CA2124407C - Fiber glass composite headliner and method of making the same - Google Patents
Fiber glass composite headliner and method of making the sameInfo
- Publication number
- CA2124407C CA2124407C CA 2124407 CA2124407A CA2124407C CA 2124407 C CA2124407 C CA 2124407C CA 2124407 CA2124407 CA 2124407 CA 2124407 A CA2124407 A CA 2124407A CA 2124407 C CA2124407 C CA 2124407C
- Authority
- CA
- Canada
- Prior art keywords
- fiber glass
- layer
- glass insulation
- backing sheet
- polypropylene
- 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 - Fee Related
Links
Landscapes
- Laminated Bodies (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
A self-supporting automotive headliner comprises a vapor impervious, polypropylene and wood fiber backing sheet with a corrugated paperboard medium adhered thereto and a layer of fiber glass insulation adhered to the corrugated paperboard medium.
The backing sheet and paperboard medium provide the structural strength for the self-supporting headliner panel and the fiber glass insulation gives the headliner panel good sound absorption properties. When forming the headliner panel, the corrugated paperboard medium is located on the backing sheet which comprises wood and polypropylene fibers and a layer of uncured fiber glass insulation is placed on the corrugated paperboard medium. The resulting laminate is molded under heat causing the polypropylene fibers in the backing sheet to melt and phenolic resin in the fiber glass insulation to cure thereby adhering the laminate together and conforming the laminate to the mold.
The backing sheet and paperboard medium provide the structural strength for the self-supporting headliner panel and the fiber glass insulation gives the headliner panel good sound absorption properties. When forming the headliner panel, the corrugated paperboard medium is located on the backing sheet which comprises wood and polypropylene fibers and a layer of uncured fiber glass insulation is placed on the corrugated paperboard medium. The resulting laminate is molded under heat causing the polypropylene fibers in the backing sheet to melt and phenolic resin in the fiber glass insulation to cure thereby adhering the laminate together and conforming the laminate to the mold.
Description
212~07 FIBER GLa8~ CO~PO8ITE
u~nT.TNER AND ~ D OF MARING T~B 8A~E
R~R~~~UND OF ~E INVENTION
This invention relates to panels for lining the interior surface of an automotive roof. More particularly, the invention relates to a self-supporting fiber glass composite headliner panel.
5The interior surface of an automobile roof is commonly cove~ed or lined with material which presents an attractive appearance and also acts as a sound absorber. Molded fiber glass panels and foam liners are examples of such liners. Basically, these products adequately perform the functions for which they 10were designed, but they are too ~p~n~ive to be used in econ' ~
automobiles. ~co~ ~ automobiles require a liner that is not only attractive and sound absorbing but one which is less costly.
one of the materials designers consider when confronted with the need to produce an in~p~n~ive sh~re~ product such as a 15he~l;n~r is wood fibers. Wood fibers are readily available, inexpensive and can be formed into ~arious shapes by a variety -of manufacturing techn;ques. Hardboard headliners have been manufactured from a wood fiber mat formed from an aqueous slurry.
The wood fiber mat is placed in a mold where resins in the wood 20fiber mat enable the mat to be compressed to a higher density and sh~pe~ under heat and pressure. However, this product is too heavy; it is difficult to mold; and it has poor acoustical pLope~Lies.
Other attempts to produce light, low cost hP~lin~rs 25involved forming the he~ nprs from two paperboard facers with a corrugated paperboard medium sandwiched between the paperboard facers. While inexpensive, these headliners lack adequate sound absorption properties and are difficult to form, without crackinq, into the ~ished shape required for a headliner panel.
-" ~12~L407 U.S. patent nos. 4,886,696 and 5,057,176, disclose a corrugated paperboard automotive headliner which solved many of the problems associated with the previously discussed headliners.
The headliner disclosed in these patents is self-supporting, inexpensive and exhibits surprisingly good sound absorption properties. While the headliner of the '696 and the '176 patents performs very well, the composite headliner of the present invention is inexpensive and provides another approach to solving the headliner problems associated with economy vehicles.
~UMM~Y OF T~E INVENTIO~
The self-supporting, composite, fiberglass headliner panel of the present invention combines the strength of a single faced corrugated sheet with the sound absorption qualities of fiber glass insulation. The single faced corrugated sheet forms the backing for the panel and comprises a vapor impervious, wood fiber filled polypropylene backing sheet and a corrugated paperboard medium. A layer of fiber glass insulation is adhered to the corrugated medium and forms the facing which is exposed to the interior of the vehicle for appearance and the absorption of sound.
In the manufacture of the self-~u~uLLing headliner panel, a coL,u~ated paperboard medium is located on a sheet of wood and polypropylene fibers and an uncured layer of fiber glass - insulation is located on the COL' u~dted paperboard medium. The resulting l inAte is placed in a heated mold. As the l~ ;n~te is shaped under heat and pressure, the polypropylene fibers in the backing sheet melt and flow around the wood fibers to cause the backing sheet to conform to the surface of the mold and to adhesively bond the corrugated medium to the backing sheet. At the same time, the resin in the fiber glass insulation cures to cause the layer of fiber glass insulation to conform to the surface of the mold and to adhesively bond the fiber glass layer to the corrugated medium.
The composite fiber glass headliner panel of the present invention is inexpensive. The he~liner panel is self-supporting and has greater strength than fiber glass or paperboard headliner ~ 1 2 ~
panels. For example, one headliner panel of the present invention could be used to line the roof of a van which now uses three headliner panels to cover the roof.
The single faced corrugated backing sheet gives the headliner panel sound tr~n! ;ssion loss while the fiber glass facing layer gives the headliner panel good sound absorption properties. Since the single faced corrugated backing sheet provides the strength for the laminate, "pillowed" areas can be used in the fiber glass facing layer for greater sound absorption without ~ ing the strength of the panel as is the case with all fiber glass headliner panels.
In the molding process, the polypropylene fibers in the backing sheet melt and the uncured phenolic resin in the fiber glass facing cures to act as the adhesives to bond the laminate together. Thus, the need to apply separate adhesives to the layers of the laminate to bond the laminate together is ~l; ;n~ted.
BRIEF D~UTPTION OF TH~ DRAWING8 FIG. 1 is a perspective view of an automotive he~liner panel of the present invention.
FIG. 2 is an enlarged partial sectional view of the headliner panel taken along line 2-2 of FIG. 1.
FIG. 3 is a schematic view of the method of forming the - headliner panel of the present invention.
~r~TPTION OF TH~ PREFERRED ~MRODTM~NT ~-FIG. 1 shows the self-supporting headliner panel 10 of the present invention which comprises a single-faced CO~L U~dted h~rking sheet 12 and a fiber glass facing layer 14. The headliner panel 10 is sh~pe~ to conform to the interior surface of an automotive roof with the convex surface of the headliner being installed adjacent the roof of the vehicle and the concave surface of the headliner being exposed to the interior of the veh~cle. The headliner panel may be installed in a vehicle by any of a variety of methods which generally utilize clips or other attachment devices. Since the methods of attaching 212~L~0 7 headliner panels to the roofs of vehicles are well known in the art and form no part of the present invention, the attachment devices are not shown.
As best shown in FIG. 2, the self-supporting headliner panel 10 of the present invention is a l~ in~te with a single faced corrugated backing sheet 12 that is installed in a vehicle adjacent or against the interior surface of the vehicle roof and a fiber glass facing layer 14 which is exposed to the interior of the vehicle. The single faced corrugated backing sheet 12 provides the structural strength of the laminate and the fiber glass facing layer 14 provides the sound absorbing properties of the laminate.
The single faced corrugated backing sheet 12 comprises a vapor impervious, wood fiber filled polypropylene sheet 16 with a corrugated paperboard medium 18 adhered thereto. The caliper of the wood fiber filled polypropylene backing sheet 16 is generally between 18 and 22 points. The preferred composition of the wood fiber filled polypropylene backing sheet 16 is about 65~ wood fibers and about 35% polypropylene by weight. However, the composition can range from 60% to 75% wood fibers and from 40% to 25% polypropylene by weight.
The preferred wood pulp fiber is a long, soft bleached southern pine which has been found to work better than short or hard wood fibers. The longer fibers function to decrease the - 2S density of the sheet 16 by creating loft. This causes the backing sheet 16 to conform more readily to the contour of the mold surface when the l~ in~te is being molded into the headliner panel 10. In addition, the longer length, soft bleached, southern pine fibers improve the tear strength of the h~ck;ng sheet 16 due to the greater entanglement of the longer fibers with ~u ,uunding fibers. The long southern pine fibers are between 50 and 150 microns long and have a diameter of between 20 to 60 microns and preferably between 30 to 50 microns. In addition to southern pine fibers, other long, soft pine fibers can also be used in the sheet 16.
In addition to providing structural strength to the laminate, the wood fiber filled polypropylene backing sheet 16 2124~07 also functions as a vapor barrier for the headliner panel 10 and prevents condensation from the metal vehicle roof from penetrating the headliner. This eliminates the need for a separate vapor barrier in the laminate and reduces the cost of the headliner panel.
The corrugated paperboard medium 18 is preferably a C flute which is 141 mils thick and contains 39 flutes per foot. The corrugated medium 18 should be at least 30 pounds per 1000 square feet of medium and can be up to 40 pounds per 1000 square feet of medium.
The fiber glass facing layer 14 is formed from a fiber glass insulation blanket having a density of between 4 and 10 pounds per cubic foot. The fiber glass facing layer 14 generally ranges in thickness from 1/8 of an inch up to about 1 1/2 inches. Since the backing sheet 16 and the corrugated medium 18 provide the structural strength of the panel laminate, portions of the fiber glass facing layer 14 can be formed at a lower density for better sound absorption without adversely affecting the strength of the headliner. These "pillowed" areas pose a problem in molded fiber glass headliners where the reduction in density of the fiber glass we~ken~ the panel.
The fiber glass composite headliner panel 10 is formed in a molding process. FIG. 3 shows a heated press 20 comprising a male mold ~-h~r 22 and a female mold - h~r 24. Both members - 25 contain heating units 26 such as electrical heaters or hot water lines which maintain the male and female non-planer press surfaces 28 and 30, respectively, at a predetermined molding temperature.
The molding temperature for this process ranges from 400 degrees to 570 degrees Fahrenheit. The curing time in the press for the laminate will vary dep~n~ing on the density of the fiber glass insulation used to form the facing layer 14.
As shown in FIG. 3, the self supporting he~liner panel is formed by locating the backing sheet 16 in the press. The backing sheet comprises wood fibers and polypropylene fibers.
The average diameter of the polypropylene fibers is between 1 and 8 microns and preferably between 1 and 4 microns. The average ~ 12 ~
diameter of the wood fibers is between 20 and 60 microns and preferably between 30 and 50 microns~ The average length of both the wood and polypropylene fibers is between 50 and 150 microns.
Sheets with larger diameter polypropylene fibers do not work in this process. When larger diameter polypropylene fibers are used in the sheet, the fibers migrate to the surface during the sheet forming process and the sheet does not process properly.
The corrugated paperboard medium 18 is located on the backing sheet 16 and a layer of uncured fiber glass insulation 14 between 4 and 6 inches thick is located on the corrugated paperboard medium. The press is then closed as shown in FIG. 3 by bringing the male mold member 22 down into the female mold member 24. The heat and pressure cause the polypropylene fibers in the backing sheet 16 to melt and flow around the wood fibers as the sheet conforms to the configuration of the female mold surface 30 thereby forming a vapor impervious sheet. The polypropylene also acts as an adhesive to bond the corrugated paperboard medium 18 to the backing sheet 16.
At the same time that the backing sheet 16 is being molded to conform to the surface 30 of the female mold h~r, the fiber glass insulation facing layer 14 is being cured and conformed to the surface 28 of the male mold h~r 22. As phenolic resin in the fiber glass insulation is cured, the resin functions as an adhesive to bond the fiber glass insulation facing layer 14 to - 25 the corrugated paperboard medium 13. When the fiber glass insulation facing layer is cured, the formed he~liner panel 10 is removed from the press 20.
While not shown, the backing sheet 16 and the corrugated paperboard medium 18 will be normally bonded together in a conventional heated corrugation -çh;ne prior to being il.LLod~ced into the press 20.
As shown in FIG. 3, the surface 28 of the male mold member 22 is inclined so that the spacing between the male mold surface 28 and the female mold surface 30 varies when the mold is closed.
Thus, the thickness and density of the fiber glass facing layer 14 varies from one area of headliner to another creating "pillowed" areas for better sound absorption in selected areas ~ 2~2~407 of the headliner. Since the single faced corrugated backing sheet 12 provides the structural strength for the self-supporting headliner panel, the l'pillowed" areas can be incorporated into the headliner without adversely affecting the physical properties of the headliner panel.
u~nT.TNER AND ~ D OF MARING T~B 8A~E
R~R~~~UND OF ~E INVENTION
This invention relates to panels for lining the interior surface of an automotive roof. More particularly, the invention relates to a self-supporting fiber glass composite headliner panel.
5The interior surface of an automobile roof is commonly cove~ed or lined with material which presents an attractive appearance and also acts as a sound absorber. Molded fiber glass panels and foam liners are examples of such liners. Basically, these products adequately perform the functions for which they 10were designed, but they are too ~p~n~ive to be used in econ' ~
automobiles. ~co~ ~ automobiles require a liner that is not only attractive and sound absorbing but one which is less costly.
one of the materials designers consider when confronted with the need to produce an in~p~n~ive sh~re~ product such as a 15he~l;n~r is wood fibers. Wood fibers are readily available, inexpensive and can be formed into ~arious shapes by a variety -of manufacturing techn;ques. Hardboard headliners have been manufactured from a wood fiber mat formed from an aqueous slurry.
The wood fiber mat is placed in a mold where resins in the wood 20fiber mat enable the mat to be compressed to a higher density and sh~pe~ under heat and pressure. However, this product is too heavy; it is difficult to mold; and it has poor acoustical pLope~Lies.
Other attempts to produce light, low cost hP~lin~rs 25involved forming the he~ nprs from two paperboard facers with a corrugated paperboard medium sandwiched between the paperboard facers. While inexpensive, these headliners lack adequate sound absorption properties and are difficult to form, without crackinq, into the ~ished shape required for a headliner panel.
-" ~12~L407 U.S. patent nos. 4,886,696 and 5,057,176, disclose a corrugated paperboard automotive headliner which solved many of the problems associated with the previously discussed headliners.
The headliner disclosed in these patents is self-supporting, inexpensive and exhibits surprisingly good sound absorption properties. While the headliner of the '696 and the '176 patents performs very well, the composite headliner of the present invention is inexpensive and provides another approach to solving the headliner problems associated with economy vehicles.
~UMM~Y OF T~E INVENTIO~
The self-supporting, composite, fiberglass headliner panel of the present invention combines the strength of a single faced corrugated sheet with the sound absorption qualities of fiber glass insulation. The single faced corrugated sheet forms the backing for the panel and comprises a vapor impervious, wood fiber filled polypropylene backing sheet and a corrugated paperboard medium. A layer of fiber glass insulation is adhered to the corrugated medium and forms the facing which is exposed to the interior of the vehicle for appearance and the absorption of sound.
In the manufacture of the self-~u~uLLing headliner panel, a coL,u~ated paperboard medium is located on a sheet of wood and polypropylene fibers and an uncured layer of fiber glass - insulation is located on the COL' u~dted paperboard medium. The resulting l inAte is placed in a heated mold. As the l~ ;n~te is shaped under heat and pressure, the polypropylene fibers in the backing sheet melt and flow around the wood fibers to cause the backing sheet to conform to the surface of the mold and to adhesively bond the corrugated medium to the backing sheet. At the same time, the resin in the fiber glass insulation cures to cause the layer of fiber glass insulation to conform to the surface of the mold and to adhesively bond the fiber glass layer to the corrugated medium.
The composite fiber glass headliner panel of the present invention is inexpensive. The he~liner panel is self-supporting and has greater strength than fiber glass or paperboard headliner ~ 1 2 ~
panels. For example, one headliner panel of the present invention could be used to line the roof of a van which now uses three headliner panels to cover the roof.
The single faced corrugated backing sheet gives the headliner panel sound tr~n! ;ssion loss while the fiber glass facing layer gives the headliner panel good sound absorption properties. Since the single faced corrugated backing sheet provides the strength for the laminate, "pillowed" areas can be used in the fiber glass facing layer for greater sound absorption without ~ ing the strength of the panel as is the case with all fiber glass headliner panels.
In the molding process, the polypropylene fibers in the backing sheet melt and the uncured phenolic resin in the fiber glass facing cures to act as the adhesives to bond the laminate together. Thus, the need to apply separate adhesives to the layers of the laminate to bond the laminate together is ~l; ;n~ted.
BRIEF D~UTPTION OF TH~ DRAWING8 FIG. 1 is a perspective view of an automotive he~liner panel of the present invention.
FIG. 2 is an enlarged partial sectional view of the headliner panel taken along line 2-2 of FIG. 1.
FIG. 3 is a schematic view of the method of forming the - headliner panel of the present invention.
~r~TPTION OF TH~ PREFERRED ~MRODTM~NT ~-FIG. 1 shows the self-supporting headliner panel 10 of the present invention which comprises a single-faced CO~L U~dted h~rking sheet 12 and a fiber glass facing layer 14. The headliner panel 10 is sh~pe~ to conform to the interior surface of an automotive roof with the convex surface of the headliner being installed adjacent the roof of the vehicle and the concave surface of the headliner being exposed to the interior of the veh~cle. The headliner panel may be installed in a vehicle by any of a variety of methods which generally utilize clips or other attachment devices. Since the methods of attaching 212~L~0 7 headliner panels to the roofs of vehicles are well known in the art and form no part of the present invention, the attachment devices are not shown.
As best shown in FIG. 2, the self-supporting headliner panel 10 of the present invention is a l~ in~te with a single faced corrugated backing sheet 12 that is installed in a vehicle adjacent or against the interior surface of the vehicle roof and a fiber glass facing layer 14 which is exposed to the interior of the vehicle. The single faced corrugated backing sheet 12 provides the structural strength of the laminate and the fiber glass facing layer 14 provides the sound absorbing properties of the laminate.
The single faced corrugated backing sheet 12 comprises a vapor impervious, wood fiber filled polypropylene sheet 16 with a corrugated paperboard medium 18 adhered thereto. The caliper of the wood fiber filled polypropylene backing sheet 16 is generally between 18 and 22 points. The preferred composition of the wood fiber filled polypropylene backing sheet 16 is about 65~ wood fibers and about 35% polypropylene by weight. However, the composition can range from 60% to 75% wood fibers and from 40% to 25% polypropylene by weight.
The preferred wood pulp fiber is a long, soft bleached southern pine which has been found to work better than short or hard wood fibers. The longer fibers function to decrease the - 2S density of the sheet 16 by creating loft. This causes the backing sheet 16 to conform more readily to the contour of the mold surface when the l~ in~te is being molded into the headliner panel 10. In addition, the longer length, soft bleached, southern pine fibers improve the tear strength of the h~ck;ng sheet 16 due to the greater entanglement of the longer fibers with ~u ,uunding fibers. The long southern pine fibers are between 50 and 150 microns long and have a diameter of between 20 to 60 microns and preferably between 30 to 50 microns. In addition to southern pine fibers, other long, soft pine fibers can also be used in the sheet 16.
In addition to providing structural strength to the laminate, the wood fiber filled polypropylene backing sheet 16 2124~07 also functions as a vapor barrier for the headliner panel 10 and prevents condensation from the metal vehicle roof from penetrating the headliner. This eliminates the need for a separate vapor barrier in the laminate and reduces the cost of the headliner panel.
The corrugated paperboard medium 18 is preferably a C flute which is 141 mils thick and contains 39 flutes per foot. The corrugated medium 18 should be at least 30 pounds per 1000 square feet of medium and can be up to 40 pounds per 1000 square feet of medium.
The fiber glass facing layer 14 is formed from a fiber glass insulation blanket having a density of between 4 and 10 pounds per cubic foot. The fiber glass facing layer 14 generally ranges in thickness from 1/8 of an inch up to about 1 1/2 inches. Since the backing sheet 16 and the corrugated medium 18 provide the structural strength of the panel laminate, portions of the fiber glass facing layer 14 can be formed at a lower density for better sound absorption without adversely affecting the strength of the headliner. These "pillowed" areas pose a problem in molded fiber glass headliners where the reduction in density of the fiber glass we~ken~ the panel.
The fiber glass composite headliner panel 10 is formed in a molding process. FIG. 3 shows a heated press 20 comprising a male mold ~-h~r 22 and a female mold - h~r 24. Both members - 25 contain heating units 26 such as electrical heaters or hot water lines which maintain the male and female non-planer press surfaces 28 and 30, respectively, at a predetermined molding temperature.
The molding temperature for this process ranges from 400 degrees to 570 degrees Fahrenheit. The curing time in the press for the laminate will vary dep~n~ing on the density of the fiber glass insulation used to form the facing layer 14.
As shown in FIG. 3, the self supporting he~liner panel is formed by locating the backing sheet 16 in the press. The backing sheet comprises wood fibers and polypropylene fibers.
The average diameter of the polypropylene fibers is between 1 and 8 microns and preferably between 1 and 4 microns. The average ~ 12 ~
diameter of the wood fibers is between 20 and 60 microns and preferably between 30 and 50 microns~ The average length of both the wood and polypropylene fibers is between 50 and 150 microns.
Sheets with larger diameter polypropylene fibers do not work in this process. When larger diameter polypropylene fibers are used in the sheet, the fibers migrate to the surface during the sheet forming process and the sheet does not process properly.
The corrugated paperboard medium 18 is located on the backing sheet 16 and a layer of uncured fiber glass insulation 14 between 4 and 6 inches thick is located on the corrugated paperboard medium. The press is then closed as shown in FIG. 3 by bringing the male mold member 22 down into the female mold member 24. The heat and pressure cause the polypropylene fibers in the backing sheet 16 to melt and flow around the wood fibers as the sheet conforms to the configuration of the female mold surface 30 thereby forming a vapor impervious sheet. The polypropylene also acts as an adhesive to bond the corrugated paperboard medium 18 to the backing sheet 16.
At the same time that the backing sheet 16 is being molded to conform to the surface 30 of the female mold h~r, the fiber glass insulation facing layer 14 is being cured and conformed to the surface 28 of the male mold h~r 22. As phenolic resin in the fiber glass insulation is cured, the resin functions as an adhesive to bond the fiber glass insulation facing layer 14 to - 25 the corrugated paperboard medium 13. When the fiber glass insulation facing layer is cured, the formed he~liner panel 10 is removed from the press 20.
While not shown, the backing sheet 16 and the corrugated paperboard medium 18 will be normally bonded together in a conventional heated corrugation -çh;ne prior to being il.LLod~ced into the press 20.
As shown in FIG. 3, the surface 28 of the male mold member 22 is inclined so that the spacing between the male mold surface 28 and the female mold surface 30 varies when the mold is closed.
Thus, the thickness and density of the fiber glass facing layer 14 varies from one area of headliner to another creating "pillowed" areas for better sound absorption in selected areas ~ 2~2~407 of the headliner. Since the single faced corrugated backing sheet 12 provides the structural strength for the self-supporting headliner panel, the l'pillowed" areas can be incorporated into the headliner without adversely affecting the physical properties of the headliner panel.
Claims (10)
1. A self-supporting headliner panel for lining the interior surface of a vehicle roof, comprising:
a vapor impervious, polypropylene and wood fiber backing sheet; the polypropylene and wood fiber backing sheet having an outer face to be adjacent an interior surface of a vehicle roof and an inner face;
a corrugated paperboard medium located on the inner face of the polypropylene and wood fiber sheet and adhered thereto to form a self-supporting laminate; and a layer of fiber glass insulation located on the corrugated paperboard medium and adhered thereto.
a vapor impervious, polypropylene and wood fiber backing sheet; the polypropylene and wood fiber backing sheet having an outer face to be adjacent an interior surface of a vehicle roof and an inner face;
a corrugated paperboard medium located on the inner face of the polypropylene and wood fiber sheet and adhered thereto to form a self-supporting laminate; and a layer of fiber glass insulation located on the corrugated paperboard medium and adhered thereto.
2. The self-supporting headliner panel of claim 1 wherein:
the polypropylene and wood fiber backing sheet comprises about 60% to 75% wood fibers by weight and 40% to 25% polypropylene by weight.
the polypropylene and wood fiber backing sheet comprises about 60% to 75% wood fibers by weight and 40% to 25% polypropylene by weight.
3. The self-supporting headliner panel of claim 1 wherein:
the layer of fiber glass insulation has areas of differing thickness with thicker areas of the layer of fiber glass insulation providing greater sound absorption than thinner areas of the layer of fiber glass insulation.
the layer of fiber glass insulation has areas of differing thickness with thicker areas of the layer of fiber glass insulation providing greater sound absorption than thinner areas of the layer of fiber glass insulation.
4. The self-supporting headliner panel of claim 1 wherein:
the polypropylene and wood fiber backing sheet comprises about 65% wood fibers by weight and about 35% polypropylene by weight;
and the layer of fiber glass insulation has areas of differing thickness with thicker areas of the layer of fiber glass insulation providing greater sound absorption than thinner areas of the layer of fiber glass insulation.
the polypropylene and wood fiber backing sheet comprises about 65% wood fibers by weight and about 35% polypropylene by weight;
and the layer of fiber glass insulation has areas of differing thickness with thicker areas of the layer of fiber glass insulation providing greater sound absorption than thinner areas of the layer of fiber glass insulation.
5. A method of forming a self-supporting panel for lining the interior surface of a vehicle roof, comprising the steps of:
providing a backing sheet of wood fibers and polypropylene fibers;
locating a corrugated paperboard medium on a surface of the backing sheet;
locating a layer of uncured fiber glass insulation having uncured phenolic resin on the corrugated paperboard medium to form a laminate comprising the backing sheet, the corrugated paperboard medium, and the layer of fiber glass insulation; and molding the laminate in a mold having a non-planer heated molding surface whereby the polypropylene fibers in the backing sheet melt and flow around the wood fibers to conform the backing sheet to the non-planer molding surface and to adhesively bond the backing sheet to the corrugated paperboard medium and the uncured phenolic resin in the layer of fiber glass insulation becomes cured to adhesively bond the layer of fiber glass insulation to the corrugated paperboard medium and to conform the layer of fiber glass insulation to the non-planer molding surface.
providing a backing sheet of wood fibers and polypropylene fibers;
locating a corrugated paperboard medium on a surface of the backing sheet;
locating a layer of uncured fiber glass insulation having uncured phenolic resin on the corrugated paperboard medium to form a laminate comprising the backing sheet, the corrugated paperboard medium, and the layer of fiber glass insulation; and molding the laminate in a mold having a non-planer heated molding surface whereby the polypropylene fibers in the backing sheet melt and flow around the wood fibers to conform the backing sheet to the non-planer molding surface and to adhesively bond the backing sheet to the corrugated paperboard medium and the uncured phenolic resin in the layer of fiber glass insulation becomes cured to adhesively bond the layer of fiber glass insulation to the corrugated paperboard medium and to conform the layer of fiber glass insulation to the non-planer molding surface.
6. The method of claim 5, wherein: the mold is heated to a temperature between 400 and 570 degrees Fahrenheit.
7. The method of claim 5 wherein: the backing sheet comprises about 60% to 75% wood fibers by weight and about 40%
to 25% polypropylene fibers by weight.
to 25% polypropylene fibers by weight.
8. The method of claim 7 wherein: the layer of fiber glass insulation has a density of between 4 and 8 pounds per cubic foot before molding.
9. The method of claim 8 wherein: the wood fibers have an average diameter between 20 and 60 microns; the polypropylene fibers have an average diameter between 1 and 8 microns; and the lengths of the wood and polypropylene fibers average between 50 and 150 microns.
10. The method of claim 5 wherein: selected areas of the layer of fiber glass insulation are less compressed during the molding step than other areas of the layer of fiber glass insulation and retain a greater thickness than said other areas of the layer of fiber glass insulation.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US6886593A | 1993-05-27 | 1993-05-27 | |
| US08/068,865 | 1993-05-27 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2124407A1 CA2124407A1 (en) | 1994-11-28 |
| CA2124407C true CA2124407C (en) | 1998-01-06 |
Family
ID=22085208
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2124407 Expired - Fee Related CA2124407C (en) | 1993-05-27 | 1994-05-26 | Fiber glass composite headliner and method of making the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2124407C (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112677895A (en) * | 2021-01-20 | 2021-04-20 | 重庆长安汽车股份有限公司 | Automobile roof lining structure |
-
1994
- 1994-05-26 CA CA 2124407 patent/CA2124407C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2124407A1 (en) | 1994-11-28 |
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