Abstract: A moldable fibrous composite comprising a first layer comprising a non-woven fabric, a second intermediate layer comprising a thermoformable material, and a third layer comprising a non-woven fabric is provided. This moldable fibrous composite can be utilized to form a one-piece trunk liner for an automobile trunk compartment. Additionally, the thermoformable material can be comprised of the same polymeric material as that of the staple fiber of the non-woven fabric of the first and third layer, thereby allowing recyclability of the moldable fibrous composite. A method is provided for the production of the moldable fibrous composite, and, additionally, a method is provided for the production of a moldable automotive trunk liner.

Abstract: This invention relates to an automobile headliner which is formed from a batt of polymeric fibers compressed and molded into a predetermined contoured shape. The headliner is characterized by being of a highly deformable resilient construction to facilitate installation in the vehicle. More specifically, the fibers forming the batt are bonded together at a multiplicity of locations which impart a self-supporting molded rigidity which allows the headliner to retain its shape in the installed condition in the vehicle, yet rendering the same highly deformable and resilient to allow it to be rolled or folded upon itself during installation and to thereafter resiliently recover to its original molded shape.