Abstract: The invention involves recycling scrap material having a thermoplastic. The invention includes a method of forming a thermoplastic pre-preg sheet for use in a subsequent molding operation. The method includes shredding a first scrap material having a thermoplastic to form fluff. The fluff has at least about 20 percent weight of thermoplastic. The method further includes sufficiently compacting the fluff into a thermoplastic state sufficient for forming the thermoplastic pre-preg sheet.

Abstract: A method for recycling materials including a significant portion of polyurethane foam includes forming the foam into a fluff of particle sized 0.25-1.0, and most preferably 0.25-0.50 inch. The material is moved to a mold and molded at an elevated temperature and pressure. Preferably, the glass transition temperature of the foam is exceeded. Other filler materials may be mixed with the fluff material. The invention recycles scrap which includes polyurethane foam, but greatly reduces the complexity of re-utilizing the scrap.

Abstract: An improved method for forming a vehicle trim panel, such as a headliner, utilizes a zig zag path to deposit fibrous pieces onto a fibrous layer to form part of the trim panel. In one method, the fibrous pieces are laid down in a zig zag pattern that does not extend across the entire lateral width of the layer. In this way, the designer can easily achieve selected areas having a greater amount of fibrous pieces. This allows the designer to achieve selected high density or thicker portions in the layer without requiring the entire layer to have the same amount of fibrous pieces. This results in greater control over the design of the layer, and also reduces the amount of fiber which must be utilized to form the layer.

Abstract: A plurality of vehicle headliners are disclosed formed of a number of different layers. Each headliner includes at least a layer formed of a mixture of binder and non-binder polyester fibers. Each of the headliners also include a cover stock layer. Several of the disclosed embodiments include natural fiber layers which provide additional strength. The inventive headliners are more recyclable than the prior art, and are less irritating to the skin due the elimination of fiberglass.

Abstract: An improved method for forming a vehicle trim panel, such as a headliner, utilizes a zig zag path to deposit fibrous pieces onto a fibrous layer to form part of the trim panel. In one method, the fibrous pieces are laid down in a zig zag pattern that does not extend across the entire lateral width of the layer. In this way, the designer can easily achieve selected areas having a greater amount of fibrous pieces. This allows the designer to achieve selected high density or thicker portions in the layer without requiring the entire layer to have the same amount of fibrous pieces. This results in greater control over the design of the layer, and also reduces the amount of fiber which must be utilized to form the layer.

Abstract: A slidable support device for garments for use in a vehicle includes a support, a hook, and a locking mechanism. The support is coupled to the vehicle. The support includes two longitudinally extending grooves that are spaced from one another. The hook includes two longitudinally extending contact surfaces that are spaced from one another. The hook contact surfaces are shaped to mate with the support grooves in a sliding engagement. Upon engagement of the hook with the support, the hook slides relative to the support. The locking mechanism releasably retains the hook at various longitudinal positions along the support.

Abstract: A stowable accessory hook for an automobile is supported in a surrounding wall structure having an opening defined by a peripheral rim. The distal tips of the hooks are recessed behind the peripheral rim of the surrounding wall structure to protect against inadvertent snagging and abrasions. The hooks are configured such that the distal tips are recessed, at least when not in use. In one embodiment the tip extends into a surrounding cup to be recessed. In another embodiment, a pair of sockets are formed behind the surrounding wall to rotatably receive a pair of pintles extending from a concave cup disposed in the opening in the surrounding wall structure. The cup is manually rotated about a horizontal pivot axis between stowed and operative positions. In the stoved position the tips are recessed. Either single or multiple cantilever hooks extend from the cup for securing plastic grocery and merchandise sacks, garment hangers, or the like.