CA1140037A - Self-supporting automotive liner panel - Google Patents
Self-supporting automotive liner panelInfo
- Publication number
- CA1140037A CA1140037A CA000337937A CA337937A CA1140037A CA 1140037 A CA1140037 A CA 1140037A CA 000337937 A CA000337937 A CA 000337937A CA 337937 A CA337937 A CA 337937A CA 1140037 A CA1140037 A CA 1140037A
- Authority
- CA
- Canada
- Prior art keywords
- layer
- liner panel
- thickness
- substrate layer
- automotive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R13/0212—Roof or head liners
- B60R13/0225—Roof or head liners self supporting head liners
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
Abstract
ABSTRACT
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 a heat resistant expanded styrene copolymer formed by the copolymerization of styrene and maleic anhydride which is relatively rigid and has a substantial resistance to bending. The intermediate layer is formed of a relatively soft, compressible, flexible, urethane foam.
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 a heat resistant expanded styrene copolymer formed by the copolymerization of styrene and maleic anhydride which is relatively rigid and has a substantial resistance to bending. The intermediate layer is formed of a relatively soft, compressible, flexible, urethane foam.
Description
~V(3;~7 .
Title: "Self-Supporting Automotive Liner Panel"
This invention relates generally to panels and refers more particularly to self-supporting automotive headliner panels.
Summary of the Invention The panel of this invention includes a substrate layer formed to the required contour for installation. The substrate layer is formed of a heat-resistant expanded plastics material which i5 relatively light in weight, is easily molded or thermoformed, and is rigid or stiff enough to hold its shape. Suitable foamed plastics materials are polystyrene, urethane, polypropylene and a copolymer of s-tyrene and maleic anhydride.
The panel also includes an in-termediate layer oE
relatiively soft compressible, flexible, expanded plas~ics material. Such mater;.al has a soet feel, is heak and sound lnsulatiny, w:ill conceal impereections in the sub-strate layer, and is relatively light in weiyht. A suitable material is flexible, compressible, polyester urethane foam. Another suitable material is latex.
The panel also includes a flexible decorative finish cover layer extending over the intermediate layer.
A knitted cloth or a vinyl skin may be used. The cover layer provides a decorative, attractive finish but without ~P
~OC~37 detracting from the softness to the touch imparted by the intermediate layer.
Brief ~escription_of the DrawinqS
Fig. 1 is a fragmentary elevational view of an automobile provided with a headliner panel constructed in accordance with this invention.
Fig. 2 is a perspective view of the headliner shown in Fig. 1.
Fig. 3 is a cross sectional view of the headliner shown installed in the roof o an automobile.
Detailed Description Referring now more particularly to the drawing, the automotive panel is shown as being in the form of a headliner and is generally designated H. I-t is installed lS in the roof of the automobile A by any suitable means, not shown. Accessories such as the housing for the shoulder harness, the dome light and sun visor brackets may be at least a part of the means for securin~ the headliner in place. The headliner is shown with cut-ou-k portions for these accesso.ries.
The headliner H is made up of a substrate 12 of relatively sti~f expanded plastics material, an inter-mediate layer 14 of relatively soft sound absorbing ex-panded plastics material, and a flexible decorative finish cover layer 16.
One very suitable ma-terial from which the sub~
strate 12 may be made is expanded polystyrene. A panel ~ .
:~L400;37 or sheet o~ that material is heat resistant and has a substantial resistance to ben~ing. It ma~ be ~ormed either by molding or by thermoforming an extruded sheet.
It is kept thin in order to reduce its weight although it has sufficient thickness to hold its shape. A thick-ness range of .040" to .250" is suitable for a substrate of expanded polystyrene, although .150" to .180~' is preferred.
The expanded polystyrene substrate 12 may have a density of 2-8 pounds per cubic foot, four pounds per cubic foot being preferred, and be made by molding in a closed mold in accordance with conventional practice, using expandable beads or pellets and a suitable blowing agent. A measured quantity of the beads are charged into a mold cavity having the contour required to be imparted to the substrate sheet for installation in the automobile.
Upon heating with low pressure steam, say 8-40 p.s.i., the blowing agent vaporizes to form distinctive cells within the softened polystyrene and with continued heating, adjacent cells weld together to form a common wall. E~pansion of the mass will continue un~il an inter connected cell structure con~orms to the shape of the mold. Subsequent cooling will fix the shape of the molded panel or sheet which can -then be ejected from the mold.
Molding of the substrate requires a rather expensive die but the end product comes out in the exact form, size and shape required.
The substrate may if desired be extruded in a flat sheet of the desired substrate thickness and then thermoformed to the correct contour on a heated pattern or die. During the extrusion process, the blowing agent may be introduced into the barrel of an ex-truder and the ,.....
~0~3~37 expandable resin extruded while expanding through an annular die, pulled over a sizing mandrel and slit to sheet form. The extruded sheet is then laid over the pattern or die and hea-t is applied to it in any suita~le manner as by the use o~ overhead heaters. A pat-tern or die is considerably less expensive than a mold. The sheet after being thermoformed on the pattern or die becomes sufficiently rigid ko hold its shape.
The substrate may also be extruded in sheet form and then compression molded in matached metal dies.
The procedures both for moldi.ng and for ex-truding followed by thermoforming to produce a self-supporting suhstrate of expanded polystyrene are well known and summarized in "Modern Plastics Encyclopedia", Volume 50, ~o. 10A, 1973-74, particularly on Pages 164-166, 362-372, and Volume 51, No. 10A, 1974-75, partic~
ularly on Pages 134-135, 366-371.
While expanded polystyrene has been ~o~md to be an excellent material erom which to forrn the sub-strat2 layer 12, an expanded styrene copolymer formecl by the copolyrnerization of styrene and maleic anhydride which is equally as stiff and resistant to bending, is preferred primarily because it has a higher heat resist-ance than polystyrene. One such copolymer containin~
6%-20% by weight of maleic anhydride, available under the trademark Dylark, is particularly recommended and has a heat resistance as much as 35F. higher than poly-styrene. The heat resistance of the expanded styrene copolymer known as Dylark, in testing based on deflection under load, indicated a heat resistance without appreciahle ~4~3~3~
deflection under load up to a -temperature of almost 240F., whereas polystyrene in a similar test deflected under load at slightly over 200F.
Substrates o an expanded styrene copolymer formed by the copolymeriza-tion o styrene and maleic anhydride can be molded or extrudea and thermoformed by the same procedures described above for expanded poly-styrene. A typical melt temperature molding range for the styrene copolymer is 400F. to 525F. A mold tem-perature range of 120F. to 170F. is recommended. Atypical melt tempera~ure range for extrusion is 380~F.
to 425F.
Dylark is available from Arco Polymers, Inc., a subsidiary of Atlantic Richfield Company, Philadelphia, PennSylvania.
Other suitable materials which may be used to form the substrate 12 are expanded urethaneand expanded polypropylene. Both of these materials provide ade~uate stiffness and lightness o~ weight. The th:ickness and
Title: "Self-Supporting Automotive Liner Panel"
This invention relates generally to panels and refers more particularly to self-supporting automotive headliner panels.
Summary of the Invention The panel of this invention includes a substrate layer formed to the required contour for installation. The substrate layer is formed of a heat-resistant expanded plastics material which i5 relatively light in weight, is easily molded or thermoformed, and is rigid or stiff enough to hold its shape. Suitable foamed plastics materials are polystyrene, urethane, polypropylene and a copolymer of s-tyrene and maleic anhydride.
The panel also includes an in-termediate layer oE
relatiively soft compressible, flexible, expanded plas~ics material. Such mater;.al has a soet feel, is heak and sound lnsulatiny, w:ill conceal impereections in the sub-strate layer, and is relatively light in weiyht. A suitable material is flexible, compressible, polyester urethane foam. Another suitable material is latex.
The panel also includes a flexible decorative finish cover layer extending over the intermediate layer.
A knitted cloth or a vinyl skin may be used. The cover layer provides a decorative, attractive finish but without ~P
~OC~37 detracting from the softness to the touch imparted by the intermediate layer.
Brief ~escription_of the DrawinqS
Fig. 1 is a fragmentary elevational view of an automobile provided with a headliner panel constructed in accordance with this invention.
Fig. 2 is a perspective view of the headliner shown in Fig. 1.
Fig. 3 is a cross sectional view of the headliner shown installed in the roof o an automobile.
Detailed Description Referring now more particularly to the drawing, the automotive panel is shown as being in the form of a headliner and is generally designated H. I-t is installed lS in the roof of the automobile A by any suitable means, not shown. Accessories such as the housing for the shoulder harness, the dome light and sun visor brackets may be at least a part of the means for securin~ the headliner in place. The headliner is shown with cut-ou-k portions for these accesso.ries.
The headliner H is made up of a substrate 12 of relatively sti~f expanded plastics material, an inter-mediate layer 14 of relatively soft sound absorbing ex-panded plastics material, and a flexible decorative finish cover layer 16.
One very suitable ma-terial from which the sub~
strate 12 may be made is expanded polystyrene. A panel ~ .
:~L400;37 or sheet o~ that material is heat resistant and has a substantial resistance to ben~ing. It ma~ be ~ormed either by molding or by thermoforming an extruded sheet.
It is kept thin in order to reduce its weight although it has sufficient thickness to hold its shape. A thick-ness range of .040" to .250" is suitable for a substrate of expanded polystyrene, although .150" to .180~' is preferred.
The expanded polystyrene substrate 12 may have a density of 2-8 pounds per cubic foot, four pounds per cubic foot being preferred, and be made by molding in a closed mold in accordance with conventional practice, using expandable beads or pellets and a suitable blowing agent. A measured quantity of the beads are charged into a mold cavity having the contour required to be imparted to the substrate sheet for installation in the automobile.
Upon heating with low pressure steam, say 8-40 p.s.i., the blowing agent vaporizes to form distinctive cells within the softened polystyrene and with continued heating, adjacent cells weld together to form a common wall. E~pansion of the mass will continue un~il an inter connected cell structure con~orms to the shape of the mold. Subsequent cooling will fix the shape of the molded panel or sheet which can -then be ejected from the mold.
Molding of the substrate requires a rather expensive die but the end product comes out in the exact form, size and shape required.
The substrate may if desired be extruded in a flat sheet of the desired substrate thickness and then thermoformed to the correct contour on a heated pattern or die. During the extrusion process, the blowing agent may be introduced into the barrel of an ex-truder and the ,.....
~0~3~37 expandable resin extruded while expanding through an annular die, pulled over a sizing mandrel and slit to sheet form. The extruded sheet is then laid over the pattern or die and hea-t is applied to it in any suita~le manner as by the use o~ overhead heaters. A pat-tern or die is considerably less expensive than a mold. The sheet after being thermoformed on the pattern or die becomes sufficiently rigid ko hold its shape.
The substrate may also be extruded in sheet form and then compression molded in matached metal dies.
The procedures both for moldi.ng and for ex-truding followed by thermoforming to produce a self-supporting suhstrate of expanded polystyrene are well known and summarized in "Modern Plastics Encyclopedia", Volume 50, ~o. 10A, 1973-74, particularly on Pages 164-166, 362-372, and Volume 51, No. 10A, 1974-75, partic~
ularly on Pages 134-135, 366-371.
While expanded polystyrene has been ~o~md to be an excellent material erom which to forrn the sub-strat2 layer 12, an expanded styrene copolymer formecl by the copolyrnerization of styrene and maleic anhydride which is equally as stiff and resistant to bending, is preferred primarily because it has a higher heat resist-ance than polystyrene. One such copolymer containin~
6%-20% by weight of maleic anhydride, available under the trademark Dylark, is particularly recommended and has a heat resistance as much as 35F. higher than poly-styrene. The heat resistance of the expanded styrene copolymer known as Dylark, in testing based on deflection under load, indicated a heat resistance without appreciahle ~4~3~3~
deflection under load up to a -temperature of almost 240F., whereas polystyrene in a similar test deflected under load at slightly over 200F.
Substrates o an expanded styrene copolymer formed by the copolymeriza-tion o styrene and maleic anhydride can be molded or extrudea and thermoformed by the same procedures described above for expanded poly-styrene. A typical melt temperature molding range for the styrene copolymer is 400F. to 525F. A mold tem-perature range of 120F. to 170F. is recommended. Atypical melt tempera~ure range for extrusion is 380~F.
to 425F.
Dylark is available from Arco Polymers, Inc., a subsidiary of Atlantic Richfield Company, Philadelphia, PennSylvania.
Other suitable materials which may be used to form the substrate 12 are expanded urethaneand expanded polypropylene. Both of these materials provide ade~uate stiffness and lightness o~ weight. The th:ickness and
2~ density ranges specified ~or expanded polystyrene also apply to substrate layers o~ expanded urethane, expanded polypropylene or an expanded styrene copolymer formed by the copolyrnerization of styrene and rnaleic anhydride including -the copolymer known as Dylark.
The substrate layer 12 may be perforated to provide a multiplicity of holes over its entire surface to improve the acoustical insulation of the panel. A hole size of .060" to .190" is recommended, preferably .170".
The intermediate relatively soft compressible ,~
layer 14 o sound absorbing ma-terial is made o~ ible compressible ure-thane ~oam, pre~erably a polyester urethane foam. A polyester urethane ~oam is preferred because it responds well to flame treatment for rendering its surface tacky enough to bond to the decorative cover layer or the substrate layer, as described more fully hereinaEter.
It is formed to approximately the same length and width dimenslons as the substrate 12, or sometimes toslightly : lesser dimensions to ~acilitate installation of the head-10 liner, and is sufficiently flexible to follow the contourof the substrate when adhered thereto as by a layer 17 of an adhesive. A suitable adhesive is a water soluble or water dispersed synthetic resinous adhesive, such for example as resin-latex. The intermediate layer 14 is not only sound absorbing as well as hea-t absorbing but protects the substrate from denting and conceals any dents in it that may exist. The soft urethane layer 14 also gives a rich texture or feel to the headliner. Its thickness will be determined primarily by the qualities oP heat and sound insulation and softness of Eeel desired, and generally will be in the range of .040" to .750", but preferably .060" to .500~. The density of the inter~
mediate layer may be 1 to 8 pounds per cubic foot, and preEerably 1 to 4 pounds per cubic Eoot.
The flexible foam layer 14 of urethane may be made by conventional molding techniques in a mold having the desired dimensions of the finished product.
The molded part may be vacuum formed over the substrate 12 and secured thereto by an adhesive such as described above. The flexible urethane foam layer 14 may also be formed by spraying it directly on the back of the sub~
strate 12 in which case no adhesive is required.
i~` 1 '
The substrate layer 12 may be perforated to provide a multiplicity of holes over its entire surface to improve the acoustical insulation of the panel. A hole size of .060" to .190" is recommended, preferably .170".
The intermediate relatively soft compressible ,~
layer 14 o sound absorbing ma-terial is made o~ ible compressible ure-thane ~oam, pre~erably a polyester urethane foam. A polyester urethane ~oam is preferred because it responds well to flame treatment for rendering its surface tacky enough to bond to the decorative cover layer or the substrate layer, as described more fully hereinaEter.
It is formed to approximately the same length and width dimenslons as the substrate 12, or sometimes toslightly : lesser dimensions to ~acilitate installation of the head-10 liner, and is sufficiently flexible to follow the contourof the substrate when adhered thereto as by a layer 17 of an adhesive. A suitable adhesive is a water soluble or water dispersed synthetic resinous adhesive, such for example as resin-latex. The intermediate layer 14 is not only sound absorbing as well as hea-t absorbing but protects the substrate from denting and conceals any dents in it that may exist. The soft urethane layer 14 also gives a rich texture or feel to the headliner. Its thickness will be determined primarily by the qualities oP heat and sound insulation and softness of Eeel desired, and generally will be in the range of .040" to .750", but preferably .060" to .500~. The density of the inter~
mediate layer may be 1 to 8 pounds per cubic foot, and preEerably 1 to 4 pounds per cubic Eoot.
The flexible foam layer 14 of urethane may be made by conventional molding techniques in a mold having the desired dimensions of the finished product.
The molded part may be vacuum formed over the substrate 12 and secured thereto by an adhesive such as described above. The flexible urethane foam layer 14 may also be formed by spraying it directly on the back of the sub~
strate 12 in which case no adhesive is required.
i~` 1 '
3~ ' The intermediate layer 14 has for its primary purposes to provide sound insulation and a soft feel and due to its softness it hides dents that may occur in the substrate 12. While flexible urethane is preferred be-cause it rates high in these ~ualities, and also is a good heat insulator and is light in weight, the layer 14 may if desired be made of other materials having similar properties, such for example as latex. The layer 14 formed of latex would have the same thickness and density L0 ranges as specified for urethane foam and ahered to the layer 12 in the same ~anner as if formed of urethane.
The procedures for molding the flexible urethane foam layer 14 are well known and summarized in the volumes of "Modern Plastics Encyclopedia", previously referred to, particularly pages 134-137, of Volume 50, ~o. lOA of 1973-74, and Pages 136-138 of Volume 51, ~o. 10~, 1974-75~
Instead of utilizing a layer of adhesive to bond the layers 12 and 14 together, they rnay be bonded to one another in ~urface-to-~ur~ace contact without any inter-vening layer or film of adhesive, as for example by flame laminating in which one o the contacting surfaces, such as the surface of the intermediate layer 14, is softened and rendered tacky by the application of heat from a torch so that upon application to the substrate layer, the con-tac~ing surfac~ will weld or fuse together. Securing layers 12 and 14 together in this manner is preferred because it eliminates the need for an adhesive, provides a superior bond and does not stiffen the intermediate layer 14 as an adhesive tends to do.
The finish layer 16 is a flexible decorative cover layer and may consist of a thin vinyl skin or a ~;~`
:
, ' . ' ~, ~ ', ' :
, O~
piece oE cloth. I-t will have the same length and width dimensions as the intermediate layer 14 and will be secured to the side of the intermediate layer 14 opposite the substrate 12. Preferably, the two layers 1~ and 1~
will be fused together in an intimate surface-to-surface contacting relation without any intervening adhesive material. For this purpose, flame laminating by heating the surface of the intermediate layer sufficiently to render it tacky and to fuse to the cover layer upon con-tact, may be employed. Alternatively, an adhesive suchas described above may be use~ to adhere the cover layer to the intermediate layer. However, an adhesive between these layers may detract from the soft feel of the head-liner by preventing the softness'of the intermediate urethane layer from transmitting through to the cover layer.
A finish vinyl cover layer should preferably be extremely thin, within a suggested thickness range of .005"
to .010" so as to be very flexi~le and to readily -transmit the softness of the intermediate urethane layer. It may be perforated, that is formed with a multiplicity of small holes, or unper~orated.
~ cloth forrned of knitted material serves as an excel]ent finish cover layer. Pre~erably a cloth of a tricot type construction which has been knitted, then dyed, and then napped for finished appearance is preferred.
The headliner H is shown in FigO 3 installed in an automobile with the substrate 12 held up against the auto roof 20 by any suitable means. The substrate has been formed to -the desired contour for installation and as before noted has a substantial resistance to bending so as to hold the shape of the headliner~ This inter-mediate layer 14 is sound insulating, provides a rich _g_ -textur~ or feel and covers and canceals an~ ~ents or imperfections in the substrate. Italgo insulates against heat. The layer 16 on -the exposed side provides a decorative finish.
The procedures for molding the flexible urethane foam layer 14 are well known and summarized in the volumes of "Modern Plastics Encyclopedia", previously referred to, particularly pages 134-137, of Volume 50, ~o. lOA of 1973-74, and Pages 136-138 of Volume 51, ~o. 10~, 1974-75~
Instead of utilizing a layer of adhesive to bond the layers 12 and 14 together, they rnay be bonded to one another in ~urface-to-~ur~ace contact without any inter-vening layer or film of adhesive, as for example by flame laminating in which one o the contacting surfaces, such as the surface of the intermediate layer 14, is softened and rendered tacky by the application of heat from a torch so that upon application to the substrate layer, the con-tac~ing surfac~ will weld or fuse together. Securing layers 12 and 14 together in this manner is preferred because it eliminates the need for an adhesive, provides a superior bond and does not stiffen the intermediate layer 14 as an adhesive tends to do.
The finish layer 16 is a flexible decorative cover layer and may consist of a thin vinyl skin or a ~;~`
:
, ' . ' ~, ~ ', ' :
, O~
piece oE cloth. I-t will have the same length and width dimensions as the intermediate layer 14 and will be secured to the side of the intermediate layer 14 opposite the substrate 12. Preferably, the two layers 1~ and 1~
will be fused together in an intimate surface-to-surface contacting relation without any intervening adhesive material. For this purpose, flame laminating by heating the surface of the intermediate layer sufficiently to render it tacky and to fuse to the cover layer upon con-tact, may be employed. Alternatively, an adhesive suchas described above may be use~ to adhere the cover layer to the intermediate layer. However, an adhesive between these layers may detract from the soft feel of the head-liner by preventing the softness'of the intermediate urethane layer from transmitting through to the cover layer.
A finish vinyl cover layer should preferably be extremely thin, within a suggested thickness range of .005"
to .010" so as to be very flexi~le and to readily -transmit the softness of the intermediate urethane layer. It may be perforated, that is formed with a multiplicity of small holes, or unper~orated.
~ cloth forrned of knitted material serves as an excel]ent finish cover layer. Pre~erably a cloth of a tricot type construction which has been knitted, then dyed, and then napped for finished appearance is preferred.
The headliner H is shown in FigO 3 installed in an automobile with the substrate 12 held up against the auto roof 20 by any suitable means. The substrate has been formed to -the desired contour for installation and as before noted has a substantial resistance to bending so as to hold the shape of the headliner~ This inter-mediate layer 14 is sound insulating, provides a rich _g_ -textur~ or feel and covers and canceals an~ ~ents or imperfections in the substrate. Italgo insulates against heat. The layer 16 on -the exposed side provides a decorative finish.
Claims (12)
1. A laminated self-supporting, automotive liner panel of predetermined contour consisting of an outer substrate layer of a heat resistant, expanded styrene copolymer formed by the copolymerization of styrene and maleic anhydride which is relatively rigid and has a substantial resistance to bending, an inter-mediate layer of relatively soft, compressible, flexible urethane foam bonded to one side of said substrate layer in direct surface-to-surface contact therewith, said intermediate layer being of sufficient thickness to pro-vide heat and sound insulation, to provide a soft feel and to conceal imperfections in said substrate layer, and an outer flexible decorative finish cover layer bonded to the side of said intermediate layer opposite said sub-strate layer in direct surface-to-surface contact there-with.
2. A laminated, self-supporting, automotive liner panel of predetermined contour consisting of an outer substrate layer of a heat resistant, expanded styrene copolymer formed by the compolmerization of styrene and maleic anhydride which is relatively rigid and has a substantial resistance to bending, an intermediate layer of relatively soft, compressible, flexible urethane foam bonded to one side of said substrate layer by means of an intervening layer of adhesive, said intermediate layer being of sufficient thickness to provide heat and sound insulation, to provide a soft feel and to conceal imper-fections in said substrate layer, and an outer flexible decorative finish cover layer bonded to the side of said intermediate layer opposite said substrate layer in direct surface-to-surface contact therewith.
3. The automotive line panel defined in Claim 2, wherein said adhesive is a water soluble synthetic resinous adhesive.
4. The automotive liner panel defined in Claim 1 or 2, wherein said copolymer contains about 6%-20%
by weight of maleic anhydride.
by weight of maleic anhydride.
5. The automotive liner panel defined in Claim 1 or 2, wherein said substrate layer has a thickness of .040"-.250" and a density of 2 to 8 pounds per cubic foot.
6. The automotive liner panel defined in Claim 1 or 2, wherein said intermediate layer has a thickness of .040"-.750" and a density of 1 to 8 pounds per cubic foot.
7. The automotive liner panel defined in Claim 1, wherein said substrate layer has a thickness of .150"-.180" and a density of 4 pounds per cubic foot, and said intermediate layer has a thickness of .060"-500"
and a density of 1 to 4 pounds per cubic foot.
and a density of 1 to 4 pounds per cubic foot.
8. The automotive liner panel defined in Claim 7, wherein said cover layer is cloth of a tricot type con-struction which has been knitted, dyed, and then napped for finished appearance.
9. The automotive liner panel defined in Claim 7, wherein said cover layer is a vinyl skin having a thickness of .005"-.010".
10. The automotive liner panel defined in claim 2, wherein said substrate layer has a thickness of .150"-.180" and a density of 4 pounds per cubic foot, and said intermediate layer has a thickness of .060"-500" and a density of 1 to 4 pounds per cubic foot.
11. The automotive liner panel defined in claim 10, wherein said cover layer is cloth of a tricot type construction which has been knitted, dyed, and then napped for finished appearance.
12. The automotive liner panel defined in Claim 10, wherein said cover layer is a vinyl skin having a thickness of .005"-.010".
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/005,956 US4188440A (en) | 1975-07-02 | 1979-01-24 | Self-supporting automotive liner panel |
| US005,956 | 1979-01-24 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1140037A true CA1140037A (en) | 1983-01-25 |
Family
ID=21718551
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000337937A Expired CA1140037A (en) | 1979-01-24 | 1979-10-18 | Self-supporting automotive liner panel |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP0022795A4 (en) |
| JP (2) | JPS56500208A (en) |
| CA (1) | CA1140037A (en) |
| WO (1) | WO1980001550A1 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20060062970A1 (en) | 2004-04-19 | 2006-03-23 | Martin James N | Embossed headliner and method of making same |
| ES2348167T3 (en) * | 2006-08-03 | 2010-11-30 | HENKEL AG & CO. KGAA | REDUCTION OF THE TRANSFER OF VIBRATIONS. |
| WO2019021676A1 (en) * | 2017-07-27 | 2019-01-31 | 林テレンプ株式会社 | Vehicle interior material and production method for vehicle interior material |
| WO2021108498A1 (en) * | 2019-11-25 | 2021-06-03 | Shawmut Llc | Discontinuous thermoformable composite products |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3755063A (en) * | 1970-03-09 | 1973-08-28 | Xox Corp | Thermoformable laminated structures |
| SE383999B (en) * | 1972-12-07 | 1976-04-12 | Dynamit Nobel Ag | INTERIOR CLOTHING FOR MOTOR VEHICLES, CONTAINERS ETC. |
| DE2365203B2 (en) * | 1973-12-31 | 1977-02-03 | Dynamit Nobel Ag, 5210 Troisdorf | PRODUCTION OF MULTI-LAYER SHEETS, PLATES, MOLDED PARTS |
| US4172918A (en) * | 1975-07-02 | 1979-10-30 | Van Dresser Corporation | Automotive liner panel |
| US4256797A (en) * | 1976-09-02 | 1981-03-17 | Inmont Corporation | Contoured resilient vehicle trim panel |
-
1979
- 1979-10-12 JP JP50015179A patent/JPS56500208A/ja active Pending
- 1979-10-12 WO PCT/US1979/000832 patent/WO1980001550A1/en not_active Application Discontinuation
- 1979-10-18 CA CA000337937A patent/CA1140037A/en not_active Expired
-
1980
- 1980-08-15 EP EP19800900036 patent/EP0022795A4/en not_active Withdrawn
-
1987
- 1987-01-17 JP JP1987005437U patent/JPS62194029U/ja active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| EP0022795A1 (en) | 1981-01-28 |
| EP0022795A4 (en) | 1981-04-24 |
| WO1980001550A1 (en) | 1980-08-07 |
| JPS62194029U (en) | 1987-12-10 |
| JPS56500208A (en) | 1981-02-26 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |