Abstract: A method for manufacturing a lightweight structural trim part is comprising the following steps: (A) inserting a plurality of layers into a molding tool comprising a first molding half (6) and a second molding half (7). The second molding half (7) comprises a plurality of cup-like indentation (8). The plurality of layers at least comprises a first air permeable skin layer (1) facing the first molding half (6), a second air tight skin layer (3,4) facing the second molding half (7), and a film layer (2) between the two skin layers. (B) Closing the molding tool and discharging gas from one side in order to press the first skin layer against the first molding half. (C) Shaping and consolidating the first porous skin layer. (D) Charging with pressurized air the first space in order to press the second skin layer against the second molding half. (E) Shaping and consolidating the second skin layer.

Abstract: A method for manufacturing a lightweight structural trim part is comprising the following steps: (A) inserting a plurality of layers into a molding tool comprising a first molding half (6) and a second molding half (7). The second molding half (7) comprises a plurality of cup-like indentation (8). The plurality of layers at least comprises a first air permeable skin layer (1) facing the first molding half (6), a second air tight skin layer (3,4) facing the second molding half (7), and a film layer (2) between the two skin layers. (B) Closing the molding tool and discharging gas from one side in order to press the first skin layer against the first molding half. (C) Shaping and consolidating the first porous skin layer. (D) Charging with pressurized air the first space in order to press the second skin layer against the second molding half. (E) Shaping and consolidating the second skin layer.

Abstract: The invention provides a lightweight vehicle flooring assembly, wherein a carrier layer (1) has a layered structure. This structure comprises a honeycomb-like core layer (7) which can be made of a suitably impregnated cardboard material and which is connected on both sides to a stiffening layer (8, 9). The inner stiffening layer (8) is made of an SMC-material, whilst the outer stiffening layer (9) is made of a needled, preferably open-celled or porous nonwoven, also suitably impregnated against humidity and dirt. The structure of the carrier layer (1) and, in particular, the sequence of the layers: skin, honeycomb structure, nonwoven is of particular significance for the mechanical stability of the carrier layer (1). The carrier layer (1) is provided with an inner and an outer lining, the inner lining comprising a PU-foam spring layer (10) and a rubber or latex mass layer (11).

Abstract: The invention provides a lightweight vehicle flooring assembly, wherein a carrier layer (1) has a layered structure. This structure comprises a honeycomb-like core layer (7) which can be made of a suitably impregnated cardboard material and which is connected on both sides to a stiffening layer (8, 9). The inner stiffening layer (8) is made of an SMC-material, whilst the outer stiffening layer (9) is made of a needled, preferably open-celled or porous nonwoven, also suitably impregnated against humidity and dirt. The structure of the carrier layer (1) and, in particular, the sequence of the layers: skin, honeycomb structure, nonwoven is of particular significance for the mechanical stability of the carrier layer (1). The carrier layer (1) is provided with an inner and an outer lining, the inner lining comprising a PU-foam spring layer (10) and a rubber or latex mass layer (11).