Lear Corporation

Scott A Barber

Brian H Scholfield

Raymond Ormachea

Robert Bailey

Don Hamilton

John Sapielak

John C Walters

Dennis Sosnowski

Ron Monk

A method for forming a headliner assembly includes forming a main body having a periphery, and a shape corresponding to a desired shape of the headliner assembly; positioning the main body in a mold having a recess; closing the mold; and injecting foam into the recess to simultaneously form an energy absorbing member and join the energy absorbing member to the main body proximate the periphery of the main body.

Method for forming headliners

An assembly for use in bonding an trim cover to a foam pad along a pair of conveyor line in a process of a plurality of stations. A plurality of tool carriers are transported along each of the conveyor lines to each station. The tool carrier supports at least one mold assembly for bonding an air impervious adhesive film between the cover and the foam pad. A collar assembly pivotally supports a press platen above the mold assembly and provides pivotal movement between an open position spaced at a predetermined angle above the mold assembly and a closed position compressing the foam pad against the trim cover and mold assembly. The tool carrier includes a pair of vacuum inlet connectors for engagement by a vacuum snorkel to provide vacuum pressure to the mold assembly and travel with the tool carrier along the conveyor line between consecutive process stations. The tool carrier also includes a pair of heat connectors and a second dirty vacuum connector which are engaged at several stations by heat snorkels and a vacuum snorkel, respectively, to provide heat to the mold assembly for melting the adhesive and then dirty vacuum pressure to cure the bond between the trim cover and foam pad. A striker assembly is positioned above the tool carrier at two different process stations for pivoting and locking the press platen between the open and closed positions.

Method and apparatus for bonding a trim cover to a foam pad along a

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Plymouth, MI, United States of America

Scott A Barber