Abstract: A method and apparatus for making a sheet of material from a fiber textile-like mat is provided, the apparatus comprising a press having a pair of movable endless belts having adjacent runs adapted to receive a mat of fibers of thermoplastic material mixed with other fibers therebetween and having outer returning runs, the press having a compressing unit for compressing the mat between the adjacent runs of the belts to densify the mat, the press having a heating unit for heating the mat between the adjacent runs of the belts, and the press having a cooling unit for cooling the mat between the adjacent runs of the belts after the mat has been heated and densified by the heating unit and the compressing unit, the heating unit that heats the mat also preheating the outer runs of the belts before the mat is received between the adjacent runs of the belts.

Abstract: A longitudinally adjustable vehicle seat construction and method of making the same are provided, the seat construction comprising a lower structural seat frame unit, a seat cushion unit supported by the lower seat frame unit, and an upper slide unit carried by the construction for sliding longitudinally on a fixed lower slide unit carried by a vehicle to thereby permit longitudinal adjustment of the seat construction in the vehicle, the upper slide unit comprising a structural part of the lower structural seat frame unit.

Abstract: A fastener receiver for a vehicle panel construction, panel construction employing same, and method of fastening such panel construction employing such receiver are provided wherein the receiver is an improved two-piece receiver which is adapted to receive a portion of an associated fastener which is fastened to a vehicle frame to thereby fasten the panel construction to such frame in a concealed manner.

Abstract: An apparatus and method are disclosed for forming a fibrous workpiece comprised of a layer of randomly disposed fibers and adhesive material dispersed throughout the fibers for binding same upon heating and compressing the fibers and adhesive material to define a unitary pad wherein the apparatus comprises a press having a first and a second platen supported for relative movement toward and away from each other, a first and a second mold supported by the first and second platens respectively with the molds having forming surfaces which define the configuration of the pad, and means for heating the workpiece wherein the heating means comprises means for providing hot humid air through the workpiece to provide a rapid penetration and improved heating of the fibers and adhesive material resulting in comparatively high speed forming of the pad with a minimum forming pressure.

Abstract: A composite laminate material and a process for making the same are provided, the process comprising the steps of providing an unbonded fibrous batt of desired thickness having a thermosetting binder material dispersed therethrough, applying a layer of desired thickness of a curable latex to at least one side of the fibrous batt, drying the layer to a predetermined moisture level to provide a dried composite material, and heating and compression molding the dried composite material to simultaneously mold the composite, cure the layer and cure the binder material by embossing a pattern into the exposed side of the layer before the layer and the binder material are cured to cause the layer to be contoured with the pattern substantially throughout the thickness thereof and thereby cause the pattern to be substantially impressed into one side of the batt so that the resulting embossed and cured layer has a substantially uniform thickness and the one side of the cured batt substantially conforms to the embossed co

Abstract: An apparatus and method are disclosed for forming a fibrous workpiece comprised of a layer of randomly disposed fibers and adhesive material dispersed throughout the fibers for binding same upon heating and compressing the fibers and adhesive material to define a unitary pad wherein the apparatus comprises a press having a first and a second platen supported for relative movement toward and away from each other, a first and a second mold supported by the first and second platens respectively with the molds having forming surfaces which define the configuration of the pad, and means for heating the workpiece wherein the heating means comprises means for providing hot humid air through the workpiece to provide a rapid penetration and improved heating of the fibers and adhesive material resulting in comparatively high speed forming of the pad with a minimum forming pressure.

Abstract: An automobile headliner and method of making same are provided wherein such headliner comprises a substrate defined by a compacted and rigidified fibrous material with the substrate having a peripheral portion which is more highly compacted than the remainder thereof and a decorative sheet is bonded to the substrate to define a single-piece laminate which has a solid cross section throughout and wherein the peripheral portion has an annular enlargement and the decorative sheet covers the enlargement and defines a sheet-covered enlargement which serves as an integral garnish molding for the headliner.

Abstract: An improved acoustical and trim acoustical panel suitable for use in the interior passenger compartments and exterior components of automotive vehicles or the like, comprising a plurality of fibrous layers of controlled different density, integrally united together at their interfaces and optionally provided with a decorative finish on one or both outer face surfaces thereof. The invention is further directed to novel methods for making such trim panels incorporating preselected contours and localized embossments therein to conform to the contour of the structural panels of vehicle bodies over which the trim panels are adapted to be mounted. In accordance with one process embodiment, a fibrous pad is formed incorporating suitable binding agents and a coextensive impervious membrane or film disposed intermediate of the face surfaces thereof.

Abstract: A process for making composite contoured sound insulating panels of a type suitable for use adjacent to structural panels of automobile vehicle bodies, which in accordance with one embodiment of the present invention, comprises forming a fibrous pad incorporating controlled amounts of heat curable thermosetting binder and a heat softenable thermoplastic binder distributed in a controlled manner therethrough.

Abstract: A process for making composite contoured sound insulating panels of a type suitable for use adjacent to structural panels of automobile vehicle bodies, which in accordance with one embodiment of the present invention, comprises forming a fibrous pad incorporating controlled amounts of a heat curable thermosetting binder and a heat softenable thermoplastic binder distributed in a controlled manner therethrough.