Abstract: A method of manufacture of a foam core board is described as well as vehicle trim panels made from such board. A foam board having a cell structure including a structure with large cells in a center portion is initially formed. This board is skived into two separate panels, each having one surface with relatively large cell structure and wherein said cells have been opened by the skiving process. This surface acts to promote enhanced sound absorption from the foam core board. This board may be laminated with appropriate decorative material and molded to make contoured resilient vehicle trim panels.

Abstract: A method of manufacture of a foam core board is described as well as vehicle trim panels made from such board. A foam board having a cell structure including a structure with large cells in a center portion is initially formed. This board is skived into two separate panels, each having one surface with relatively large cell structure and wherein said cells have been opened by the skiving process. This surface acts to promote enhanced sound absorption from the foam core board. This board may be laminated with appropriate decorative material and molded to make contoured resilient vehicle trim panels.

Abstract: A process for making a smooth perforated contoured resilient panel of a type suitable for use as a decorative headliner in the passenger compartment of vehicles or the like. A thermoplastic composite laminar sheet comprising a pair of films tenaciously bonded to the opposed faces of an intervening thermoplastic foam core having closed cells containing air and residual blowing agent is perforated in flat sheet form whereafter it is heated to an elevated temperature to effect heat softening and expansion of the foam core resulting in localized dimpled recesses in the faces adjacent to the apertures or perforations. The heated expanded sheet is thereafter thermoformed between appropriately contoured mold surfaces to effect a contouring and compaction of the sheet to a thickness substantially equal to or less than the thickness of the dimpled or recessed sections forming a contoured sheet having substantially smooth exterior surfaces.