Vehicle headliner and laminate therefor
AssigneeJason, Inc.
InventorsMichael D. Sandoe, Michael G. Zimmer
Life of this patent
Estimating the term…
Abstract
A headliner made from a laminate comprising a core layer sandwiched between two stiffening layers to form an I-beam construction that provides the necessary strength for the headliner. The core layer is preferably a blend of nonwoven fibers including some fine denier fibers to provide improved sound absorption properties. The stiffening layers also comprise a blend of nonwoven fibers. Both the core layer and the stiffening layers include some binder fibers to bond together the various fibers within each layer and the layers to each other.
Claims64
A laminate for use in making a thermoformed article, the laminate comprising:
- first and second strengthening layers and a core layer disposed between the strengthening layers, with the strengthening layers providing the predominate flexural rigidity for the laminate and the core layer providing the predominate sound absorption for the laminate;
- the core layer comprises a batt of nonwoven thermoplastic fibers comprising:
- 20-50% fine fibers with a denier in the range of 0.8-3.0;
- and
- 10-50% binder fibers for at least binding together the fine fibers;
- and
- regular fibers having denier in the range of 4.0-15 denier;
- the first and second strengthening layers comprise a batt of nonwoven polymeric fibers comprising:
- regular fibers having a denier greater than the fine fibers of the core layer and in an amount to provide flexural rigidity to the laminate.
A headliner for a vehicle comprising:
- first and second strengthening layers and a core layer disposed between the strengthening layers, with the strengthening layers providing the predominate flexural rigidity for the headliner to prevent sagging and the core layer providing the predominate sound absorption for the headliner;
- the core layer comprises a batt of nonwoven thermoplastic fibers comprising:
- 20-50% fine fibers with a less than 2.7 for absorbing sound;
- and
- 10-50% binder fibers for at least binding together the fine fibers;
- and
- the first and second strengthening layers comprise a batt of nonwoven polymeric fibers comprising:
- regular fibers having a denier greater than the fine fibers of the core layer and of an amount to provide flexural rigidity to the headliner.
A laminate for use in making a thermoformed article, the laminate comprising:
- first and second strengthening layers and a core layer disposed between the strengthening layers, with the strengthening layers providing the predominate flexural rigidity for the laminate and the core layer providing the predominate sound absorption for the laminate;
- the core layer comprises a batt of nonwoven thermoplastic fibers comprising:
- 20-50% fine fibers with a denier in the range of approximately 0.8-3.0 denier for absorbing sound;
- 10-50% binder fibers for at least binding together the fine fibers;
- and
- the balance of regular fibers having a denier in the range of about 4.0-15.0;
- the first and second strengthening layers comprising a batt of nonwoven polymeric fibers and have a density greater than the core layer.
A laminate for use in making a thermoformed article, the laminate comprising:
- first and second strengthening layers and a core layer disposed between the strengthening layers, with the strengthening layers providing the predominate flexural rigidity for the laminate and the core layer providing the predominate sound absorption for the laminate;
- the core layer comprises a batt of nonwoven thermoplastic fibers comprising:
- 20-50% fine fibers with a denier in the range of approximately 0.8-3.0 denier for absorbing sound;
- and
- 10-50% binder fibers for at least binding together the fine fibers;
- and
- the first and second strengthening layers comprise a batt of nonwoven polymeric fibers and the core layer has a resistivity greater than at least one of the first and second strengthening layers.
Dependencies are inferred from the claim text.