CN1303337A - 由可热成型的热塑性泡沫片材构成的车辆头顶内衬 - Google Patents

由可热成型的热塑性泡沫片材构成的车辆头顶内衬 Download PDF

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Publication number
CN1303337A
CN1303337A CN99806608A CN99806608A CN1303337A CN 1303337 A CN1303337 A CN 1303337A CN 99806608 A CN99806608 A CN 99806608A CN 99806608 A CN99806608 A CN 99806608A CN 1303337 A CN1303337 A CN 1303337A
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China
Prior art keywords
foamed materials
vehicle
headliner
stratum nucleare
basically
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Pending
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CN99806608A
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English (en)
Inventor
M·H·图西姆
M·C·科乃尔
L·罗伦佐
C·P·克里斯坦森
W·J·夏弗
K·W·苏
G·V·甘德
R·L·麦克吉
C·P·帕克
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Dow Chemical Co
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Dow Chemical Co
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Publication of CN1303337A publication Critical patent/CN1303337A/zh
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Abstract

本发明公开了一种具有改进头顶内衬的车辆。该头顶内衬包括热成型的核层。该核层包含挤制热塑性泡沫材料和可有可无的一层或多层相邻的基本上非发泡的热塑性塑料。该核层基本上没有热固性材料且优选没有玻璃纤维打毛层或沙罩。优选将装饰层如毛毡层或织物层层压到核层上。该头顶内衬基本上耐流挂且能够在安装在车辆中时基本上保持其热成型形状。还公开了一种组装或制造头顶内衬并将其安装在车辆中的方法。

Description

由可热成型的热塑性泡沫片材构成的车辆头顶内衬
本发明的背景
本发明涉及具有由挤制热塑性泡沫材料构成的热成型核层的车辆头顶内衬(headliner)。该核层和头顶内衬在安装于车辆中时甚至能够在高温下基本上保持它们的形状和轮廓。
头顶内衬是施用到车辆中乘客室顶下侧的层压品。头顶内衬有各种用途，包括缓冲、美观、绝热、和隔音。
用于商业制造车辆的头顶内衬由于实际需求和头顶内衬所暴露的环境条件而较复杂且技术非常高。头顶内衬必须具有足够的刚性以防因重力流挂，但足够易弯以易于制造和/或热成型和安装。头顶内衬还可以是总体冲击保护体系的一个组件，当乘客室中的人员突然接触时可提供一定程度的缓冲作用。头顶内衬还必须能够经受在车辆暴露于阳光加热时的高温。头顶内衬还必须能够成型为所需的形状、构型、或轮廓。
目前商业上采用的头顶内衬通常由多层聚氨酯泡沫材料和/或玻璃/玻璃纤维打毛层或沙罩形成，它们用聚氨酯粘合剂粘附并热压到一起至所需形状和轮廓。通常在面向乘客室内的表面上将毛毡或织物施用到头顶内衬上。头顶内衬的例子包括，公开于美国专利5460870、5486256、5582906和5670211中的那些，在此将其作为参考并入本发明。
目前市售头顶内衬有许多缺点。它们由于昂贵的组分材料和复杂的制造方法及工艺而高价。热固性粘合剂，如聚氨酯粘合剂是昂贵的且需要多步费时的施用和固化方法及工艺。玻璃、玻璃纤维、碳、或其它纤维状形式的材料、以及聚氨酯泡沫材料片材的增强织物或沙罩还必须与热固性粘合剂一起散布成层状排列。这些增强材料是昂贵的，且需要与热固性粘合剂一起多步整合到制品中。此外，组分材料和头顶内衬成品通常难以(如果不是不可能的话)有效回收。
需要一种由较便宜的组分材料构成且能够以不太复杂和昂贵的制造工艺进行安装的头顶内衬。还需要一种头顶内衬，它能够提供类似于采用热固性材料和增强织物或沙罩的头顶内衬所具有的使用特性和属性。如果头顶内衬和/或其组分材料容易回收，将更加理想。
本发明的综述
按照本发明，提供了一种具有改进头顶内衬的车辆。该车辆具有一个位于其中的乘客室和位于乘客室顶上的室顶。头顶内衬位于该室顶的下侧附近。该头顶内衬包含热成型核层。该核层包含挤制热塑性泡沫材料和可有可无的一层或多层邻近的基本上非发泡热塑性塑料。该核层基本上没有热固性材料且优选没有玻璃/玻璃纤维打毛层(matte)或沙罩(scrim)。该核层基本上耐流挂且在将该车头安装在车辆中时能够基本上保持其热成型形状。优选将装饰层，如毛毡层或织物层层压到该核层上。
按照本发明，还提供了一种组装或制造头顶内衬并将其安装在车辆中的方法。该方法包括：a)提供一种可热成型的核层，包含挤制热塑性泡沫材料和可有可无的一层或多层相邻的基本上非发泡热塑性塑料，其中所述核层基本上没有热固性材料，基本上耐流挂，且在将头顶内衬安装在车辆中时能够基本上保持其形状；b)将该核层通过向其上施加热和机械压力而热成型为头顶内衬；c)将该头顶内衬邻近室顶的下侧进行安装或施用。优选将装饰层层压到面向乘客室内的核层表面上。该装饰层可在核层热成型之前或之后层压到核层上。
附图的简要描述
图1是具有头顶内衬的车辆的部分横截面的片断透视图。
图2是图1剖面的侧视图，其中给出了车辆的室顶和头顶内衬。
图3是具有头顶内衬的车辆的室顶的片断透视图，其中所述头顶内衬给出了剖面。
图4是具有头顶内衬的车辆的室顶的片断透视图，其中所述头顶内衬给出了剖面。
图5是给出了具有发泡部分和非发泡部分的头顶内衬的一部分。
图6-11是给出了头顶内衬组件的一部分的几种构型。
本发明的详细描述
单就头顶内衬而言，该头顶内衬提供了本领域未知的许多优点。这些优点大部分涉及该头顶内衬中的可热成型核层。这些优点包括：该头顶内衬容易热成型为所需形状、构型或轮廓；该头顶内衬具有足够刚性以防流挂并基本上保持其形状-即使暴露于通常车辆在热气候和/或直接日光条件下中所遇到的高温；该头顶内衬优选由较便宜和可回收的热塑性塑料构成。
在本发明中，包含热塑性泡沫材料的核层相对已有技术中可用于头顶内衬的其它泡沫材料层具有显著的优点。美国专利5670211公开了具有聚氨酯泡沫材料的柔性或半刚性泡沫材料片材的头顶内衬，该泡沫材料用聚氨酯粘合剂加工并成型为头顶内衬。该专利还公开，PPO、膨胀聚苯乙烯、和膨胀聚丙烯的其它泡沫材料片材可替代聚氨酯泡沫材料。本发明的核层优于该专利的教导内容，即，它基本上没有热固性粘合剂且更容易回收。包含挤制热塑性泡沫材料的核层也比聚氨酯泡沫材料更容易热成型且在给定密度下比膨胀(珠粒)泡沫材料更有强度，而且比聚苯乙烯泡沫材料的耐热变形性高。美国专利3637458公开了非常薄的挤制聚丙烯泡沫材料片材，据说可用于一系列洗涤场合，包括用作头顶内衬。该专利没有提及这种头顶内衬的结构以及所公开的聚丙烯泡沫材料片材在其中的功能。泡沫材料可在头顶内衬中具有不同的功能以提供结构和机械性能或用作装饰织物层的缓冲衬垫。美国专利5536793公开了一种聚酯泡沫材料，据说可用于许多场合，包括用作头顶内衬。该专利由于与美国专利3637458相同的原因而介绍不足。
附图描绘了本发明的实施方案。在图1中，车辆10具有室顶12、乘客室14、和头顶内衬16。图1给出了沿着圆虚线2-2的剖面，对应于在图2中看见的横截面侧视图。图2给出了室顶12，其上粘附或固定有头顶内衬16。头顶内衬16包括常规的挤制热塑性泡沫材料层20、粘合剂层22、和织物层24。图3给出了室顶/头顶内衬组合的另一实施方案。在图3中，头顶内衬30粘附或固定到车辆室顶32上。头顶内衬30包括挤制的合并线材热塑性泡沫材料34和织物层36。在头顶内衬30中，线材一般竖直取向且一般与室顶32的平面垂直。图4给出了室顶/头顶内衬组合的另一实施方案。在图4中，头顶内衬40粘附或固定到车辆室顶42上。头顶内衬40包括挤制的合并线材热塑性泡沫材料44和织物层46。在头顶内衬40中，线材一般水平取向且一般与室顶42的平面平行。
可以使用本领域已知的粘合剂，将头顶内衬的各层相互粘附或将头顶内衬粘附到车的室顶上。可用的粘合剂包括热固性粘合剂如聚氨酯树脂和环氧树脂、和热塑性粘合剂如聚乙烯、聚丙烯、乙烯共聚物、丙烯共聚物、和类似物。可用的粘合剂介绍于美国专利5460870和5670211。粘合剂可通过本领域已知的任何方式，例如通过喷射、涂布、或以膜形式进行施用。优选的粘合剂为热塑性的，这样成本较低且可能回收。粘合剂的存在对本发明并不重要。该泡沫材料可以是闭孔或开孔。开孔含量按照ASTM D2856-A来测定。闭孔泡沫材料的优点是较好的绝热性能，而开孔泡沫材料的优点是较好的隔音作用、尺寸稳定性、和在热成型时的热传递效果。
热塑性泡沫材料在热成型之前的密度优选为约16-200千克/立方米，更优选约16-80千克/立方米。按照ASTM D3576，该泡沫材料的平均泡孔尺寸为约0.1-5.0毫米，优选约0.2-0.3毫米。所述泡沫材料密度和泡孔尺寸范围一般针对热塑性泡沫材料。最优选的密度和泡孔尺寸范围可根据该泡沫材料的组成和所需的物理性能而变化。例如，泡沫材料通常可通过增加密度或泡孔尺寸而制得更刚性。
特别理想的泡沫材料是丙烯聚合物、聚酯、和聚酰胺的那些泡沫材料，在热成型之前的密度为约16-160千克/立方米，优选约24-100千克/立方米。
热塑性泡沫材料优选作为整体结构挤出，但也可利用本领域已知的任何方式，例如热焊接或粘合剂层，通过将两个或多个较薄的热塑性泡沫材料片材层压到一起而形成。
该泡沫材料必须在车辆室顶由于阳光加热所常遇到的高温下耐热变形且尺寸稳定。按照SAE 883，就膨胀和收缩而言，该泡沫材料的尺寸稳定性为约5％或更低，更优选约1％或更低。
该泡沫材料可制成任何横截面尺寸或构型，如泡沫材料片材或厚板。特别有用的泡沫材料在横截面中的较小尺寸(厚度)为1.5毫米或更高，优选3毫米或更高。
可以将一层或多层装饰材料如，毛毡或织物施用到通常朝向乘客室内或(用于美观的)内室的头顶内衬的表面上。该层可以是本领域已知的任何种类。商业上常用的是毛毡或机织织物。有用的织物包括机织聚酯、尼龙、和聚丙烯纤维的织物。毛毡或织物层优选由与泡沫材料相同或类似的聚合物材料构成。该毛毡或织物层可通过本领域已知的任何方式，如热焊接、粘合剂膜、或粘合剂液体或涂料而粘附到泡沫材料上。优选的粘合剂层是无需利用粘合剂而热焊接到核层上的热塑性纤维的机织织物。热焊接是指，将织物层加热使得纤维变粘或有粘性且能够粘附到核层上而无需利用粘合剂。如果在热成型过程中或当核层处于高温时施用到核层上，那么织物层可热焊接到核层上。
优选的头顶内衬完全由可回收材料构成。有用的可回收材料包括丙烯聚合物如聚丙烯；高密度聚乙烯；聚酯如聚对苯二甲酸乙二醇酯；和聚碳酸酯。最优选的头顶内衬完全由具有类似组成并因此可回收到一起的可回收材料构成。例如，头顶内衬可包含任何以下物质：丙烯聚合物泡沫材料和机织聚丙烯织物层的层压品；聚对苯二甲酸乙二醇酯泡沫材料和机织聚对苯二甲酸乙二醇酯织物层的层压品；或聚酰胺(尼龙)泡沫材料和聚酰胺织物层。如果需要，可以一起使用不同的可回收材料，例如：a)丙烯聚合物泡沫材料和聚酯或聚酰胺机织织物层的层压品、和b)聚酯泡沫材料和聚丙烯或聚酰胺机织织物层的层压品。
该泡沫材料容易热成型为所需形状、构型或轮廓。通常，该头顶内衬的泡沫材料和其余部分基本上具有与车辆室顶相同的形状、构型或轮廓，因为头顶内衬位于室顶下方。术语“可热成型”是指，该泡沫材料可在热和机械压力下，利用本领域已知的任何常规方式热成型或制成不同的形状或轮廓。通常，该泡沫材料的形式为基本上平整的片材或厚板，并在热和压力下压制形成类似于车辆室顶(该泡沫材料位于其下方)的形状和轮廓的异型片材。如果需要，可以将装饰层如机织热塑性纤维的织物层在热成型工艺中热焊接到泡沫材料上。
泡沫材料的物理性能和耐热性可这样增强：在泡沫材料上形成或诱导形成基本上非发泡的皮，例如通过将塑料膜或片材层压到泡沫材料上，通过用塑料树脂将其涂覆；将泡沫材料的一个或多个表面加热至其玻璃化转变温度或熔点之上以使皮上的泡孔结构塌陷，或将任何前述方式组合使用。膜、片材或涂层可包含任何已知的热塑性树脂或热固性树脂。有用的热塑性树脂包括以上在构成该泡沫材料时所述的那些，且有用的热固性树脂包括聚氨酯和环氧树脂。
头顶内衬可通过本领域已知的任何方式，例如利用机械装置进行粘附或固定而施用到车辆室顶的下方。机械装置包括夹子、侧模制件、和顶(圆顶)光源组件。
有用的热塑性泡沫材料包括(但不限于)丙烯聚合物、聚酯、聚酰胺、聚碳酸酯、高密度聚乙烯、氯化聚乙烯、聚苯醚、聚苯醚与聚苯乙烯的共混物、丙烯/乙烯共聚物、热塑性聚氨酯、EPDM与聚乙烯的共混物、聚丙烯与EPDM的共混物、聚丙烯与乙烯/苯乙烯共聚物的共混物。乙烯/苯乙烯共聚物和包含其的泡沫材料介绍于美国专利5460818，在此将其作为参考并入本发明。优选的泡沫材料包括丙烯聚合物泡沫材料和聚酯泡沫材料。更优选的泡沫材料包括聚丙烯泡沫材料、单体混合比为95/5-99.5/0.5的丙烯/乙烯共聚物泡沫材料、和聚对苯二甲酸乙二醇酯泡沫材料。
核层的最优选泡沫材料是一种挤制丙烯聚合物泡沫材料。合适的那些聚合物材料包括丙烯均聚物(聚丙烯)、以及丙烯与可共聚烯属不饱和单体的共聚物。丙烯聚合物材料还可包括非丙烯类聚合物。丙烯聚合物材料可仅由一种或多种丙烯均聚物、一种或多种丙烯共聚物、一种或多种丙烯均聚物和共聚物的共混物、或任何前述物质与非丙烯类聚合物的共混物构成。与组成无关，丙烯聚合物材料包含大于50％重量，优选约70％或更高的丙烯单体单元。
合适的单烯属不饱和共聚单体包括烯烃、乙酸乙烯酯、丙烯酸甲酯、丙烯酸乙酯、甲基丙烯酸甲酯、丙烯酸、衣康酸、马来酸、马来酸酐和类似物。丙烯共聚物优选包含约45％重量或更低的烯属不饱和共聚单体。
适合加入丙烯聚合物材料中的非丙烯类聚合物包括高、中、低、和线型低密度聚乙烯、聚丁烯-1、乙烯/丙烯酸共聚物、乙烯/乙酸乙烯酯共聚物、乙烯/丙烯共聚物、苯乙烯/丁二烯共聚物、乙烯/苯乙烯共聚物、乙烯/丙烯酸乙酯共聚物、离聚物和类似物。
特别有用的丙烯共聚物是丙烯与一种或多种非丙烯类烯烃的共聚物。丙烯共聚物包括丙烯与选自乙烯、C4-C101-烯烃和C4-C10-二烯的烯烃的无规、嵌段、和接枝共聚物。丙烯共聚物还包括丙烯与选自乙烯和C4-C81-烯烃的1-烯烃的无规三元聚合物。在同时具有乙烯和C4-C81-烯烃的三元聚合物中，乙烯含量优选为45％重量或更低。C4-C101-烯烃包括直链和支链C4-C101-烯烃，如1-丁烯、异丁烯、1-戊烯、3-甲基-1-丁烯、1-己烯、3,4-二甲基-1-丁烯、1-庚烯、3-甲基-1-己烯、和类似物。C4-C10-二烯的例子包括1,3-丁二烯、1,4-戊二烯、异戊二烯、1,5-己二烯、2,3-二甲基-1,3-己二烯和类似物。
此外，如本文所述，丙烯聚合物材料按照ASTM D 1238条件L的熔体流速为约0.05-50，优选0.1-20。
优选的丙烯聚合物树脂是这样一些丙烯树脂，它们是支化的或轻微交联的聚合物材料。支化(或轻微交联)可通过本领域一般已知的方法，如化学或辐射支化/光交联法而实现。美国专利4916198描述了在使用聚丙烯树脂制备最终聚丙烯树脂产品之前制成支化/轻微交联聚丙烯树脂的这样一种树脂、以及一种制备该聚丙烯树脂的方法，在此将其作为参考并入本发明。制备支化/轻微交联聚丙烯树脂的另一方法是，将化学化合物与聚丙烯树脂一起加入挤出机中，然后在挤出机中进行支化/轻微交联反应。美国专利4714716给出了该方法，在此将其作为参考并入本发明。
有用的挤制丙烯聚合物泡沫材料参见美国专利5438795、5527573和5567742，在此将其作为参考并入本发明。
有用的挤制聚酯泡沫材料(包括聚对苯二甲酸乙二醇酯(PET)泡沫材料)参见美国专利5000991、5234640和5536793，在此将其作为参考并入本发明。
泡沫材料可由其它的有用热塑性塑料，如高密度聚乙烯、氯化聚乙烯、EPDM橡胶(乙烯/丙烯/二胺共聚物)与聚乙烯的TPO混合物制成。
有用的热塑性泡沫材料优选非交联的，但可以轻微交联。但术语“非交联的”包括在不利用交联剂或辐射的情况下自然发生的轻微程度的交联作用。按照ASTM D2765-84，方法A，非交联泡沫材料包含低于5％的凝胶。按照ASTM D2765-84，方法A，轻微交联泡沫材料可包含5-15％的凝胶。发泡剂可包括本领域已知的任何发泡剂，如具有有机和/或无机组成的化学发泡剂和物理发泡剂。适用的无机发泡剂包括二氧化碳、氮气、氩气、水、空气、氮气和氦气。合适的有机发泡剂包括具有1-9个碳原子的脂族烃、和具有1-4个碳原子的卤化脂族烃。脂族烃包括甲烷、乙烷、丙烷、正丁烷、异丁烷、正戊烷、异戊烷、新戊烷、和类似物。还包括醇，如乙醇、甲醇和丙醇。在卤化烃中，氟化烃是优选的。氟化烃的例子包括氟甲烷、全氟甲烷、氟乙烷、1,1-二氟乙烷、1,1,1-三氟乙烷(R-143a)、1,1,1,2-四氟乙烷(R-134a)、五氟乙烷、全氟乙烷、2,2-二氟丙烷、1,1,1-三氟丙烷、全氟丙烷、全氟丁烷、全氟环丁烷。可用于本发明的部分卤化的氯代烃和氟氯烃包括氯甲烷、二氯甲烷、氯乙烷、1,1,1-三氯乙烷、1,1-二氯-1-氟乙烷(HCFC-141b)、1-氯-1,1-二氟乙烷(HCFC-142b)、1,1-二氯-2,2,2-三氟乙烷(HCFC-123)、和1-氯-1,2,2,2-四氟乙烷(HCFC-124)。完全卤化的氟氯烃包括三氯一氟甲烷(CFC-11)、二氯三氟甲烷(CFC-12)、三氯三氟甲烷(CFC-113)、二氯四氟乙烷(CFC-114)、一氯五氟丙烷、和二氯六氟丙烷。完全卤化的氟氯烃由于其臭氧消耗能力而不优选。化学发泡剂包括偶氮二甲酰胺、偶氮二异丁腈、苯磺酰肼、4,4-氧苯磺酰基-氨基脲、对甲苯磺酰基氨基脲、偶氮二甲酸钡、N,N’-二甲基-N,N’-二亚硝基对苯二甲酰胺、和三肼基三嗪。
在制备能够形成泡沫材料的聚合物凝胶时，加入聚合物熔体中的发泡剂的量为约0.2-4.0摩尔/千克聚合物，优选约0.3-3.0摩尔/千克聚合物，最优选约0.5-2.50摩尔/千克聚合物。
热塑性泡沫材料一般在挤出工艺中制成，即，将热塑性塑料加热形成塑化或熔化的聚合物材料，向其中加入物理发泡剂以形成可发泡的凝胶，然后将该凝胶挤过模头以形成泡沫材料产品。发泡剂可通过本领域已知的任何方式，例如利用挤出机、混合器、搅拌机或类似设备，加入或混入塑料熔体中。将发泡剂在较高压力下与塑料熔体混合，这样可基本上防止熔体膨胀且一般能够将发泡剂均匀分散在该熔体内。视需要，将成核剂混入该聚合物熔体中。发泡剂和成核剂的加料速率可通过调节以获得较低密度的泡沫材料和较小的泡孔尺寸，这样可得到具有薄泡孔壁的泡沫材料。加入发泡剂之后，通常将可发泡凝胶冷却至较低温度以优化泡沫材料产品的物理性能。然后将该凝胶挤过一个具有所需形状的模头，到达一个具有较低压力的区域以形成泡沫材料产品。如果使用化学发泡剂，将其加入熔化的聚合物材料中，然后挤出或传送至具有较高温度的区域，在此发泡剂分解形成气体，通常为二氧化碳。熔化的聚合物材料/气体混合物膨胀形成泡沫材料。
制备热塑性泡沫材料的其它合适方法是美国专利4824720、5348795、5527573、5567742和WO88/06094中描述的合并泡沫材料法，在此将其作为参考并入本发明。这些专利涉及使用包含多个孔的模头，来制备包含多股合并挤制线材或型材的开孔和闭孔聚烯烃泡沫材料的方法。这些孔排列使得，相邻熔化挤出物液流之间在发泡过程中发生接触，这样接触表面就以足够的粘附性相互粘附，得到一种整体结构。合并泡沫材料的多个线材应该保持粘附到整体结构中以防线材在制备、成型和使用该泡沫材料时遇到的应力下脱层。
该挤制的合并线材泡沫材料具有各向异性物理性能的优点。这些泡沫材料在挤出方向上具有比垂直或水平方向较大的压缩强度和耐冲击性。如果按照图3的头顶内衬所示将线材垂直取向，那么比起由常规狭缝模头挤出的整体结构常规热塑性泡沫材料，可发现给定密度的泡沫材料对头部撞击具有较大的耐冲击性。
WO88/06094涉及合并线材泡沫材料挤出工艺，其中可以堵塞或密封多孔挤出模头内的某些孔，这样可生产出具有直径或尺寸较大的连续纵向通道的合并线材泡沫材料。具有这种较大通道的合并线材泡沫材料可按照图4所示方式用于头顶内衬，这样电线或用于排风、冷却、或受热空气的导管可根据需要由乘客室的前方引导至该室的后面或后部。
美国专利4323528(在此将其作为参考并入本发明)涉及，利用储料挤出工艺来制备聚烯烃泡沫材料。该工艺包括：1)将热塑性材料与发泡剂混合形成一种聚合物凝胶；2)将该凝胶挤出到保压区，该区保持在不会使该混合物发泡的温度和压力下；该保压区具有一个用于确定开向低压(凝胶在该低压下发泡)区的孔的模头和一个密闭该模头孔的可开启门；3)定期打开该门；4)利用可移动撞锤，基本上同时将机械压力施用到凝胶上，将其从保压区经由模头孔喷射到具有较低压力的区；然后5)使射出的凝胶膨胀形成泡沫材料。
泡沫材料强度可通过向头顶内衬的泡沫材料部分加入较薄的基本上非发泡的板或型材而增强。这可通过任何合适的方法而实现，例如在有或没有发泡剂的情况下，直接使用挤出物或塑料熔体，将其传送经过挤出模头内的不同孔并使其合并形成同时具有发泡和非发泡树脂部分的板/型材组合体，这样挤制得到所需的板/型材和泡沫材料组合体。另一方法是挤出泡沫材料，其条件使得在挤出时接触板或型材，这样可形成所需的组合体。在泡沫材料的挤出横截面中，非发泡树脂板或部分可以是规则或不规则图案。板或型材可相互交叉或非交叉。非发泡型材或板在泡沫材料内的可能横截面图案包括蜂窝状、环状、长方形或对角线网格图案。图5给出了具有长方形网格图案的板/型材和泡沫材料组合体，它具有发泡部分51和非发泡部分52。
通过用热线切割泡沫材料并随后重组或合并这些切断的泡沫材料片，还可制备出具有发泡和非发泡部分的挤制结构，这样它们就热焊接在一起。优选的是，在用热线切断泡沫材料之后，立即进行热焊接。在合并这些切断的泡沫材料片之后，将热施用到泡沫材料上，使邻近该线的泡沫材料的泡孔结构崩塌，并在泡沫材料内形成非发泡的板或型材。
通过将发泡和非发泡型材或层相互层压成一种交替构型以形成整体结构，还可制造出具有发泡和非发泡部分的结构。这些型材或层可通过热焊接或粘附而层压到一起。
此外，可以将成核剂加入发泡工艺中以控制泡沫材料泡孔的尺寸。优选的成核剂包括无机物质如碳酸钙、滑石、粘土、二氧化钛、硅石、硫酸钡、硬脂酸钙、硬脂酸钡、硅藻土、柠檬酸与碳酸氢钠的混合物、和类似物。成核剂的用量可以是约0.01-5重量份/100重量份聚合物树脂。优选范围为0.1-约3重量份。
还可在泡沫材料和发泡工艺中加入各种添加剂，如颜料、抗氧化剂、酸捕捉剂、紫外线吸收剂、阻燃剂、加工助剂、挤出助剂、和类似物。
泡沫材料的物理性能和耐热性可通过加入填料形式的有机或无机材料颗粒或纤维而增强。这些颗粒或纤维可在制造过程中加入能够形成泡沫材料的组合物。有用的材料包括炭黑颗粒、粘土颗粒、碳或石墨纤维、聚丙烯纤维、聚酯纤维、和尼龙纤维、玻璃纤维、和丙烯腈纤维。泡沫材料的物理性能和耐热性还可通过向泡沫材料上层压包含这些颗粒和/或纤维的非发泡膜/片材层或涂层而增强。纤维可以是任何长度，短(原纤)或长。它们可作为织物或半固化片无规分散或机织或放置在一起。
可以使用本领域已知的粘合剂，将头顶内衬的各层相互粘附或将头顶内衬粘附到车的室顶上。可用的粘合剂包括热固性粘合剂如聚氨酯树脂和环氧树脂、和热塑性粘合剂如聚乙烯、聚丙烯、乙烯共聚物、丙烯共聚物、和类似物。可用的粘合剂介绍于美国专利5460870和5670211。粘合剂可通过本领域已知的任何方式，例如通过喷射、涂布、或以膜形式进行施用。优选的粘合剂为热塑性的，这样成本较低且可能回收。粘合剂的存在对本发明并不重要。
可以将一层或多层装饰材料如，毛毡或织物施用到通常朝向乘客室内或(用于美观的)内室的头顶内衬的表面上。该层可以是本领域已知的任何种类。商业上常用的是毛毡或机织织物。有用的织物包括机织聚酯、尼龙、和聚丙烯纤维的织物。毛毡或织物层优选由与泡沫材料相同或类似的聚合物材料构成。该毛毡或织物层可通过本领域已知的任何方式，如热焊接、粘合剂膜、或粘合剂液体或涂料而粘附到泡沫材料上。优选装饰层是无需利用粘合剂而热焊接到核层上的热塑性纤维的机织织物。热焊接是指，将织物层加热使得纤维变粘或有粘性且能够粘附到核层上而无需利用粘合剂。如果在热成型过程中或当核层处于高温时施用到核层上，那么织物层也可热焊接到核层上。
优选的头顶内衬完全由可回收材料构成。有用的可回收材料包括丙烯聚合物如聚丙烯；高密度聚乙烯；聚酯如聚对苯二甲酸乙二醇酯；和聚碳酸酯。最优选的头顶内衬完全由具有类似组成并因此可回收到一起的可回收材料构成。例如，头顶内衬可包含任何以下物质：丙烯聚合物泡沫材料和机织聚丙烯织物层的层压品；聚对苯二甲酸乙二醇酯泡沫材料和机织聚对苯二甲酸乙二醇酯织物层的层压品；或聚酰胺(尼龙)泡沫材料和聚酰胺织物层。如果需要，可以一起使用不同的可回收材料，例如：a)丙烯聚合物泡沫材料和聚酯或聚酰胺机织织物层的层压品、和b)聚酯泡沫材料和聚丙烯或聚酰胺机织织物层的层压品。
该泡沫材料容易热成型为所需形状、构型或轮廓。通常，该头顶内衬的泡沫材料和其余部分基本上具有与车辆室顶相同的形状、构型或轮廓，因为头顶内衬位于室顶下方。术语“可热成型”是指，该泡沫材料可在热和机械压力下，利用本领域已知的任何常规方式热成型或制成不同的形状或轮廓。通常，该泡沫材料的形式为基本上平整的片材或厚板，并在热和压力下压制形成类似于车辆室顶(该泡沫材料位于其下方)的形状和轮廓的异型片材。如果需要，可以将装饰层如机织热塑性纤维的织物层在热成型工艺中热焊接到泡沫材料上。
泡沫材料的物理性能和耐热性可这样增强：在泡沫材料上形成或诱导形成基本上非发泡的皮，例如通过将塑料膜或片材层压到泡沫材料上，通过用塑料树脂将其涂覆；将泡沫材料的一个或多个表面加热至其玻璃化转变温度或熔点之上以使皮上的泡孔结构塌陷，或将任何前述方式组合使用。膜、片材或涂层可包含任何已知的热塑性树脂或热固性树脂。有用的热塑性树脂包括以上在构成该泡沫材料时所述的那些，且有用的热固性树脂包括聚氨酯和环氧树脂。
头顶内衬可通过本领域已知的任何方式，例如利用机械装置进行粘附或固定而施用到车辆室顶的下方。机械装置包括夹子、侧模制件、和顶光源组件。
术语“车辆”包括本领域已知的那些，如汽车、卡车、休闲车、运动车、飞机、火车、和船。
图6-10给出了具有不同头顶内衬构型的部分。图6给出了两个由具有竖直取向的泡沫材料线材构成的泡沫材料片材61和62、泡沫材料衬底的织物片材63、和粘合剂膜64和65的层。在一个优选实施方案中，该头顶内衬仅在头顶内衬的需要附加能量吸收能力的某些部位上包含第二泡沫材料片材62，例如沿着最靠近乘客门的头顶内衬侧，但其它地方由单个泡沫材料片材构成以尽量降低头顶内衬在这些其它部位的厚度。粘合剂膜64和65可用于粘附织物和泡沫材料层66和67并增加头顶内衬的总体挺度。如果需要，这些膜层可以省略并利用任何其它的合适方式将织物和泡沫材料层相互粘附，例如通过将泡沫材料层热焊接到一起并在邻近其的泡沫材料层上使用液体织物粘合剂。
图7-9给出了两层泡沫材料在头顶内衬内可能取向的几种方式。在这些构型中，顶泡沫材料层71、81和91由线材泡沫材料构成，这些泡沫材料定位使得线材与车辆室顶垂直，这样可获得最大的能量吸收效果。所给出的底泡沫材料层是一种具有垂直于室顶的线材的线材泡沫材料层72、非线材泡沫材料82、和定位使得线材垂直于车辆室顶的线材泡沫材料92。在这些实施方案中，泡沫材料层可通过合适的方式，例如通过使用粘合剂、粘合剂膜、或通过将它们热焊接到一起而相互粘附。
图10给出了作为单个线材泡沫材料片的头顶内衬泡沫材料的一部分，它已切割或模塑成所需形状，具有较薄部分和较厚部分，所述较厚部分沿着最靠近乘客侧门的头顶内衬侧放置。图11给出了具有三层线材泡沫材料96、97和98的头顶内衬的一部分，所述第三层提供附加的能量吸收能力。
实施例
在以下实施例中，制备出可热成型和制造成适合安装到车辆中的头顶内衬的泡沫材料。
实施例1
生产出挤制聚丙烯泡沫材料片材。
用于生产该泡沫材料的装置包括串联的挤出机、混合器、冷却器、和环状挤出模头。将聚合物以颗粒形式加料到挤出机中，在此将其与添加剂混合形成聚合物熔体。将该聚合物熔体传送至混合器，在此在压力下向其中加入发泡剂以形成可发泡凝胶。将可发泡凝胶传送至模头，在此将其由心轴周围的环状孔膨胀，形成沿着管状泡沫材料片材产品。然后将管状片材劈开成平整片材。
丙烯聚合物树脂是98/2聚丙烯(均聚物)树脂[Montell HMS树脂PF-814]。发泡剂是8pph异丁烷(每百份的份数，基于聚合物重量)。所用添加剂是0.2pph滑石(成核剂)、0.1pph Iraganox 1010(抗氧化剂)、和0.1pph Ultranox 626(抗氧化剂)。
该泡沫材料的厚度为5mm(毫米)且宽度为1600毫米，开孔含量为1.6％，密度为2.7磅/立方英尺(pcf)(43.2千克/立方米(kgm))，且平均泡孔尺寸为1.7毫米。该泡沫材料按照美国专利5527573所述的可发泡指数值为5.3。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例2
在实施例1所公开的装置上，生产出另一挤制聚丙烯泡沫材料片材，其中采用与实施例1相同的发泡剂含量和加载量和基本上相同的加工条件，但模头间隙开口较大且接取速度较慢。
该泡沫材料的厚度为9毫米且宽度为1600毫米，开孔含量低于2％，密度为2.41pcf(38kgm)，且平均泡孔尺寸为1.7毫米。该泡沫材料按照美国专利5527573所述的可发泡指数值为4.7。该泡沫材料较刚性，且在支撑其自身重量时不流挂。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例3
在实施例1所公开的装置上，生产出另一挤制丙烯共聚物泡沫材料片材，其中采用与实施例1相同的发泡剂含量和加载量和基本上相同的加工条件。
该泡沫材料的厚度为7毫米且宽度为1600毫米，开孔含量为19％，密度为2.9pcf(46.1kgm)，且平均泡孔尺寸为1.75毫米。该泡沫材料按照美国专利5527573所述的可发泡指数值为5.8。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例4
在实施例1所公开的装置上，生产出另一挤制聚丙烯泡沫材料片材，其中采用相同的发泡剂和添加剂并添加硬脂酸钙粉末用于附加泡孔成核。将聚丙烯聚合物以990磅/小时(449千克/小时)的速率与0.42pph滑石、0.3pph UltranoxTM 815P稳定剂(来自GE SpecialtyChemcials)、0.3pph硬脂酸钙一起加料到挤出机中。将该塑化凝胶混合物与3.9pph异丁烷在压力下混合，冷却至161℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在16”直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为7毫米且宽度为1290毫米，开孔含量为20.4％，密度为3.3pcf(52.9kgm)，且平均泡孔尺寸为3.6毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为175psi(1.21MPa)，且可发泡指数为13.6。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例5
在实施例1所公开的装置上，生产出另一挤制聚丙烯泡沫材料片材，其中采用相同的发泡剂和添加剂并添加硬脂酸钙粉末用于附加泡孔成核。将聚丙烯聚合物以1380磅/小时(626千克/小时)的速率与0.30pph滑石、0.21pph UltranoxTM 815P稳定剂(来自GE SpecialtyChemcials)、0.3pph硬脂酸钙一起加料到挤出机中。将该塑化凝胶混合物与3.9pph异丁烷在压力下混合，冷却至161.5℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在20英寸直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为10.9毫米且宽度为1600毫米，开孔含量为2.2％，密度为3.4pcf(54.5kgm)，且平均泡孔尺寸为5.2毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为141psi(1MPa)，且可发泡指数为20.3。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例6
由75％聚丙烯PF-814(来自Montell)和25％AFFINITYTMPL-1880聚乙烯(来自Dow Chemical Company)的共混物生产出挤制泡沫材料片材。PL-1880是一种聚乙烯树脂，其熔体指数为1.0dg/min，密度为0.9020克/毫升，且I10/I2为9.0。在实施例l所公开的装置上生产该泡沫材料片材。将聚合物共混物以1000磅/小时(454千克/小时)的速率与0.4pph滑石和0.3pph UltranoxTM 815P稳定剂(来自GESpecialty Chemcials)一起加料到挤出机中。将该塑化凝胶混合物与6.0pph异丁烷在压力下混合，冷却至157℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在20英寸直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为7毫米且宽度为1600毫米，开孔含量为14.4％，密度为3.6pcf(57.7kgm)，且平均泡孔尺寸为3.4毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为72psi(0.5MPa)，且可发泡指数为14.0。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例7
由75％聚丙烯PF-814(来自Montell)和25％AFFINITYTMPL-1880聚乙烯(来自Dow Chemical Company)的共混物生产出挤制泡沫材料片材。PL-1880是一种聚乙烯树脂，其熔体指数为1.0dg/min，密度为0.9020克/毫升，且I10/I2为9.0。在实施例1所公开的装置上生产该泡沫材料片材。将聚合物共混物以1000磅/小时(454千克/小时)的速率与0.4pph滑石和0.3pph UltranoxTM 815P稳定剂(来自GESpecialty Chemcials)一起加料到挤出机中。将该塑化凝胶混合物与6.0pph异丁烷在压力下混合，冷却至157℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在20英寸直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为9.8毫米且宽度为1600毫米，开孔含量为5.8％，密度为2.7pcf(43.3kgm)，且平均泡孔尺寸为4.5毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为70psi(0.5MPa)，且可发泡指数为13.0。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例8
由75％聚丙烯PF-814(来自Montell)和25％AFFINITYTM PL-1880聚乙烯(来自Dow Chemical Company)的共混物生产出挤制泡沫材料片材。PL-1880是一种聚乙烯树脂，其熔体指数为1.0dg/min，密度为0.9020克/毫升，且I10/I2为9.0。在实施例1所公开的装置上生产该泡沫材料片材。将聚合物共混物以1200磅/小时(545千克/小时)的速率与0.4pph滑石和0.3pph UltranoxTM 815P稳定剂(来自GESpecialty Chemcials)一起加料到挤出机中。将该塑化凝胶混合物与6.0pph异丁烷在压力下混合，冷却至156℃，然后传送至环状模头，在此将其膨胀至具有较低压力的区，在20英寸直径冷却心轴上拉伸形成一种管状泡沫材料片材产品。该管状片材随后劈开成平整片材。
该泡沫材料的厚度为14.6毫米且宽度为1600毫米，开孔含量为3.3％，密度为2.6pcf(41.7kgm)，且平均泡孔尺寸为3.2毫米。该泡沫材料较刚性，在支撑其自身重量时不流挂，且可热成型。该泡沫材料按照SAE J949所述方法测定的断裂弯曲强度值为58psi(0.4MPa)，且可发泡指数为9.5。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例9
将实施例8的泡沫材料片材层压上1.6密耳(0.04毫米)厚的多层膜。该膜由两层组成：a)乙烯一丙烯酸共聚物/线型低密度聚乙烯共混物(60/40)；b)均聚物聚丙烯。粘合剂层a)占膜厚度的XX％。将该膜层压到泡沫材料的一面。层压之后，将膜/泡沫材料结构切成3英寸×12英寸截面并按照SAE Test J949测试弯曲强度。所得结构需要大于25牛顿才能弯曲1英寸(25.4毫米)。该泡沫材料的可发泡指数为9.5。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例10
将实施例5的泡沫材料片材层压上如实施例9所述的1.6密耳(0.04毫米)厚的多层膜。将该膜层压到泡沫材料的一面。层压之后，将膜/泡沫材料结构切成3英寸×12英寸截面并按照SAE Test J949测试弯曲强度。该泡沫材料的可发泡指数为20.3。所得结构需要大于45牛顿才能弯曲1英寸(25.4毫米)。实施例5的泡沫材料需要20牛顿来弯曲1英寸(25.4毫米)。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。
实施例11
将实施例7的泡沫材料片材层压上如实施例9所述的1.6密耳(0.04毫米)厚的多层膜。将该膜层压到泡沫材料的一面。层压之后，将膜/泡沫材料结构切成3英寸×12英寸截面并按照SAE Test J949测试弯曲强度。该泡沫材料的可发泡指数为13.0。所得结构需要大于14牛顿才能弯曲1英寸(25.4毫米)。将该泡沫材料切割并模塑成车辆头顶内衬的所需型材，然后将一层装饰织物粘附到其上。将该头顶内衬安装在邻近车辆室顶下方的车辆中，然后利用合适的粘合剂粘附。

Claims (32)

1．一种车辆，该车辆具有乘客室和位于乘客室顶上的室顶，该车辆具有一个位于室顶下方的头顶内衬，该头顶内衬包括一热成型核层，该核层包含挤制的热塑性泡沫材料和可有可无的一层或多层相邻的基本上非发泡的热塑性塑料，该核层基本上没有热固性材料，该核层基本上耐流挂且能够基本上保持其形状。
2．根据权利要求1的车辆，其中所述核层已将装饰层层压到其主要表面之一。
3．根据权利要求2的车辆，其中所述装饰层选自毛毡层和织物层。
4．根据权利要求1的车辆，其中所述核层基本上没有热固性或热塑性材料的纤维打毛层。
5．根据权利要求1的车辆，其中所述核层基本上由挤制热塑性泡沫材料组成，所述头顶内衬还具有层压到所述核层的一个主要表面上的装饰层。
6．根据权利要求1的车辆，其中所述核层基本上由挤制热塑性泡沫材料和一层或多层基本上非发泡热塑性塑料组成。
7．根据权利要求1的车辆，其中所述泡沫材料在制造或热成型之前的密度为约16-160千克/立方米。
8．根据权利要求1的车辆，其中所述泡沫材料在制造或热成型之前的密度为约16-80千克/立方米。
9．根据权利要求1的车辆，其中所述热塑性塑料包含以丙烯聚合物材料总重为基础计大于50％重量的丙烯单体单元。
10．根据权利要求1的车辆，其中所述热塑性塑料包含以丙烯聚合物材料总重为基础计约70％重量或更高的丙烯单体单元。
11．根据权利要求1的车辆，其中所述泡沫材料是聚酯泡沫材料。
12．根据权利要求1的车辆，其中所述泡沫材料是聚碳酸酯。
13．根据权利要求1的车辆，其中所述泡沫材料是聚酰胺。
14．根据权利要求1的车辆，其中所述泡沫材料的横截面厚度为1.5毫米或更高。
15．根据权利要求1的车辆，其中所述泡沫材料的横截面厚度为3毫米或更高。
16．根据权利要求1的车辆，其中所述泡沫材料由两个或多个层压片材制成。
17．根据权利要求9的车辆，其中所述泡沫材料是合并线材构型的挤制泡沫材料。
18．根据权利要求1的车辆，其中所述泡沫材料具有颗粒和/或纤维形式的填料。
19．根据权利要求1的车辆，其中所述泡沫材料的横截面厚度为1.5毫米或更高，所述热塑性塑料包含以丙烯聚合物材料总重为基础计大于50％重量的丙烯单体单元，所述泡沫材料在制造或热成型之前的密度为约16-160千克/立方米。
20.根据权利要求1的车辆，其中所述泡沫材料的横截面厚度为3毫米或更高，所述热塑性塑料包含以丙烯聚合物材料总重为基础计约70％重量或更高的丙烯单体单元，所述泡沫材料在制造或热成型之前的密度为约16-80千克/立方米。
21．根据权利要求1的车辆，其中所述泡沫材料在其中具有一个或多个非发泡板或型材。
22．一种组装头顶内衬并将其安装在车辆中的方法，该车辆具有一个乘客室和位于乘客室顶上的室顶，该方法包括：a)提供一种可热成型的核层，它包含挤制热塑性泡沫材料和可有可无的一层或多层相邻的基本上非发泡热塑性塑料，其中所述核层基本上没有热固性材料，基本上耐流挂，且能够基本上保持其形状；b)将该核层通过向其上施加热和机械压力而热成型为头顶内衬；c)将该头顶内衬定位在室顶的下侧。
23．根据权利要求22的方法，其中将装饰层邻近所述核层平行放置并层压到其上，所述装饰层在核层热成型之前或之后层压到所述核层上。
24．根据权利要求22的方法，其中所述泡沫材料的横截面厚度为1.5毫米或更高，所述热塑性塑料包含以丙烯聚合物材料总重为基础计大于50％重量的丙烯单体单元，所述泡沫材料在制造或热成型之前的密度为约16-160千克/立方米。
25．根据权利要求22的方法，其中所述泡沫材料的横截面厚度为3毫米或更高，所述热塑性塑料包含以丙烯聚合物材料总重为基础计约70％重量或更高的丙烯单体单元，所述泡沫材料在制造或热成型之前的密度为约16-80千克/立方米。
26．根据权利要求22的方法，其中所述泡沫材料在其中具有一个或多个非发泡板或型材。
27．根据权利要求22的方法，其中所述泡沫材料是聚酯泡沫材料。
28．根据权利要求22的方法，其中所述泡沫材料是聚碳酸酯泡沫材料。
29．根据权利要求22的方法，其中所述泡沫材料是聚酰胺泡沫材料。
30．根据权利要求1的方法，其中所述泡沫材料在其中具有一个或多个非发泡板或型材。
31．一种车辆头顶内衬，它具有至少一层厚度为1.5-25毫米的热成型核层所述核层由挤制热塑性泡沫材料组成，所述泡沫材料在热成型之前的凝胶含量低于10％，开孔含量低于50％，密度为16-200千克/立方米，宽度至少为12英寸，且平均泡孔尺寸为1.0-5.5毫米。
32．根据权利要求30的头顶内衬，其中所述热塑性泡沫材料的可发泡指数大于2.0。
CN99806608A 1998-05-27 1999-04-29 由可热成型的热塑性泡沫片材构成的车辆头顶内衬 Pending CN1303337A (zh)

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