Foam in place urethane for structural headliners
AssigneeLear Corporation
InventorsBari William Brown, George Bernard Byma
Life of this patent
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Abstract
A method for forming a headliner assembly includes forming a main body blank having a periphery in a shape corresponding to a desired shape of the headliner assembly, the mold has a correspondingly shaped surface with a recess including an intermediate wall portion. The method includes introducing foam into the recess to simultaneously form at least one foam beam enclosing a selected component area, and join the at least one beam to the main body. The intermediate wall can be an accessory, and the beam may be formed to surround the component area. Additional foam application may be included to acoustically control the headliner's response to buzz, squeaks and rattles.
Claims15
A method for forming a headliner comprising:
- forming a main body by shaping a substrate blank;
- positioning said blank in a mold having at least one mold surface conforming to said shaping and having a recess including an intermediate wall separating a portion of the recess;
- closing the at least one mold surface against said blank;
- and
- introducing foam into said recess to form a foam beam and to join said foam beam to said blank.
A method for forming a headliner comprising:
- forming a main body by shaping a substrate blank;
- positioning said blank in a mold having at least one mold surface conforming to said shaping and having a recess extending across a dimension of said shaping;
- applying a component in alignment with at least a portion of said recess to one of said substrate and a surface of said mold recess;
- closing the at least one mold surface against said blank;
- and
- injecting foam into said recess to form a foam beam and embedding said component at said portion of said recess, and joining said foam beam to said blank.
A method for forming a headliner comprising:
- forming a main body by shaping a substrate blank;
- positioning said blank in a mold having at least one mold surface conforming to said shaping and having a first recess extending across a dimension of said shaping, and at least one second recess;
- closing the at least one mold surface against said blank;
- injecting foam into said recess extending across said dimension to form a foam beam and to join said foam beam to said blank;
- and
- injecting an acoustic foam into said at least one second recess to form a foam pad in contact with said substrate.
Dependencies are inferred from the claim text.