Abstract: A motor vehicle bed or bed liner is vacuum formed from a single layer or two layer panel of thermoplastic material having a scuffed or roughened surface. The single layer panel is typically extruded and is homogeneous, being either a single material such as HDPE or a uniform mixture of materials. The two layer panel is co-formed of two layers of material which will typically be distinct compositions and characteristics. The upper surface of the panel is scuffed or roughened by a brush which contacts the surface. A bank of individually adjustable rollers supports the panel during the roughening operation and facilitates adjustment of the extent of contact or impingement of the brush on the surface of the panel at a plurality of transverse locations across the panel. The roughened panel is then vacuum formed into, for example, a truck bed or bed or cargo compartment liner.

Abstract: A method of manufacturing a laminated pickup truck bed and bed liner includes the steps of forming by extrusion or another process a substrate layer of a desired thickness and strength of a thermoplastic material such as high-density polyethylene (HDPE) which may include fibers or a fibrous mat which improves its strength and ruggedness. Also formed by extrusion or another process is an upper layer having specific characteristics such as electrical charge dissipation or improved skid or slip resistance. The upper layer may be fabricated of a thermoplastic material such as HDPE and includes dispersed conductive material such as carbon particles, carbon, fibers or conductive polymers which dissipate or carry static electrical charges to a vehicle ground. Skid or slip resistance may be achieved by controlling the upper layer surface texture or the use of various materials and mixtures.