Abstract: A process for making a composite substrate with cover utilizes heated dies of a forming tool to deform and heat the substrate. The heated substrate is then placed in a marriage tool having a room temperature lower die for receiving the substrate, and a heated upper die. A cover material layer is placed over the substrate and the marriage tool is closed. The cover material includes a heat activatable adhesive and with the marriage tool closed, the heat from the upper die adheres the cover material layer to the substrate while the room temperature die cools the substrate. In this way, when the marriage tool is opened, the composite structure can be removed without deformation.
Abstract: An interior trim substrate and method of making same uses a corrugated synthetic fiber liner having upper and lower sides. An upper synthetic fiber liner is bonded to the upper side of the corrugated liners and a lower synthetic fiber liner is bonded to the lower side of the corrugated synthetic fiber liner. In this way, an all synthetic fiber headliner substrate which is or can be made 100% recyclable, is formed.
Abstract: A heat moldable composite panel is particularly useful as an automotive headliner and other as structural parts which must have heat and sound insulating properties as well as sound absorbing properties. The panel comprises a corrugated core which is advantageously dual arched core or corrugated metal foil, with opposite sides. One side is covered by a linerboard and is attached to the core through thermoplastic adhesive. The opposite side is covered by a thermoformable foam layer which is attached to the core by heat activatable adhesive. The entire structure is formable in a molding die at relatively low temperatures.
Abstract: A shaped panel and method of manufacture thereof comprises an open-cell core having multiple cells with cell walls extending perpendicularly to the opposite sides of the core. Linerboard covers one or both sides of the core with thermoplastic resin being provided as adhesive between the core and the one or more linerboards. The resulting sandwich structure is heated and shaped in a mold.