Method of making a multiple-density fibrous acoustical panel

Abstract

An improved acoustical and trim acoustical panel suitable for use in the interior passenger compartments and exterior components of automotive vehicles or the like, comprising a plurality of fibrous layers of controlled different density, integrally united together at their interfaces and optionally provided with a decorative finish on one or both outer face surfaces thereof. The invention is further directed to novel methods for making such trim panels incorporating preselected contours and localized embossments therein to conform to the contour of the structural panels of vehicle bodies over which the trim panels are adapted to be mounted. In accordance with one process embodiment, a fibrous pad is formed incorporating suitable binding agents and a coextensive impervious membrane or film disposed intermediate of the face surfaces thereof. The composite pad is placed in an appropriately contoured mold and pneumatic pressure is applied to one side thereof to effect a densification and molding of the stratum of fibers disposed between the membrane and the mold surface without appreciably compacting the opposite fibrous layer, while simultaneously setting the binding agent to form a contoured shape-retaining pad having a dual-density fibrous structure.