Abstract: A method of making a lightweight panel having a relatively soft foam-backed cover sheet supported on a relatively hard, self-supporting core in one simple step. An assembly of foam layers is built up comprising a core-forming foam layer, an intermediate foam layer, and a cover-backing foam layer, with a scrim sheet over the core-forming foam layer and a cover sheet over the cover-backing foam layer. The core-forming layer is impregnated with a heat-activatable hardening compound. The intermediate layer as well as the cover-backing layer may also, if desired, be impregnated with a heat-activatable hardening compound but usually in lesser amounts. The hardening compound coats the cell walls of the foam. The panel is formed by subjecting this layered assembly to heat and pressure between contoured dies in a single compression molding operation at a temperature at which the hardening compound is activated.

Abstract: A mounting bracket assembly for a sunshade including an inner bracket having an integrally formed square boss that is inserted into a corresponding hole in the sheet metal roof of a vehicle. A bracket arm is snapped into the inner bracket, and includes a key that fits within an arcuate keyway in the inner bracket. Upon initial pivoting of the bracket arm, the key engages the end wall of the keyway and causes the inner bracket to rotate to a locked position wherein the square boss is against the back surface of the roof and the key freely moves within the arcuate keyway through the range of sunshade operation. An outer bracket snaps over the inner bracket prior to its insertion into the roof, in order to keep the assembly against the headliner when the inner bracket is rotated. A tool having an arcuate tip may be inserted into an opening in the inner bracket for removal of the sunshade.

Abstract: A headliner and retainer bar assembly adapted to be installed in the roof of a vehicle, comprising a headliner panel, a retainer bar extending along the front edge portion of the panel on the top side of the panel next to the roof of the vehicle, and accessory components including sun visors on the bottom, finish side of the panel. The accessory components are secured to the retainer bar by fasteners which extend through the headliner panel to provide a sandwich assembly capable of being installed as a unit. Fasteners, preferably of the type which are installed by being pushed into the designated attaching holes and then strongly resist being pulled back out, secure the retainer bar to the roof frame structure of the vehicle.

Abstract: A moldable fibrous mat from which a permanently rigid product of predetermined shape can be molded by the application of heat and/or pressure. The mat consists essentially of base fibers and carrier fibers and a thermosetting ingredient, with the base fibers having a substantially higher softening temperature, if any, than the carrier fibers. The fibers intertwine to resist separation. The carrier fibers are bonded to the base fibers and to each other to form connections, the thermoset remaining dormant in the making of the mat. There is also disclosed a method by which the moldable fibrous mat is made and product made from the mat, which product may be of uniform density or have areas of differing density.

Abstract: A moldable fibrous mat from which a product of predetermined shape can be molded by the application of heat and/or pressure. The mat consists essentially of base fibers and carrier fibers with the base fibers having a substantially higher softening temperature, if any, than the carrier fibers. The fibers intertwine to resist separation. The carrier fibers are bonded to the base fibers and to each other to form connections. There is also disclosed a method by which the moldable fibrous mat is made and product made from the mat, which product may be of uniform density or have areas of differing density.

Abstract: A contoured self-supporting automotive liner panel, such as a headliner, which comprises an outer substrate layer of expanded plastics material which is relatively rigid and has a substantial resistance to bending, an intermediate layer of relatively soft, compressible, flexible, expanded plastics material, and an outer flexible decorative finish cover layer.

Abstract: A contoured self-supporting automotive liner panel, such as a headliner, which comprises an outer substrate layer, an intermediate layer and an outer flexible, decorative, finish cover layer. The substrate layer is formed of expanded plastics material which is relatively rigid and has a substantial resistance to bending. The intermediate layer is formed of a relatively soft, compressible, flexible, expanded plastics material.

Abstract: A contoured self-supporting automotive liner panel, such as a headliner, which comprises an outer substrate layer of expanded plastics material which is relatively rigid and has a substantial resistance to bending, an intermediate layer of relatively soft, compressible, flexible, expanded plastics material, and an outer flexible decorative finish cover layer.

Abstract: A method of forming a flexible sheetlike structure such as an automotive headliner by treating a sheet of fiberboard or other similar material with water at an elevated temperature to make the sheet sufficiently ductile to permit forming without tearing or blowing, and placing the water-treated sheet between heated dies to form the sheet to a compound curvature by the application of heat and pressure. The sheet may or may not be perforated. The method also includes finishing one side of the die-formed sheet by securing a decorative or sound-absorbing layer thereto. The sheet is placed on a support and the layer is applied over the adhesive coated upper surface of the sheet. A cover is draped over the support to provide an air seal over the layer and sheet and is drawn against the support by differential pressure, either pressure or vacuum to press the layer against the sheet and adhere the two together.

Abstract: A method of forming a flexible sheetlike structure such as an automotive head-liner by treating a sheet of fiberboard or other woodlike fibrous material with water at an elevated temperature to make the sheet sufficiently ductile to permit forming without tearing or blowing, and placing the water-treated sheet between heated dies to form the sheet to a compound curvature by the application of heat and pressure. The sheet may or may not be perforated. The method also includes finishing one side of the die-formed sheet by securing a decorative or sound-absorbing layer thereto. The sheet is placed on a support and the layer is applied over the adhesive coated upper surface of the sheet. A cover is draped over the support to provide an air seal over the layer and sheet and is drawn against the support by differential pressure, either pressure or vacuum to press the layer against the sheet and adhere the two together.