Rigid thermoformable foam for headliner application
AssigneeJohnson Controls Technology Company
InventorBrian L. Erickson
Life of this patent
Estimating the term…
Abstract
A thermoformable laminate including a rigid thermoplastic foam sheet and a fiber reinforcing layer adhered to each of two opposite faces of the rigid thermoplastic foam sheet is heated to the thermoforming softening temperature of the rigid thermoplastic foam sheet, and shaped and compressed to form a headliner having varying thicknesses, including a major portion of the headliner which is relatively thin and highly compressed, and at least one relatively thick, lightly compressed or non-compressed impact absorption area. The thermoformable laminate and method make it possible to form a headliner with integral impact absorption areas from a laminate of uniform thickness and density, using a single thermoforming operation.
Claims21
A thermoformable laminate comprising:
- a rigid thermoplastic foam sheet, and a fiber reinforcing layer adhered to each of two opposite faces of the rigid thermoplastic foam sheet, wherein the rigid thermoplastic foam sheet is doped with carbon black at a concentration of from about 0.0000081 to about 0.0081% by weight.
A method of forming a headliner with at least one integral impact absorption area, comprising:
- providing a thermoformable laminate including a rigid thermoplastic foam sheet having a thermoforming softening temperature range, a substantially uniform thickness, and a substantially uniform density, and a fiber reinforcing layer adhered to each of two opposite faces of the rigid thermoplastic foam sheet;
- heating the thermoformable laminate to the thermoforming softening temperature range;
- and
- shaping and compressing the heated thermoformable laminate to form a headliner having varying thicknesses, including a major portion of the headliner which is relatively thin and highly compressed, and at least one relatively thick, lightly compressed or non-compressed impact absorption area.
A method of forming a headliner with at least one integral impact absorption area, comprising:
- providing a thermoformable laminate including a rigid thermoplastic foam sheet having a thermoforming softening temperature range, a substantially uniform thickness, and a substantially uniform density, and a fiber reinforcing layer adhered to each of two opposite faces of the rigid thermoplastic foam sheet;
- heating the thermoformable laminate to the thermoforming softening temperature range;
- and
- shaping and compressing the heated thermoformable laminate to form a headliner having varying thicknesses, including a major portion of the headliner which is relatively thin and highly compresses, and at least one relatively thick, lightly compressed or non-compressed impact absorption area, wherein the rigid thermoplastic foam sheet is doped with carbon black at a concentration of from about 0.0000081 to about 0.0081% by weight.
A vehicle headliner with at least one integral impact absorption area, comprising:
- a thermoformed laminate including a unitary, rigid thermoplastic foam sheet which has a major portion which is relatively thin and dense, and at least one relatively thick, lower density impact absorption area.
A thermoformable laminate comprising:
- a rigid thermoplastic foam sheet, and a fiber reinforcing layer adhered to each of two opposite faces of the rigid thermoplastic foam sheet, wherein the rigid thermoplastic foam sheet has a density of from about 1.5 to about 2.5 pounds per cubic foot and a thickness of from about 18 millimeters to about 25 millimeters.
A thermoformable laminate comprising:
- a rigid polyurethane foam sheet and a fiber reinforcing layer adhered to each of two opposite faces of the rigid polyurethane foam sheet, wherein the rigid polyurethane foam sheet has a thickness of from about 18 millimeters to about 25 millimeters.
Dependencies are inferred from the claim text.