Insulating laminate

A contoured vehicle headliner, said headliner being formed of a composite laminate including a finish surface and an opposite substrate support surface adapted to be bonded to a vehicle roof, said composite laminate comprising:

• a finish lamina,
• a fiber mat impregnated with a polymeric resin bonded to said finish lamina,
• said fiber mat including a blend of fibers of different fineness ranging from 5 to 30 denier,
• a polymeric foam lamina bonded to said fiber mat and a scrim bonded to said foam lamina forming said substrate support surface,
• said scrim comprising randomly arranged nonwoven thermoset polymeric filaments having fineness of about two to ten denier, said filaments bonded at the filament junctions forming a support for said headliner and said substrate support surface.

A contoured vehicle headliner, said headliner being formed of a composite laminate including a finish surface and an opposite substrate support surface adapted to be bonded to a vehicle roof, said composite laminate comprising:

• a finish lamina,
• a fiber mat impregnated with a polymeric resin bonded to said finish lamina,
• said fiber mat including a blend of fibers of different fineness ranging from 5 to 30 denier,
• a thermoplastic polymeric film having a thickness of less than five millimeters located between said finish lamina and said fiber mat,
• a polymeric foam lamina bonded to said fiber mat and a scrim bonded to said foam lamina forming said substrate support surface,
• said scrim comprising randomly arranged nonwoven thermoset polymeric filaments bonded at the filament junctions forming a support for said headliner and said substrate support surface.

A contoured vehicle headliner, said headliner being formed of a composite laminate including a finish surface and an opposite substrate support surface adapted to be bonded to a vehicle roof, said composite laminate comprising:

• a finish lamina,
• a fiber mat impregnated with a polymeric resin bonded to said finish lamina,
• said fiber mat including a blend of fibers of different fineness ranging from 5 to 30 denier,
• a flexible, relatively thin film located between said finish lamina and said fiber mat, said film having a plurality of spaced openings in a predetermined pattern adapted to absorb sound primarily at predetermined frequencies in the low to mid ranges,
• a polymeric foam lamina bonded to said fiber mat and a scrim bonded to said foam lamina forming said substrate support surface,
• said scrim comprising randomly arranged nonwoven thermoset polymeric filaments bonded at the filament junctions forming a support for said headliner and said substrate support surface.

A contoured vehicle headliner, said headliner formed of a composite laminate including a finish surface and an opposite substrate support surface to be bonded to a vehicle roof, said composite laminate comprising:

• a finish lamina;
• a fiber mat bonded to said finish lamina;
• a polymeric foam lamina bonded to said fiber mat;
• a scrim comprising thermoset polymeric filaments bonded at the filament junctions forming a support for said headliner and said substrate support surface;
• and
• a thin thermoplastic polymeric film having a thickness of less than 5 millimeters located between said finish lamina and said fiber mat bonding said finish lamina to said fiber mat.