Abstract: Provided is a laminated member for a novel automobile interior ceiling material which has good film formability, lightweight and high rigidity, excellent moldability on cold-pressing after preheating, no problem of wrinkles, improved shrinkage and heat resistance of a post-molding product (automobile interior ceiling material), and a small post-molding dimensional error. A laminated member (A) has a seven-layered structure including filler-containing polypropylene sheets (4 and 5) laminated on both sides of a foamed polyurethane sheet (1) with hot melt materials (adhesive layers) (2 and 3) interposed therebetween, and an adhesive layer (6) laminated to adhere an interior material (8) to an outer surface of one-sided filler-containing polypropylene sheet (4) and a backing material (7) adhered to an outer surface of the other-sided filler-containing polypropylene sheet (5).

Abstract: A process for making a composite substrate with cover utilizes heated dies of a forming tool to deform and heat the substrate. The heated substrate is then placed in a marriage tool having a room temperature lower die for receiving the substrate, and a heated upper die. A cover material layer is placed over the substrate and the marriage tool is closed. The cover material includes a heat activatable adhesive and with the marriage tool closed, the heat from the upper die adheres the cover material layer to the substrate while the room temperature die cools the substrate. In this way, when the marriage tool is opened, the composite structure can be removed without deformation.

Abstract: An interior trim substrate and method of making same uses a corrugated synthetic fiber liner having upper and lower sides. An upper synthetic fiber liner is bonded to the upper side of the corrugated liners and a lower synthetic fiber liner is bonded to the lower side of the corrugated synthetic fiber liner. In this way, an all synthetic fiber headliner substrate which is or can be made 100% recyclable, is formed.