A method of manufacturing a headliner assembly for use in the interior compartment of an automotive vehicle comprising the steps of: placing a mold release film onto a concave mold surface of a lower mold assembly for providing a barrier against the mold surface; placing a fiber mat on the mold rele
A method of manufacturing a headliner assembly for use in the interior compartment of an automotive vehicle comprising the steps of: placing a mold release film onto a concave mold surface of a lower mold assembly for providing a barrier against the mold surface; placing a fiber mat on the mold release film; applying a foamable material directly onto the fiber mat; expanding the foamable material around the fiber mat to embed the fiber mat therein; placing an adhesive film onto a convex mold surface of an upper mold assembly; positioning the lower mold assembly directly beneath the upper mold assembly; moving the upper mold assembly in mating engagement with the lower mold assembly to define a mold cavity between the convex mold surface and concave mold surface; curing the foamable material within the mold cavity; and bonding the mold release film and adhesive film to the foamable material with the fiber mat embedded therebetween. A layer of scrim is then adhered to the mold release film and a layer of fabric is adhered to the adhesive film for providing a decorative cover to the headliner assembly.
대표청구항▼
What is claimed is: 1. A headliner for an interior compartment of a vehicle, the vehicle having a roof defined by a length and a width, said headliner comprising: a foam core having a length and width dimensioned to substantially cover the length and width of the roof of the vehicle, wherein a port
What is claimed is: 1. A headliner for an interior compartment of a vehicle, the vehicle having a roof defined by a length and a width, said headliner comprising: a foam core having a length and width dimensioned to substantially cover the length and width of the roof of the vehicle, wherein a portion of said foam core defines a head impact contour formed on a first surface of the foam core, said head impact contour including a series of undulations, wherein said series of undulations manage a load associated with head impact whereby the load is distributed among a plurality of the undulations under a head impact condition, wherein said series of undulations comprise a series of peaks separated by valleys, wherein said series of peaks are adapted to manage the load associated with head impact under a head impact condition, and wherein each of said valleys include a depth, said foam core comprises a material, and said series of undulations are provided on said first surface of said foam core and define a first surface profile, and wherein a sidewall connects each of said peaks and valleys such that two sidewalls envelope each peak, and further wherein said material extends uninterrupted below the envelope of each of said peaks and extends to a depth greater than said depth of any adjacent valley. 2. A headliner according to claim 1, wherein a transition between at least one peak and an adjacent valley is non-linear. 3. A headliner according to claim 1, wherein one of at least one peak defined by said series of peaks and at least one valley define a curved surface. 4. A headliner according to claim 1, further comprising a fiberglass mat embedded within said foam layer. 5. A headliner for a vehicle having a roof, the roof having a length and a width, said headliner comprising: a core comprised of a foam material having a length and width dimensioned substantially coextensive with the length and width of the root said foam core defining at least one body impact energy absorbing area adapted to manage energy attributed to impact of a body thereon, said at least one body impact energy absorbing area including a plurality of zones of increased foam material, each of said zones defining a crest of a peak, wherein each of said peaks are separated by a zone of decreased material that defines a basin of a valley, and wherein said material has a thickness at the basin that is less than a material thickness at the crest, and further wherein multiple peaks dissipate energy associated with impact of a head thereon during a head impact condition, wherein said peaks and valleys define a series of undulations on a first surface of said foam core such that a plurality of undulations dissipate energy associated with the impact of the head during the head impact condition, wherein said valleys include a depth and wherein said foam material is uninterrupted under each of said peaks to a depth greater than said depth of said valleys immediately adjacent said peak. 6. A headliner according to claim 5, wherein said series of peaks and valleys form a sinusoidal profile. 7. A headliner according to claim 5, wherein a transition between at least one peak and an adjacent valley is non-linear. 8. A headliner according to claim 5, wherein one of at least one peak and at least one valley define a curved surface. 9. A headliner for an interior compartment of a vehicle comprising: a foam core having a portion that defines a head impact contour formed on a first surface of the foam core, said head impact contour including a series of undulations, wherein said series of undulations manage a load associated with head impact whereby the load is distributed among a plurality of the undulations under a head impact condition, wherein said first surface along said head impact contour has a first profile and a second surface opposing said first surface has a second profile, and wherein said undulations are provided on said first surface to define said first profile, and further wherein said second profile is asymmetric from said first profile. 10. A headliner for an interior compartment of a vehicle comprising: a foam core defining a head impact contour formed on a first surface of the foam core, said head impact contour including a series of undulations, wherein said series of undulations manage a load associated with head impact whereby the load is distributed among a plurality of the undulations under a head impact condition, wherein said series of undulations comprise a series of peaks separated by valleys, wherein said series of peaks are adapted to manage the load associated with head impact under a head impact condition, wherein each of said valleys have a depth, and wherein all portions of a second surface of said foam core opposite said first surface and beneath an envelope of any one of said series of peaks extends continuously beneath said depth of any adjacent valleys such that foam material is uninterrupted under the envelope to a depth greater than said depth of said adjacent valleys.
Fletemier Todd ; Ette Robert ; Long Richard, Laminated structures with multiple denier polyester core fibers, randomly oriented reinforcement fibers, and methods of manufacture.
Helwig Gregory S. ; Pathmanathan Vallipuram,GBX ; Heseltine Robert W.,GBX, Method for producing a non-woven glass fiber mat comprising bundles of fibers.
Klapper Kenneth P. (Hillsborough County FL) Laughlin Wayne E. (Pinellas County FL) Oliver John P. (Pinellas County FL), Thermoformable polyisocyanurate foam laminates for interior finishing applications.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.