Van Dresser Corporation

Richard P Doerer

Joseph T Karpik

Edward J Bihun

A method of making a lightweight panel having a relatively soft foam-backed cover sheet supported on a relatively hard, self-supporting core in one simple step. An assembly of foam layers is built up comprising a core-forming foam layer, an intermediate foam layer, and a cover-backing foam layer, with a scrim sheet over the core-forming foam layer and a cover sheet over the cover-backing foam layer. The core-forming layer is impregnated with a heat-activatable hardening compound. The intermediate layer as well as the cover-backing layer may also, if desired, be impregnated with a heat-activatable hardening compound but usually in lesser amounts. The hardening compound coats the cell walls of the foam. The panel is formed by subjecting this layered assembly to heat and pressure between contoured dies in a single compression molding operation at a temperature at which the hardening compound is activated. The layers of the assembly are bonded together either by the hardening compound or by thermoplastic films placed between layers which are melted by the heat of the molding operation and become adhesive when melted.

Panel and method of making the same

A moldable fibrous mat from which a permanently rigid product of predetermined shape can be molded by the application of heat and/or pressure. The mat consists essentially of base fibers and carrier fibers and a thermosetting ingredient, with the base fibers having a substantially higher softening temperature, if any, than the carrier fibers. The fibers intertwine to resist separation. The carrier fibers are bonded to the base fibers and to each other to form connections, the thermoset remaining dormant in the making of the mat. There is also disclosed a method by which the moldable fibrous mat is made and product made from the mat, which product may be of uniform density or have areas of differing density.

Moldable fibrous mat and product molded therefrom

A moldable fibrous mat from which a product of predetermined shape can be molded by the application of heat and/or pressure. The mat consists essentially of base fibers and carrier fibers with the base fibers having a substantially higher softening temperature, if any, than the carrier fibers. The fibers intertwine to resist separation. The carrier fibers are bonded to the base fibers and to each other to form connections. There is also disclosed a method by which the moldable fibrous mat is made and product made from the mat, which product may be of uniform density or have areas of differing density.

Moldable fibrous mat and method of making the same

A contoured self-supporting automotive liner panel, such as a headliner, which comprises an outer substrate layer of expanded plastics material which is relatively rigid and has a substantial resistance to bending, an intermediate layer of relatively soft, compressible, flexible, expanded plastics material, and an outer flexible decorative finish cover layer.

Automotive liner panel

A contoured self-supporting automotive liner panel, such as a headliner, which comprises an outer substrate layer, an intermediate layer and an outer flexible, decorative, finish cover layer. The substrate layer is formed of expanded plastics material which is relatively rigid and has a substantial resistance to bending. The intermediate layer is formed of a relatively soft, compressible, flexible, expanded plastics material.

Self-supporting automotive liner panel

A method of forming a flexible sheetlike structure such as an automotive headliner by treating a sheet of fiberboard or other similar material with water at an elevated temperature to make the sheet sufficiently ductile to permit forming without tearing or blowing, and placing the water-treated sheet between heated dies to form the sheet to a compound curvature by the application of heat and pressure. The sheet may or may not be perforated. The method also includes finishing one side of the die-formed sheet by securing a decorative or sound-absorbing layer thereto. The sheet is placed on a support and the layer is applied over the adhesive coated upper surface of the sheet. A cover is draped over the support to provide an air seal over the layer and sheet and is drawn against the support by differential pressure, either pressure or vacuum to press the layer against the sheet and adhere the two together.

Method of treating and forming a panel

A method of forming a flexible sheetlike structure such as an automotive head-liner by treating a sheet of fiberboard or other woodlike fibrous material with water at an elevated temperature to make the sheet sufficiently ductile to permit forming without tearing or blowing, and placing the water-treated sheet between heated dies to form the sheet to a compound curvature by the application of heat and pressure. The sheet may or may not be perforated. The method also includes finishing one side of the die-formed sheet by securing a decorative or sound-absorbing layer thereto. The sheet is placed on a support and the layer is applied over the adhesive coated upper surface of the sheet. A cover is draped over the support to provide an air seal over the layer and sheet and is drawn against the support by differential pressure, either pressure or vacuum to press the layer against the sheet and adhere the two together.

Growing community of inventors

Grosse Pointe, MI, United States of America

Richard P Doerer