# US 7,744,150 B2 · Roof liner and procedure for obtaining a roof liner for vehicles > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,744,150 B2 - Document ID: US7744150B2 - Status: Granted - Kind: B2 - Application number: 11/774,484 - Filed: 2007-07-06 - Published: 2009-07-09 - Granted: 2010-06-29 - Earliest claimed: 2006-07-11 - Assignees: Groupo Antolin-Ingenieria, S.A. - Inventors: Anselmo Ariznavarreta Esteban; Francisco Javier Morente Manero - Web page: https://patentgrep.com/patent/US7744150B2 ## CPC - B32B 5/245: {another layer next to it being a foam layer} - B32B 5/18: characterised by features of a layer {of} foamed material - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 19/06: next to a fibrous or filamentary layer - B32B 27/12: next to a fibrous or filamentary layer - B32B 2255/02: on fibrous or filamentary layer - B32B 2262/0284: Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT] - B32B 2266/0278: Polyurethane - B32B 2605/00: Vehicles - B60R 13/0225: {self supporting head liners} - Y10T 156/1043: Subsequent to assembly - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The procedure comprises the following steps: a) joining a foam layer (1) and a plastic fibre mat (2); b) joining a plurality of additional layers (3, 4, 5, 6) to the central core (1, 2), joining at least one of said additional layers (3, 4, 5, 6) to the central core by a second thermostable adhesive (8, 9); c) applying pressure and heat to the product to give it a predetermined configuration and to polymerize the adhesive. The invention also relates to a roof liner. ## Claims ### Claim 1 Procedure for obtaining a roof liner for a vehicle, comprising the following steps: a) joining a foam layer and a mat of plastic fibres using a first adhesive placed between said foam layer and said mat, to form a central core comprising said foam layer and said mat; b) joining a plurality of additional layers to the central core to form a layered product comprising said central core and said additional layers, joining at least one of said additional layers to the central core by a second adhesive; c) applying pressure to the layered product in a press to give it a predetermined configuration; wherein said second adhesive comprises a thermosetting adhesive; and wherein in step c) pressure and heat are applied in the press to produce a substantial polymerisation of the second adhesive. ### Claim 2 (depends on 1) Procedure according to claim 1, in which, in step b), said second adhesive is applied on the greater free surfaces of the central core to join the additional layers to said central core. ### Claim 3 (depends on 1) Procedure according to claim 1, in which said first adhesive comprises a thermosetting adhesive. ### Claim 4 (depends on 1) Procedure according to claim 1, in which a reinforcement layer is placed between the foam layer and the mat of plastic fibres. ### Claim 5 (depends on 1) Procedure according to claim 1 in which, in step a), the mat of plastic fibres has a weight per unit surface greater than or equal to 100 g/m2 and less than or equal to 500 g/m2. ### Claim 6 (depends on 1) Procedure according to claim 1 in which, in step a), the mat of plastic fibres is a non-woven mat. ### Claim 7 (depends on 6) Procedure according to claim 6, in which, in step a), said mat of plastic fibres comprises plastic fibres interlinked to constitute a set of fibres joined mechanically without adhesive. ### Claim 8 (depends on 1) Procedure according to claim 1, in which said plastic fibres comprise PET fibres. ### Claim 9 (depends on 8) Procedure according to claim 8, in which at least 90% of said plastic fibres are PET fibres. ### Claim 10 (depends on 1) Procedure according to claim 1, in which from 10% to 30% of said plastic fibres are recycled fibres. ### Claim 11 (depends on 1) Procedure according to claim 1 in which, in step a), the foam layer has a density greater than or equal to 10 kg/m3 and less than or equal to 45 kg/m3. ### Claim 12 (depends on 1) Procedure according to claim 1, in which the foam layer is a semi-rigid layer. ### Claim 13 (depends on 1) Procedure according to claim 1, in which the foam layer is a polyurethane layer. ### Claim 14 (depends on 1) Procedure according to claim 1, in which the second adhesive is a thermosetting resin. ### Claim 15 (depends on 1) Procedure according to claim 1, in which in step b) at least one reinforcement layer is applied in correspondence with a first surface of the central core, and at least one reinforcement layer is applied in correspondence with a second surface of the central core. ### Claim 16 (depends on 15) Procedure according to claim 15, in which at least one of said reinforcement layers is a layer of natural or mineral reinforcement fibres. ### Claim 17 (depends on 15) Procedure according to claim 15, in which at least one of said reinforcement layers is a PET film. ### Claim 18 (depends on 1) Procedure according to claim 1, in which, before step a), the mat of plastic fibres is obtained by cutting it from a roll of interlinked plastic fibres material. ### Claim 19 (depends on 1) Procedure according to claim 1, in which, before step a), a stack of foam layers is disposed so that the foam layer is obtained from said stack of foam layers. ### Claim 20 (depends on 1) Procedure according to claim 1, in step b), said additional layers comprise at least one reinforcement layer and one hidden surface coating. ### Claim 21 (depends on 1) Procedure according to claim 1, in which in step b) said additional layers also comprise an exposed surface coating. ### Claim 22 (depends on 1) Procedure according to claim 1, in which an exposed surface coating is applied after step c). ### Claim 23 (depends on 1) Vehicle roof liner, obtained by the procedure according to claim 1. ### Claim 24 Vehicle roof liner comprising: a central core comprising a foam layer and a mat of plastic fibres joined by a first adhesive placed between said foam layer and said mat; b) a plurality of additional layers joined to the central core, at least one of said additional layers being joined to the central core by a second adhesive; wherein said second adhesive comprises a thermosetting adhesive. ### Claim 25 (depends on 24) Roof liner according to claim 24, in which said second adhesive is applied on the greater surfaces of the central core to join the additional layers to said central core. ### Claim 26 (depends on 24) Roof liner according to claim 24, in which the first adhesive also comprises a thermosetting adhesive. ### Claim 27 (depends on 24) Roof liner according to claim 24, which additionally comprises a reinforcement layer between the foam layer and the mat of plastic fibres.