Abstract: The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the substrate.

Abstract: A laminate for use as a headliner for an automobile comprises a core that is a mixture of basalt fibers and polypropylene binder. A scrim layer is provided adjacent a first side of the core. An adhesive layer and a covering are provided adjacent a second side of the core. The laminate can be manufactured by heating the core, providing a scrim layer adjacent the first side of the core and providing an adhesive layer and a covering adjacent the second side of the core to complete the laminate. A method for recycling a laminate comprises the steps of providing a laminate material formed of composite materials including reinforcement fibers that have a higher melting point than the incineration point of the other composite materials and heating the laminate to a temperature below the melting point of the basalt and above the incineration point of the other composite materials to reduce the other composite materials to ash without melting the basalt.

Abstract: A laminate for use as a headliner comprises a core having an inner layer of thermoplastic binder adjacent opposing sides thereof. A basalt structural reinforcement layer is provided adjacent each inner layer of thermoplastic binder. An outer layer of thermoplastic binder is applied adjacent each reinforcement layer. A scrim layer is applied adjacent one outer layer of thermoplastic binder and an adhesive layer and covering are provided adjacent the other outer layer of thermoplastic binder. A method of manufacturing the laminate comprises the steps of providing a scrim layer and a layer of thermoplastic binder. A basalt structural reinforcement layer is provided adjacent the layer of thermoplastic binder. Another layer of thermoplastic binder is provided adjacent the basalt structural reinforcement layer. A core is provided adjacent the layer of thermoplastic binder. Another basalt structural reinforcement layer is provided adjacent the core.

Abstract: A laminate for use as a headliner comprises a core having an adhesive layer provided adjacent opposing sides thereof. Basalt fiber structural reinforcement layers are provided adjacent each adhesive layer. A scrim layer is provided next to one reinforcement layer while a film barrier and covering are provided adjacent the other reinforcement layer. A method for manufacturing the laminate comprises the steps of providing a core, providing basalt fiber reinforcement layers adjacent opposing sides of the core, providing adhesive layers between opposing sides of the core and the reinforcement layers, applying a scrim layer to one reinforcement layer and a film barrier and covering to the other reinforcement layer to complete the laminate. According to a method for recycling a laminate, laminate material formed of composite materials including reinforcement fibers that have a melting point above the incineration point of the other composite materials is provided.

Abstract: A structural reinforcement layer for use in a laminate for a vehicle headliner comprises at least one of carbon fibers and natural fibers. A thermoplastic binder may adhere the fibers to one another. A method for manufacturing a laminate comprising a the structural reinforcement layer comprises the steps of providing a core, providing a first reinforcement layer containing carbon fibers adjacent one of opposing sides of the core, providing adhesive layers on each of the opposing sides of the core, applying a barrier film and covering to the first reinforcement layer to the first reinforcement layer. Applying a scrim mat comprising a reinforcement layer, a barrier film and a scrim layer to the other of the opposing sides of the core to complete the laminate. According to a method for recycling a laminate, laminate material formed of composite materials including carbon fibers that have a melting and/or degradation point above the incineration point of the other composite materials is provided.

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Abstract: Acoustical attenuating devices (52) and method of forming them. The attenuating devices (52) include an exterior layer (64), a sound absorption layer (66), and multiple perforated layers (68) coupled to the sound absorption layer (66). The perforated layers (68) include a perforated structural layer (70) and a perforated substrate layer (72). The perforated structural layer (70) and the perforated substrate layer (72) provide structural stiffness and define multiple resonating tubes (88) that attenuate sound.

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Abstract: Acoustical attenuating devices (52) and method of forming them. The attenuating devices (52) include an exterior layer (64), a sound absorption layer (66), and multiple perforated layers (68) coupled to the sound absorption layer (66). The perforated layers (68) include a perforated structural layer (70) and a perforated substrate layer (72). The perforated structural layer (70) and the perforated substrate layer (72) provide structural stiffness and define multiple resonating tubes (88) that attenuate sound.

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Abstract: The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The multiple density substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the multiple density substrate.

Abstract: The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The multiple density substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the multiple density substrate.