MXPA01010629A - Vehicle headliner including a polyurethane substrate and multi-layered laminate, and method of making the same - Google Patents

Abstract

A headliner for the interior of the vehicle, such as an automobile, includes a porous polyurethane substrate (102) having an A-side surface and a B-side surface. The B-side surface is united with reinforcing layer. The A-side surface is concealed with a decorative cloth (106), optionally having a foamed backing (108), exposed to the interior of the vehicle. Interposed between the A-side surface and the decorative cloth is a multi-layered laminate (120), which includes an adhesive layer (122) for adhering the multi-layered laminate to the decorative cloth, a barrier layer (124) for preventing the polyurethane or polyurethane precursors from bleeding therethrough during formation of the substrate;and a shape-retaining layer (126) having sufficient strength to prevent the pores in the A-side surface of the substrate from substantially influencing the outer appearance of the decorative cloth.

Description

- - A VEHICLE AWNING INCLUDING A POLYURETHANE SUBSTRATE AND A MULTI-LAYER LAMINATE, AND THE MANUFACTURING METHOD OF THE SAME.

FIELD OF THE INVENTION. This invention relates to awning components for vehicles, and in particular to awning components comprising an impregnated polyurethane substrate and at least one multilayer laminate for joining the substrate to a decorative material. This invention also relates to a method of manufacturing the awning components. BACKGROUND OF THE INVENTION. Awnings are commonly installed on vehicles to provide a decorative appearance for the roofs of the interior compartments of a vehicle. An example of a construction of a known awning is shown in FIG. 2 and in general is designated by the reference number 200. As shown in FIG. 2 the awning 200 includes a relatively thick rigid substrate 202, which may be a material based on a polymer, impregnated with a glass fiber, such as a polyurethane impregnated with glass fiber. The surface of the substrate 202 faces or faces toward the interior compartment of the vehicle (not shown) is known in the industry as "the A side". In the illustrated embodiment, the side A has a stop layer or barrier 204 which contacts the side A surface of the substrate 202. The stop layer or barrier 204 is commonly made of a polyethylene film. The stopping layer 204 is interposed between the substrate 202 and a decorative fabric material 206 having a cellular or foamed reinforcement or backing 208. The decorative fabric material 206 is exposed to the interior compartment of the vehicle and hides the substrate 202 and the stop layer or sight barrier. Placed on the opposite side of the substrate 202, also known in the industry as the "B side" of the substrate 202, is another barrier layer 210, which can be made of a material similar to that of the barrier layer 204. A vibration damping layer 212 (also known as an anti-crunching layer) is optionally interposed between the barrier layer 210 and the vehicle chassis (not shown) to minimize noise and squeaks caused by relative movement between the awning 200 and the chassis of the vehicle during the operation of the vehicle. Vibration dampening layer 212 is commonly made of a cellular or foamed polymeric material. It is known that in order to produce the awning 200, the stop layers 204 and 210 are placed on the mold dies facing opposite each other, then the fiberglass layers are placed on the stop layers 204 and 210. so that the layers of fiberglass face one another to define a molding cavity between them. Then, the polyurethane precursors, such as polyols and polyisocyanates, are mixed and sprayed into the mold and the polyurethane is formed by compression molding, which causes the glass fiber to be dispersed in the polyurethane substrate 202. The fiberglass-impregnated substrate 202 with the attached stop layers 204 and 210 are removed after the mold, adjusted and bonded with the decorative fabric material 206 with a reinforcement or backing 208 foamed on the A side and the 212 layer. vibration damper on side B. The process of manufacturing a conventional awning discussed above has problems that significantly affect its usefulness and productivity. In particular, the polyurethane formation reactions between the polyisocyanates and the polyols due to their very particular tendency to generate a substrate having pores or voids in the surfaces of the substrate, which includes the surface A. The pores are generated mainly during the reaction between the polyol, the catalyst, the water, and the isocyanate. The pores can be generated during the initial foaming of the awning, and / or may become visible after the substrate 202 is cooled. The cooling may take from 24 to 48 hours due to the relatively large thickness of the substrate 202, which may be in the order of 4 mm to 28 mm. Although the substrate 202 is concealed from the interior compartment by means of the barrier layer 204, molded and the decorative fabric material 206, the molded barrier layer 204 and the decorative fabric material 206 tend to form the profile of the surface A of the substrate 202. As a consequence, the pores in the substrate 202 can cause undesirable slits or holes that are formed in the decorative fabric material 206. These holes or slits that are visible with respect to the interior compartment of the vehicle, therefore, guarantee additional processing steps to make the awning visually acceptable. To address or solve the problem of unwanted slots and holes in the decorative fabric material 206, it is common to store the substrate 202 for at least 24 to 27 hours after the molding is completed to allow the substrate 202 to cool sufficiently to allow the slits to appear on the surface A. After this period of storage, either the slits are covered via a correction procedure (using, for example, polypropylene mesh tape) or, if the slits or voids they are very abundant, the substrate is discarded.

- - However, the storage, inspection, and correction of the substrates 202 are time-consuming and labor-intensive and require substantial storage space. Furthermore, the storage of 24 hours to 32 hours of the substrates 202 is sometimes insufficient to allow the detection of the slits or gaps on the surface of the substrate. In particular, the relatively large thickness of the urethane substrate 202 compounds the problem of detecting slits or voids in the surface A of the substrate 202, since sometimes the slits do not appear for several days or weeks. On occasions in which the awning has already been shipped to a buyer and / or has been installed in a vehicle before the cracks and gaps appear, the cancellation of the parts and the disassembly of the interiors of the vehicle to remove the awning defective can result, which alters the manufacturer and increases costs. In addition, the post-assembly inspection of the awning 202 also increases labor costs. Thus, there is a significant need in the art for a vehicle awning that eliminates or at least significantly reduces the formation of crevices and holes and the problems associated with the detection of slits and holes in the awning. The process should desirably be capable of being implemented without requiring significant modifications to existing processes and manufacturing equipment. BRIEF DESCRIPTION OF THE INVENTION It is, therefore, an object of this invention to solve the aforementioned problems associated with the related art as well as to address or solve the need expressed above. In accordance with the principles of this invention, these and other objects are achieved by providing an awning in which the reinforcement layer interposed between the surface A of the substrate and the decorative fabric material comprises a multilayer laminate. The multilayer laminate includes at least one adhesive layer for adhering the multilayer laminate to the decorative fabric, a stop layer or barrier, and a shape retaining layer. The stop layer or barrier is constructed and arranged to prevent the exudation of the polyurethane or the polyurethane precursors through them during the molding of the polyurethane. The shape retaining layer has sufficient strength to substantially prevent pores in the substrate from influencing the outer appearance of the decorative fabric material. There is also provided in this a process of manufacturing an awning that overcomes the problems discussed above and achieves the need to identify the foregoing - in the art. Desirably, the practice of the inventive process does not require or only requires minor modifications to the conventional process equipment; Thus, a little capital investment is needed to convert the inventive process. The principles of this invention set forth above are applicable to various types of vehicles, including passenger cars, trucks, vans, utility vehicles, and others. BRIEF DESCRIPTION OF THE DRAWINGS The appended drawings facilitate an understanding of this invention when describing one embodiment of the invention and comparing it with a known awning. In the drawings: Figure 1 is a sectional view of an awning according to an embodiment of this invention; Figure 2 is a sectional view of a known awning; and Figure 3 is a schematic view showing an example of the placement of an awning in a vehicle. DETAILED DESCRIPTION OF THE INVENTION Now with reference more particularly to the drawings, an awning of one embodiment of this invention is shown in Figure 1 and generally designated by reference numeral 100. The awning 100 includes a relatively thick rigid substrate 102, which may be a material based on a polymer impregnated with fiberglass, such as a polyurethane impregnated with fiberglass. The surface of the substrate 102 faces towards the interior compartment of the vehicle (not shown) is known in the industry as the side surface A, in view of the opposite surface of the substrate 102 facing or placing away from the interior of the vehicle when the awning 100 is assembled is referred to as the surface of the B side. In general, the thickness of the impregnated substrate 102 is, for example, in the range of about 4 mm to about 24 mm, and more preferably is from 4 mm to 18 mm. Representative densities for the impregnated substrate 102 range from 48 Kg / m2 to 160 Kg / m2 (3.0 to 10.0 lb / ft2). Placed on the surface of the side A of the substrate 102 is a multilayer laminate 120, which in the illustrated embodiment is a three layer laminate. The multilayer laminate 120 is interposed between the substrate 102 and the decorative fabric material 106 having an optional foamed or cellular reinforcement or backing. The decorative fabric material 106, which may be manufactured, by way of example, of nylon, rayon, polyester, cotton, or combinations thereof, is exposed in the interior compartment of the vehicle and conceals the substrate 102 and the laminate 120. of the - - view. The thickness of the three layer laminate 120 may be in the range of about 0.025 mm to 0.051 mm (ie, 1.0 mil to 2.0 mil, or 0.0010 inch to 0.0020 inch), preferably 0.038 mm to 0.051 mm (i.e. , 1.5 thousandths to 2 thousandths of an inch, or 0.0015 inches to 0.0020 inches). The first layer of the three-layer laminate 120 is an adhesive layer 122, which adheres the multilayer laminate 120 to the decorative fabric 106 and to its optional cellular or foamed reinforcement. In a preferred embodiment, the adhesive layer 122 is ethylene-vinyl acetate, although other less preferred adhesives, such as polyethylene, can be used. In general, the deposition of the adhesive layer 122 is controlled to produce a thickness which, when measured as a concentration over a cross section of the adhesive layer 122, is in the range of 30 g / m2 to 40 g / m2. The ethylene-vinyl acetate layer 122 is preferably treated with corona discharge, for example fire treated or electrically or electrostatically charged, to have a dyne level of 46 to 55, preferably 47 to 49 dynes. The adhesive layer 122 should have a softening temperature lower than the temperature at which the decorative fabric material 106 is thermally degraded, so that the adhesive layer 122 can be softened or fused without discoloring the decorative fabric material 106. In general, softening temperatures of about 99 ° C (210 ° F) to about 104 ° C (220 ° F) are preferred for the adhesive layer 122. The second layer of the laminate 120 is a stop or barrier layer 124 that functions to prevent exudation of the polyurethane and the polyurethane precursors through the laminate 120 during the molding process, such as compression molding, in which the laminate 120 is placed in the molding die prior to injection of the polyurethane precursors to form the substrate 102. The stop or barrier layer 124 preferably is a film comprising polyethylene, preferably with pores not larger than 25 microns. Other materials, such as polypropylene, polyethylene-polypropylene copolymer films, and other olefin polymers, copolymers and terpolymers can be used, while materials can provide the desired stopping function in a suitable thickness while exhibiting proper molding , the point of fluidity and softening. In general, the deposition of the stopping or barrier layer 124 is controlled to produce a thickness which, when measured as a concentration on a cross section of the stopping or barrier layer 124, it is in the range of 10 g / m2 to 20 g / m2, preferably 16 g / m2. The elongation of the stopping layer 124 is preferably at least 40%. The third layer of the laminate 120 is a retaining layer 126 of the shape having sufficient strength to prevent the configuration of the shape retaining layer 126 from being influenced by the pores in the substrate 102. The retaining layer 126 of the This way prevents the decorative fabric material 106 from conforming to the pores on the surface of the A side of the substrate 102 so that the decorative fabric material 106 is free of holes and slits. In general, the deposition of shape retaining layer 126 is controlled to produce a thickness, which when measured as a concentration on a cross section of shape retaining layer 126, is in a range of 30 g. / m2 at 40 g / m2. The shape retention layer 126 preferably comprises a spunbonded (or "non-woven") polypropylene or polyester. As referred to herein, spunbond or nonwoven materials are characterized by an absence in the distinction of directional properties. As with the stopping layer 124, the shape retaining layer 126 preferably has an extension or elongation of at least 40%. Antioxidants may be added to shape and stop or barrier layers 124 and 126.

- - Retaining layer 126 of the shape of the laminate 120, which is preferably disposed near the substrate 102, is primarily responsible for imparting to the laminate 120 most of its physical properties, although the arresting or barrier layer 124 has sufficient influence as to Distinct in the directional properties of the laminate 120. Desirably, the laminate 120 has a machine tensile strength and a tensile strength of transverse machines (ASTM D 882-83) in ranges of 1898370-2038990 kg / m2 (2700 -2900 psi) and 1687440-1828060 kg / m2 (2400-2600 psi), respectively, and more preferably 2044280 kg / m2 and 1757750 kg / m2 (2800 psi and 2500 psi), respectively. The extension or elongation (ASTM D 882-89) of the laminate 120 is preferably 40-60%, with the extension or elongation of the 45% machine and the 56% cross machine. The tear strength (ASTM D 1922-67) is preferably 512 ± 50 grams / 16 folds along the machine direction and 316 ± 50 grams / 16 folds along the direction of the cross machine.

It can be understood that additional layers, which include more than one of the layers 122, 124, and 126, can be included in the multilayer laminate 120, while the additional layers do not interfere with the functions discussed above of the layers 122. , 124, and 126. According to a preferred embodiment, the laminate 120 can be prepared as follows. The retaining layer 126 of the non-woven shape is extruded by about 0.13 mm to 0.15 mm (5 or 6 mils, or 0.005 inches to 0.006 inches) in thickness over the arresting or barrier layer 124. Layers 124 and 126 then run through a press roll to achieve a desired film thickness of about 0.025 mm to 0.051 mm (i.e., 1.0 mil to 2.0 mil, or 0.0010 inch to 0.0020 inch), This way a bi-laminate is formed. The layers 124 and 126 are then passed through a series of cooling rollers, followed by a series of heating elements to heat the bi-laminate. After the bi-laminate is formed, the adhesive layer 122 is fed into the bi-laminate of the layers 124 and 126 then passed through the layers 124 and 126 through a series of hot rollers which compress and laminate the film 122 adhesive to the layer 124 to make the tri-laminate 120. The tri-laminate 120 is cooled and, optionally, cut and / or rolled for temporary storage. Placed on the opposite side of the substrate 102, also known in the industry as the "B side" of the substrate 102, is a stop or barrier layer 110. In a preferred embodiment, the stop or barrier layer 110 is a Rochelle (polyethylene copolymer) film, which is available from Rochelle Plastics of Rochelle, Illinois and has a glass transition temperature Tg of 83 ° C. It is also contemplated within the scope of the invention to use other materials such as the stop or barrier layer 110, which includes the use of the multi-layer laminate described above as the stop layer 110. A vibration damping layer 112 is optionally interposed between the arrest or barrier layer 110 and the vehicle chassis (not shown) to minimize the noises and squeaks caused by relative movement between the awning 100 and the vehicle chassis. A representative vibration damping layer 112 is flame laminated polyether grade 11330XXX, available from General Foam of East Rutherford, N.J. As referred to herein, the vibration damping layer 112 also surrounds a thin canvas or cambray material, such as one that has either (a) a bilaminate structure composed of a nonwoven polypropylene film and a polypropylene film, polyethylene, or a polypropylene-polyethylene copolymer or (b) a tri-laminate composed of two non-woven polypropylene films, between which is placed a polypropylene film, polyethylene, or a polypropylene-polyethylene copolymer. The thickness of the non-woven polypropylene is preferably controlled to provide about 33.9 grams / m2 (1 ounce / yard2) of material, since polyethylene and / or polypropylene is about 35.9 grams / m2 (30 grams) / yard2). A manufacturing process of an awning according to an embodiment of this invention will now be described in detail. The substrate 102 is generated in a continuous manner by stacking on a Rochelle conveyor apparatus (polyethylene copolymer film, such as DOW 906, DOW 909, and Nolar films) of a barrier or stop layer 110 and a fiber layer. glass, and loading the stacked layers onto a first die of a compression molding apparatus. A suitable fiberglass roll is available from Nicofiber of Shawnee, Ohio, product number N754, and preferably has a thickness of 0.2 mm to 0.3 mm (ie 8-12 thousandths of an inch, or 0.008 inches to 0.012 inches). A separate conveyor apparatus supplies the multi-layered laminate 120, stacked with another layer of glass fiber to a second die of the compression molding apparatus so that the layers of fiberglass face each other and form a cavity therebetween. . Then, the precursor materials of the polyurethane, ie, the polyols and the polyisocyanates, are sprayed into the mold and the polyurethane is compression molded. The spraying process can be done via standard X-Y standards, with the nozzle placed 30.5 to 61 cm (12 to 24 inches) from the spray surface. Representative polyols and isocyanates are RIMLINE 87335 and RUBINATE 8700, respectively, both of which are available from ICI of Sterling Heights, Michigan. For these particular materials, the ratio (in grams) of isocyanate to polyol is preferably about 0.541: 1 ± 0.050. Due to the rapid reactivity of the polyurethane precursors with one another, the spraying step should be conducted rapidly, preferably in the order of no more than 5 to 10 seconds, more preferably 5 to 6 seconds. The precursors can be introduced into the mold cavity at a chemical temperature of about 32 ° C ± 5 ° C (about 90 ° F ± 10 ° F). Alternative polyols and isocyanates are the BASF ELASTOFLEX TF-23640R polyol and the TF-23640T isocyanate, available from BASF of Wyandotte, Michigan. For these alternative materials, the ratio (in grams) of isocyanate to the polyol is preferably 0.537 ± 0.040, and the temperature at which the precursors are introduced into the mold cavity is preferably about 26.7 ° C ± 2.7 ° C - - (80 ° F ± 5 ° F). According to known molding techniques, one or both of the dies move in one direction with another to a closed position, in which the molding die is slightly separated apart from one another (eg via spacers) during the compression molding to allow the urethane to foam to a desired thickness. During the reaction of the polyurethane precursors and the foaming of the polyurethane, the glass fiber is dispersed in the polyurethane substrate from the opposite die surfaces. The compression molding takes 1 to 2 minutes, preferably 60 to 80 seconds, although the molding time may depend on the thickness of the foam composition, ie its cross section. The temperature of the upper and lower mold halves may be, for example, 74 ° C ± 5 ° C (approximately 16 ° F ± 10 ° F) and 63 ° C ± 5 ° C (approximately 145 ° F ± 10 ° F), respectively. During foaming, the polyurethane is dispersed in the fiberglass. In general, the dispersion of the fibers is not homogeneous throughout the substrate polyurethane 102; preferably, high concentrations of glass fiber are usually found on the opposite surfaces of the polyurethane substrate 102.

- - The molding time is directly dependent on the amount of urethane applied during the spraying process and the thickness of the cross section of the cavity of the mold to be filled. The composition and weight of the fiberglass also affects the cycle time and the integrity of the finished product. The content of the binder is preferably in the range of 4.0 to 6.5% by weight, preferably 5.0% by weight, of the weight of the glass fiber. The glass fiber content is preferably in a range of about 9.8745 to 14.9617 dynes / cm2 (0.33 to 0.50 ounces per square foot). The fiberglass-impregnated substrate 102 with the multi-layered laminate 120 adhered and the reinforcing layer 110 is then removed from the mold, cut, and bonded with the decorative fabric material 106 with a cellular reinforcement or optional foaming on the fabric. side A and the vibration damping layer 112 on the B side. Cutting excess material, known in the art as surplus, can be made by means of a water jet process. The above detailed description of the preferred embodiments of the invention has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise modalities described. Many modifications and variations will be apparent - - for those with experience in this technique. The modalities were selected and described in order to explain much better the principles of the invention and their practical application, thereby allowing other persons with the skill in the art to understand the invention for various modalities and with various modifications when adapted to the use particular contemplated. It is intended that the field of the invention be defined by the following claims. It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention. Having described the invention as above, property is claimed as contained in the following:

Claims (20)

- -
1. CLAIMS 1. An awning that can be mounted against a roof of a vehicle, to form a part of the interior of the vehicle, the awning characterized in that it comprises: a substrate comprising a polyurethane and having a surface of the A side facing or facing the interior of the vehicle and a surface of side B facing or facing away from the interior of the vehicle when the awning is mounted on the vehicle, the surface of side A has pores therein; at least one side B-reinforcing layer bonded to the surface of side B of the substrate; at least one decorative fabric material exposed to the interior of the vehicle and constructed and arranged to conceal the substrate from the view of the interior of the vehicle when the awning is mounted on the vehicle, the decorative fabric material optionally being provided with a cellular or foamed reinforcement; and at least one multilayer laminate interposed between the surface of the A side of the substrate and the decorative fabric material, the multilayer laminate comprises: at least one adhesive layer which adheres the multilayer laminate to the decorative fabric material; at least one stop layer or barrier constructed and arranged to prevent exudation of the polyurethane or the polyurethane precursors therethrough during the formation of the substrate; and at least one retaining layer of the shape having sufficient strength to prevent the pores on the surface of the side A of the substrate from substantially influencing the outer appearance of the decorative fabric material.
2. 2. The awning according to claim 1, characterized in that the stop layer or barrier is interposed between the adhesive layer and the retaining layer of the shape of the multilayer laminate. The awning according to claim 2, characterized in that the adhesive layer comprises ethylene-vinyl acetate. 4. The awning according to claim 2, characterized in that the shape retaining layer comprises a non-woven material. The awning according to claim 4, characterized in that the non-woven material is non-woven polypropylene. 6. The awning according to claim 2, characterized in that the stop layer or barrier comprises polyethylene. The awning according to claim 2, characterized in that the adhesive layer comprises ethylene-vinyl acetate, the shape-retaining layer comprises non-woven polypropylene, and the stop-barrier layer comprises polyethylene. The awning according to claim 7, characterized in that the adhesive layer adheres to the cellular reinforcement of the decorative fabric material and furthermore where the cellular reinforcement provides a damping sensation to the awning. The awning according to claim 7, characterized in that the substrate is impregnated with at least one reinforcing material. The awning according to claim 9, characterized in that the reinforcing material is glass fiber. The awning according to claim 7, characterized in that the B side includes at least one vibration damping layer that is constructed and arranged to reduce the noise generated by the relative movement between the vehicle roof and the awning when mounted . 12. An awning that can be mounted against a vehicle roof to form a part of the interior of the vehicle, the awning characterized in that it comprises: a substrate impregnated with glass fiber and comprising a polyurethane and having a surface of the A side that - faces or faces the interior of the vehicle and a surface of side B facing or facing away from the interior of the vehicle when the awning is mounted on the vehicle, the surface of side A has pores; at least one vibration damping layer is constructed and arranged to reduce the noise generated by relative movement between the vehicle roof and the awning when mounted on the vehicle; at least one reinforcing layer of the B side interposed between the vibration dampening layer and the substrate, the reinforcing layer of the B side joins the surface of the B side of the substrate; at least one decorative fabric material exposed inside the vehicle and constructed and arranged to conceal the substrate from the view of the interior of the vehicle when the awning is mounted on the vehicle, the decorative fabric material optionally having a cellular reinforcement or backing or foamed to provide a cushioning sensation to the decorative fabric material; and at least one multilayer laminate interposed between the surface of the A side of the substrate and the decorative fabric material, the multilayer laminate comprises: at least one adhesive layer that adheres the multilayer laminate with the decorative fabric material, the adhesive layer comprises ethylene-vinyl acetate; at least one retaining layer of the shape having sufficient strength to prevent the pores on the surface of the side A of the substrate from substantially influencing the outer appearance of the decorative fabric material, the shape retaining layer comprising non-woven polypropylene; and at least one stop layer or barrier constructed and arranged to prevent exudation of the polyurethane or polyurethane precursors through the barrier layer during the formation of the substrate, the barrier layer is interposed between the adhesive layer and the barrier layer. the shape retention layer. The method according to claim 12, characterized in that the adhesive layer comprises ethylene-vinyl acetate, the shape-retaining layer comprises non-woven polypropylene, and the stop-barrier layer comprises polyethylene. A vehicle characterized in that it comprises the awning in accordance with claim 1. 15. A vehicle characterized in that it comprises the awning in accordance with claim 12. 16. A method of manufacturing an awning that can be mounted against a roof of a vehicle to form a part - of the interior of the vehicle, the awning comprises a polyurethane substrate having a surface of side A facing or facing the interior of the vehicle and a surface of side B facing or facing away from the interior of the vehicle. vehicle when the awning is mounted on the vehicle, the surface of side A has pores and adheres to at least one multi-layer laminate with at least one decorative fabric material placed in layers thereon, the decorative fabric material is constructed and arranges to hide the substrate and laminate of multiple layers from the view of the interior of the vehicle when the awning is mounted on the vehicle, said method characterized in n comprising: placing the multilayer laminate on the first surface of the mold die, the multilayer laminate comprises at least one adhesive layer for joining the multilayer laminate with the decorative fabric material, in at least one layer stop or barrier constructed and arranged to prevent the exudation of polyurethane or polyurethane precursors therethrough during the formation of the substrate, and at least one shape retention layer, which has sufficient strength to prevent pores on the surface of side A substantially influence on the outer appearance of the decorative cloth material; - - the positioning of at least one reinforcing layer on the second surface of the mold die so that a mold cavity is formed between the multi-layer laminate and the reinforcement layer; the introduction of the composition of the polyurethane precursor into the mold cavity and the foaming of the polyurethane precursor composition to form the substrate having the multilayer laminate attached to the A side thereof and the reinforcement layer bonded to the side B of the same; and the removal of the substrate with the multi-layer laminate and the reinforcing layer bonded thereto, from the mold cavity and the adhesion of the decorative fabric material to the A side thereof. The method according to claim 16, characterized in that the adhesive layer comprises ethylene-vinyl acetate, the shape-retaining layer comprises non-woven polypropylene, and the stop-barrier layer comprises polyethylene. 18. The method according to claim 17, characterized in that said method further comprises the placement of layers of reinforcing fibers in the multilayer laminate and the reinforcing layer before said step of introducing a composition of the polyurethane precursor. - - in the mold cavity so that the foaming step disperses the fibers in the substrate. The method according to claim 18, characterized in that the stop layer or barrier is interposed between the adhesive layer and the retaining layer of the multilayer laminate shape. The method according to claim 19, characterized in that it further comprises the joining of the B side to at least one vibration damping layer constructed and arranged to reduce the noise generated by the relative movement between the vehicle roof and the awning when it mounts.