Johns Manville

Indiana Acoustical Components

Larry Maxwell Bauman

David W Bainbridge

Mario P Tocci

A molded, self-supporting, composite part or panel for automotive and similar applications comprises a vapor impervious wood fiber filled polymeric (preferably polypropylene) sheet adhered to one major face of a corrugated paperboard medium and a layer of fibrous insulation (preferably glass fiber) or a second wood fiber filled polymeric sheet adhered to a second major face of the corrugated paperboard medium. The sheet and corrugated medium provide the structural strength for the composite and the fibrous insulation, when used, provides the composite with good sound absorption properties. The wood fiber filled polymeric sheet is formed during the molding process from a wood and polymeric fiber sheet. The heat and pressure of the molding process cause the polymeric fibers to melt and flow about the wood fibers to form the wood fiber filled sheet and bond the sheet securely to the corrugated medium. A thermoset binder can be used in the sheet to strengthen the composite and help the composite retain its molded shape prior to cooling. Uncured binder in the fibrous insulation is cured during the molding process to bond the fibrous insulation to the corrugated medium.

Method of making self-supporting composite structures

A self-supporting headliner panel for lining the interior surface of an automotive roof comprises a front sheet, a back sheet and an intermediate corrugated sheet adhered to the front and back sheets. The front sheet and the back sheet each comprise wood fibers and polypropylene. To form the panel, a laminate of the front sheet, the back sheet and the intermediate corrugated sheet is molded in a heated mold which melts polypropylene fibers in the front and back sheet causing the laminate to conform to the shape of the mold and adhering the three sheets together.

Growing community of inventors

Defiance, OH, United States of America

Larry Maxwell Bauman