to a contour corresponding to the non-planar configurations of the mold sections. Furthermore, each mold section is sufficiently rigid such that the mold sections do not substantially flex when the mold sections are forcefully biased together.

Apparatus for molding articles

A method of making a headliner assembly includes providing a porous member having first and second sides. A negative pressure is developed on the second side of the porous member, and particulate material is selectively deposited proximate the first side of the porous member to form a particulate layer having an outline that corresponds with a desired outline of the headliner assembly. The particulate material is drawn toward the first side of the porous member by the negative pressure developed on the second side of the porous member. The particulate layer is then thermoformed to form the headliner assembly.

Method of making a part using selective particulate deposition

A headliner for motor vehicles includes first and second sheets of material in juxtaposition to each other and adapted for positioning in a mold having two mold portions. The material of at least one of the sheets is fluid deformable with respect to another of the sheets, and is attachable to the material of the other of the sheets by the mold portions at sufficient locations to outline a potential duct between the sheets. The potential duct is adapted to receive fluid between the sheets for forming an actual duct. When fluid is received between the sheets, the material of the at least one sheet is deformed with respect to the material of the other of the sheets to define the actual duct. In one embodiment of the headliner, at least one head impact block is disposed in the duct. The headliner may also include at least one substantially air-impermeable layer disposed within the duct and attached to at least one of the the first and second sheets. Furthermore, the layer preferably includes a polymer powder.

Growing community of inventors

Haar, Germany

George B Byma