Abstract: A method of forming a lap mat for use in a subsequent molding operation to form a headliner includes forming a first continuous particulate layer having a non-uniform composition; folding the first continuous particulate layer to form a plurality of first layers; and binding the first layers together wherein the first layers cooperate to define a first region having a first material composition, and a second region having a second material composition different than the first material composition.

Abstract: The invention involves recycling scrap material having a thermoplastic. The invention includes a method of forming a thermoplastic pre-preg sheet for use in a subsequent molding operation. The method includes shredding a first scrap material having a thermoplastic to form fluff. The fluff has at least about 20 percent weight of thermoplastic. The method further includes sufficiently compacting the fluff into a thermoplastic state sufficient for forming the thermoplastic pre-preg sheet.

Abstract: A method of forming a headliner includes providing a lap mat including a first region having a first material composition, and a second region having a second material composition different than the first composition, wherein the second region is configured as at least one of an energy management region and a support region; positioning the mat between two mold sections of a mold; and moving at least one of the mold sections toward the other mold section to shape the mat into a desired shape. A method for forming the mat is also disclosed.

Abstract: A method for recycling materials including a significant portion of polyurethane foam includes forming the foam into a fluff of particle sized 0.25-1.0, and most preferably 0.25-0.50 inch. The material is moved to a mold and molded at an elevated temperature and pressure. Preferably, the glass transition temperature of the foam is exceeded. Other filler materials may be mixed with the fluff material. The invention recycles scrap which includes polyurethane foam, but greatly reduces the complexity of re-utilizing the scrap.

Abstract: A unique headliner includes a pair of spaced polyester fiber mat layers. The polyester fiber layers are preferably felt layers which are needled and consist of a mixture of low and high melt polyester fiber pieces. The low melt fiber pieces are provided with an adhesive sheathing that melts at a low temperature to bond the fiber pieces together. The polyester layers are spaced on opposed side of a polyurethane foam central layer. The combined headliner construction has good strength and acoustic characteristics.

Abstract: An improved headliner utilizes burlap layers to provide strength to the headliner sandwich. The burlap layers are placed on both sides of a central foam core to create an I-beam construction.

Abstract: A plurality of vehicle headliners are disclosed formed of a number of different layers. Each headliner includes at least a layer formed of a mixture of binder and non-binder polyester fibers. Each of the headliners also include a cover stock layer. Several of the disclosed embodiments include natural fiber layers which provide additional strength. The inventive headliners are more recyclable than the prior art, and are less irritating to the skin due the elimination of fiberglass.

Abstract: The invention relates to a method for the recycling of trim components of vehicles. The method comprises the steps of shredding manufacturing scrap and post-consumer scrap from vehicle headliners into small particles to produce fluff. This fluff is then combined with water and a binder reagent composed of either polyisocyanates, or polyisocyanates combined with various polyols. The solution of fluff, binder reagent and water are mixed, and then placed in a mold where the mixture is formed into a pre-preg sheet. Subsequently, the pre-preg sheet is subjected to compression molding at elevated temperatures to produce a finished composite trim panel. As part of the final compression molding step, a decorative coverstock can be included to produce a finished trim panel having a decorative cover.

Abstract: Several headliner embodiments include a felt layer connected to a cover layer. In the preferred embodiments a pair of felt layers are positioned on both sides of a central mat layer. The mat layer provides loft, while the felt layers in combination with the mat layers provide other desired characteristics for the headliner.

Abstract: The invention relates to a method for the recycling of trim components of vehicles. The method comprises the steps of shredding manufacturing scrap and post-consumer scrap from vehicle headliners into small particles to produce fluff. This fluff is then combined with water and a binder reagent composed of either polyisocyanates, or polyisocyanates combined with various polyols. The solution of fluff, binder reagent and water are mixed, and then placed in a mold where the mixture is formed into a pre-preg sheet. Subsequently, the pre-preg sheet is subjected to compression molding at elevated temperatures to produce a finished composite trim panel. As part of the final compression molding step, a decorative coverstock can be included to produce a finished trim panel having a decorative cover.

Abstract: Thermoplastic blends of polyurethane polymers, chlorinated polyethylene polymer, optionally polyethylene resins and antimony trioxide, and a flame retardant selected from 1,2,3,4,7,8,9,10,13,13,14,14-dodecachloro-1,4,4a,6a,7,10,10a,12a-octahydro -1,4:7,10-dimethanodibenzocyclooctane, 1,2,3,4,5,6,7,8,10,10,11,11-dodecachloro-1,4,4a,4b,5,8,8a,9a-octahydro-1,4 :5,8-dimethanodibenzofuran, 6-(1',4',5',6',7',7'-hexachloronorborn-5'-en-2'-yl)-1,2,3,4,10,10-hexachlo ro-1,4,4a,5,6,7,8,8a,-octahydro-1,4:5,8-dimethanonaphthalene, and 6-(1',4',5',6',7',7'-hexachloronorborn-5'-en-2'-yl)-1,2,3,4,10,10-hexachlo ro-1,4,4a,5,6,7,8,8a-octahydro-1,4-methanonaphthalene, are flame resistant and also essentially retain the good physical properties of a polyurethane-chlorinated polyethylene polymer blend not containing a flame retardant.