Abstract: A preform of complex three-dimensional shape is prepared by a directed fiber preforming process in which a flow of chopped fibers are drawn by vacuum against a foraminous screen having a shape corresponding to that of preform to be made. The screen has depressed regions that are susceptible to excessive build-up of the chopped fibers. To counteract the build-up in these areas, a baffling system is provided behind the screen having baffle plates which are extendable into and out of blocking engagement with the backside of the problem depressed regions to govern the vacuum draw and hence the deposit and build-up of fibers across the depressed regions.

Abstract: An apparatus (10) for use in manufacturing a fibrous preform with a narrow channel flange includes a foraminous preform screen (12), a fiber nozzle (28) that blows a stream of chopped fibers onto the screen (12) and binder nozzles (32) that spray binder into the fiber stream. Air blown from air nozzles (30) helps guide the fibers and a ducted fan (26) helps draw and hold them onto the screen (12). The screen (12) is formed with a narrow channel flange (16) having a shape identical to the narrow channel flange of the fibrous preform to be manufactured. The screen's flange (16) has a channel floor (36) extending laterally outward from the screen's main body (14) and a channel outer wall (38) projecting perpendicularly away from the channel floor (36) toward the fiber nozzle (28). A hinge (40) connects the channel floor (36) to the channel outer wall (38). To allow the nozzles to deposit a more uniform layer (42) of fibers, the outer wall (38) is rotated outward to lie parallel with the channel floor (36).

Abstract: An automotive interior trim part (10) is made by molding a substrate retainer layer (16), forming a skin layer (12) and forming an intermediate layer (14). The intermediate layer (14) is formed from a plurality of clusters of entangled high melt and low melt kinked fibers of polyethylene terephthalate (PET). The PET layer is blown into a partially closed mold that has the skin and retainer positioned in each mold die. The mold undergoes induced vibrations to promote tightening of the packed clusters. The mold is then fully closed to compress the PET fibers into full density. Heated air is then blown into the mold to soften the low melt fibers to adhere them to the retainer layer and skin. Cool air is then blown into the mold to resolidfy the clusters and form the intermediate layer into its molded shape.