Abstract: The disclosed foam laminate preferably includes a corrugated paper sheet, a layer of thermosetting resin foam wherein the corrugations extend into and are bonded to the foam layer and a relatively flexible finish sheet bonded to the foam layer. The corrugated sheet preferably includes a corrugated paper sheet bonded to a relatively flat sheet. In the disclosed automotive headliner, the corrugations preferably extend perpendicular to the headliner side edges, providing support for the concave midportion of the headliner and preventing delamination of the paper and foam laminae.

Abstract: The method of this disclosure relates to the application of a foam layer, in fluid form, to either an impervious or a relatively porous substrate and to the formation of a contoured foam laminate using a relatively rigid foam. The method of applying foam to a porous substrate includes heating the substrate prior to the application of the fluid foam. Upon striking the heated substrate, the foam forms a blow barrier to prevent foam bleedthrough. The method also optionally includes forming the laminate in a die prior to completion of foaming.The laminate includes a flexible substrate, preferably a polyurethane foam layer and an optional lattice skrim located between the substrate and the exposed surface of the foam layer.

Abstract: A method of bonding a flexible superstrate, such as a flexible finish sheet, to a contoured substrate, such as a contoured fiberboard, particularly in mass production. The disclosed method includes supporting the contoured substrate in a downwardly facing cavity of a female die. The substrate may be coated with adhesive before receipt in the die cavity. A flexible superstrate is then positioned beneath the die cavity on a flexible sealing sheet. The die is then closed and a vacuum is drawn through the die cavity and contoured substrate to draw the sealing sheet into the die cavity. The flexible superstrate or finish sheet is thus drawn in face-to-face contact with the contoured face of the substrate, bonding the finish sheet to the substrate.

Abstract: An improved decorative resilient laminar panel and the method of fabricating said panel which is characterized by its shape-retaining compound contour and selected embossments over predetermined areas thereof and which comprises a perforated thermoplastic resin foam disposed between a pair of perforated cover sheets which are coated with a moisture-resistant sealing material. The resilient laminar panel is particularly applicable for use as automobile interior trim panels in which the exposed face surfaces thereof are provided with decorative coatings or decorative plies to enhance the aesthetic and functional characteristics thereof.