Method for forming headliners
AssigneeLear Corporation
InventorsSCOTT A. BARBER, JOHN C. WALTERS, BRIAN H. SCHOLFIELD
Life of this patent
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Abstract
A method for forming a headliner assembly includes forming a main body having a periphery, and a shape corresponding to a desired shape of the headliner assembly; positioning the main body in a mold having a recess; closing the mold; and injecting foam into the recess to simultaneously form an energy absorbing member and join the energy absorbing member to the main body proximate the periphery of the main body.
Claims8
A method for forming a headliner assembly, the method comprising:
- forming a main body having a periphery, and a shape corresponding to a desired shape of the headliner assembly;
- positioning the main body in a mold having a recess;
- closing the mold;
- and
- injecting foam into the recess to simultaneously form an energy absorbing member and join the energy absorbing member to the main body proximate the periphery of the main body.
A method for forming a headliner assembly, the method comprising:
- forming a main body having a periphery, and a shape corresponding to a desired shape of the headliner assembly;
- positioning the main body in a mold having multiple recesses;
- closing the mold;
- and
- injecting foam into the recesses and onto the main body to form multiple energy absorbing members proximate the periphery of the main body.
A method for forming a headliner assembly, the method comprising:
- forming a main body having a shape corresponding to a desired shape of the headliner assembly, the main body including a backing layer, a substrate layer, and a cover layer, wherein the substrate layer is sandwiched between the backing layer and the cover layer, and wherein the backing layer has first and second surfaces, the second surface being attached to the substrate layer;
- positioning the main body between two mold portions of a mold, one of the mold portions having first and second recesses;
- closing the mold;
- injecting foam into the first recess at a first injection density to form a first energy absorbing member on the first surface of the backing layer;
- and
- injecting foam into the second recess at a second injection density different than the first injection density to form a second energy absorbing member on the first surface of the backing layer;
- wherein the first and second energy absorbing members have different densities.
Dependencies are inferred from the claim text.