Abstract: An improved attachment clip for use in securing automotive interior trim components to structural members within the motor vehicle is disclosed. The improved attachment clip includes an H-shaped body member adapted to be anchored directly to a core layer of the trim component, and an attachment clip member provided for securing the attachment clip and, in turn, the trim component to the rigid mounting structure. The H-shaped body member includes a central stem and a first pair of elongated prongs which project forwardly and transversely relative to the central stem. A second pair of elongated prongs project from the central stem so as to extend in a opposite direction from the first pair of prongs and which have a down-turned end portion. The first pair of elongated prongs are offset below a planar surface defined by an underside surface of the central stem and the second pair of prongs so as to extend generally parallel thereto.

Abstract: A method of forming a contoured fiberglass-resin sheet or panel having a smooth finish surface, including large self-supporting contoured panels, such as used for automotive headliners and interior automotive panels. The method includes first forming an uncured resin impregnated fiberglass sheet in a contoured die under sufficient pressure to substantially fully compress the fiberglass sheet and simultaneously curing the smooth finish contoured surface only of the sheet. The sheet is then reformed and cured in the final contoured configuration, which may include areas of different density, as required by the application of the panel. A second uncured resin-fiberglass sheet may be applied over the first partially cured sheet, prior to reforming, to better control the density, and form a permanently laminated contoured panel.

Abstract: A strong foam core structural member having an integral skin and a method of forming the foam core structure using conventional tooling, such as a clamshell mold. The method includes injecting a fluid foamable resin reaction mixture under pressure in a mold between a pair of pervious, absorbant, flexible sheets, preferably each including a nonresilient open mesh skrim. The sheets are thus expanded against the mold faces by the foaming reaction mixture, which saturates the sheets and forms a smooth skin integral with the foam core. The pervious sheets permit entrapped gasses to escape, forming a smooth integral skin on the foam core, which substantially improves the strength of the structure. The structure may also be strengthened by adding perforated reinforcement plates and injecting the fluid resin reaction mixture through and around the plates. The reinforcement plates thus become integral with the foam core.

Abstract: A method of forming a reinforced foam structure or laminate wherein a low density, fast reacting liquid foamable resin is sprayed under pressure into a low density fiberglass mat to penetrate and wet the fibers. The foam then expands within the fiberglass mat, forming a low density foam sheet having fiberglass distributed substantially continuously therethrough. A support or cover sheet is preferably laminated to the foam-fiberglass sheet and the laminate is formed under heat and pressure in a die into a contoured shape, simultaneously curing the resin foam.

Abstract: The disclosed foam laminate preferably includes a corrugated paper sheet, a layer of thermosetting resin foam wherein the corrugations extend into and are bonded to the foam layer and a relatively flexible finish sheet bonded to the foam layer. The corrugated sheet preferably includes a corrugated paper sheet bonded to a relatively flat sheet. In the disclosed automotive headliner, the corrugations preferably extend perpendicular to the headliner side edges, providing support for the concave midportion of the headliner and preventing delamination of the paper and foam laminae.

Abstract: The method of this disclosure relates to the application of a foam layer, in fluid form, to either an impervious or a relatively porous substrate and to the formation of a contoured foam laminate using a relatively rigid foam. The method of applying foam to a porous substrate includes heating the substrate prior to the application of the fluid foam. Upon striking the heated substrate, the foam forms a blow barrier to prevent foam bleedthrough. The method also optionally includes forming the laminate in a die prior to completion of foaming.The laminate includes a flexible substrate, preferably a polyurethane foam layer and an optional lattice skrim located between the substrate and the exposed surface of the foam layer.

Abstract: A method of forming a self-supporting contoured foam plastic laminate, including spraying a relatively flexible open cell plastic foam, preferably polyurethane, on a sheet which is to become part of the laminate, applying a second sheet over the foam layer and promptly forming the contoured laminate under pressure in a die. The disclosed laminate includes a corrugated paper sheet, wherein the corrugations extend into and are bonded to the foam layer and a relatively flexible finish sheet bonded to the foam layer. In the disclosed automotive headliner, the corrugations extend perpendicular to the headliner side edges, providing support for the concave midportion of the headliner and preventing delamination of the paper and foam laminae.

Abstract: The method of this disclosure permits the application of a foam layer, in fluid form, to a relatively porous substrate and the formation of a contoured foam laminate using a relatively rigid foam. The method includes heating the substrate prior to application of the fluid foam and forming the laminate in a die prior to completion of foaming. The laminate includes a flexible substrate, preferably a polyurethane foam layer and a lattice skrim located between the substrate and the exposed surface of the foam layer.

Abstract: An improved decorative resilient laminar panel and the method of fabricating said panel which is characterized by its shape-retaining compound contour and selected embossments over predetermined areas thereof and which comprises a perforated thermoplastic resin foam disposed between a pair of perforated cover sheets which are coated with a moisture-resistant sealing material. The resilient laminar panel is particularly applicable for use as automobile interior trim panels in which the exposed face surfaces thereof are provided with decorative coatings or decorative plies to enhance the aesthetic and functional characteristics thereof.

Abstract: A decorative covering material and a process for applying said covering material to vehicle panels such as the roof panel of automobiles to enhance the exterior appearance thereof. The decorative covering material comprises a heat-softenable plastic sheet incorporating a coating of a heat-activatable adhesive over substantially the entire undersurface thereof and which sheet is pretrimmed to a preselected shape and size, and incorporates fastening strips along at least a portion of the terminal edges thereof for securing the decorative material over the panel to prevent movement thereof relative to the panel surface. The decorative covering material is further characterized as embodying, in the inner central area thereof, a contour and wherein the plastic material incorporates a residual memory whereupon a shrinkage of the covering materials occurs during a heating thereof to form a smooth and taut covering layer over the exterior surface of a panel to which it is applied.