Abstract: An improved mounting system for conveying electrical energy to and from a moving glass panel, such as a sunroof, utilizes a retractable cord. The retractable cord is mounted within a channel which guides the glass panel. In this way, the cord is protected.

Abstract: An insulated window system for a vehicle includes a first wall of plastic material disposed in a window opening of the vehicle and a second wall of plastic material disposed in the window opening and spaced a predetermined distance from the first wall to form a gap therebetween.

Abstract: A solar roof for motor vehicles having a cover (10) with solar cells (22) which are located between an outside cover plate (20) and an inside covering (24), at least one power consumer which is supplied from the solar cells and which is separate from the solar cover (10), and a contact-making means for establishing an electrical connection between the solar cells (22) and the power consumer. The contact-making means has cover-side contacts (30) and roof-side contacts (42) which, at least in the closed solar cover end position, make an electrical connection between the solar cells and the power consumer. To make the cover-side contacts (30) as simple, space-saving and still reliable as possible, the cover-side are integrated within the solar cover (10).

Abstract: According to one aspect of the invention, a multi-layer automotive interior trim panel (10) comprises a decorative covering layer (12) and a supportive substrate layer (16). The substrate layer (16) is comprised of a rigid material formed into a predetermined shape for supporting the covering layer. The trim panel also includes an intermediate layer (18) disposed between the covering layer and the supportive substrate layer comprised of cushioning material. The intermediate layer includes a mat (20) of polymeric fibers, with the mat having a plurality of indentations (24) to provide a cushioning effect. A corresponding method for producing the interior trim panel having the three layers includes several steps. The first step is heating the cushion layer (18) to a predetermined temperature. The second step is melting a portion of the polymeric fibers in the cushion layer. The third step is stamping the cushion layer to form the plurality of indentations (24).

Abstract: A headliner for motor vehicles includes first and second sheets of material in juxtaposition to each other and adapted for positioning in a mold having two mold portions. The material of at least one of the sheets is fluid deformable with respect to another of the sheets, and is attachable to the material of the other of the sheets by the mold portions at sufficient locations to outline a potential duct between the sheets. The potential duct is adapted to receive fluid between the sheets for forming an actual duct. When fluid is received between the sheets, the material of the at least one sheet is deformed with respect to the material of the other of the sheets to define the actual duct. In one embodiment of the headliner, at least one head impact block is disposed in the duct. The headliner may also include at least one substantially air-impermeable layer disposed within the duct and attached to at least one of the the first and second sheets. Furthermore, the layer preferably includes a polymer powder.

Abstract: A solar heated windshield comprises two matching glass sheets with a hollow interlayer therebetween for inhibiting frost or ice formation on the outer glass sheet by collecting and retaining solar energy within the interlayer. The inner sheet includes a tinted film such that solar energy passing through the windshield is partially deflected into the interlayer to warm the air contained therein. Deflected solar energy may also impinge on or be deflected into a reservoir containing a heat retentive and conductive liquid such as propylene glycol. Air within the interlayer will be warmed repetitively by the heated glycol through the fluid motion of convection. Heat may be transferred by convection to air throughout the interlayer or only to specifically focused areas.

Abstract: A chromogenic window panel assembly, and a chromogenic skylight each includes an outer panel and a chromogenic member having an optical property which varies according to an applied signal. A chromogenic light pipe includes a light harvesting member and a chromogenic member having an optical property which varies according to an applied signal. A chromogenic vehicle sunroof, a chromogenic aircraft window assembly, and a chromogenic window assembly each includes a panel having a particular panel contour corresponding to a surface contour and a chromogenic panel having an optical property which varies according to an applied signal. A chromogenic block includes two panels and a chromogenic panel having an optical property which varies according to an applied signal.

Abstract: A transparent or opaque sheet is affixed onto the inner surface of a side door window glass of a vehicle for coloration, light blockage, decoration and the like. In the sheet-affixed window glass, the sheet is directly but detachably affixed onto the inner surface of the window glass via a front holder and a back holder.

Abstract: A vehicle acoustic system is attachable over a vehicle interior sheet metal component. The system includes a bubble pack which has a first film layer and a second film layer secured to the first film layer, wherein the first and second film layers cooperate to form a plurality of pockets therebetween. The pockets include a gas disposed therein, such that the pockets are at least partially compressible. The bubble pack is adapted to be positioned in direct contact with the sheet metal component. The gas disposed in the pockets could be air or any other lightweight gas. A plurality of kinetic energy dissipating granules may be disposed within the pockets for enhanced noise isolation. Alternatively, damping liquids or gels may be disposed in the pockets. Various embodiments are described.

Abstract: An automobile roof headliner includes a relatively stiff molded backing sheet and a relatively deformable foam panel adhesively secured to the undersurface of the backing sheet. Marginal edge areas of the foam panel in contact with hard side rails on the roof are provided with resilent deformable foam inserts that prevent the hard side rails from interfering with the energy-absorption action of the foam panel.

Abstract: The present invention relates to a vehicle sunroof having variable optical transmission and a method for making the same. Specifically, a vehicle sunroof is provided that, in accordance with the present invention, comprises a relatively thin film having variable optical transmission and a relatively thick substrate layer of clear plastic material adhered to a surface of the relatively thin film. The relatively thin film is positioned in a first molding die of a pair of injection molding dies such that it is adjacent a surface of the first die. The relatively thick substrate layer is adhered to one surface of the relatively thin film while in contact therewith in a molten state under heat and pressure within a cavity defined by the injection molding dies.

Abstract: A shade cover for a motor vehicle, which is usable when the motor vehicle is in operation as well as parked or in storage. The cover includes a rigid panel with a top surface, a bottom surface, a body portion, and an edge portion and has an area greater than the area of the vehicle's roof. The cover further includes a securing member for attaching the panel in a spaced relationship and at its bottom surface to the motor vehicle's roof. A reflective outer layer extends continuously across the top surface throughout the area of the panel. The body portion of the panel has an area substantially equal to the area of the vehicle's roof and presents the periphery from which the edge portion extends angularly outwardly and downwardly for providing shade to the vehicle's interior. At least a portion of the edge portion is transparent to allow a passenger of the vehicle to see therethrough. The cover also includes a ventilating louver member formed in the panel.

Abstract: Heat blocker system and methods are provided for preventing heat flow into the passenger compartment (118) of a vehicle (10) to reduce a heat buildup therein. A hole (12) may be formed in the door jamb region (16) or other convenient place that is not visible. A tubular insertion member (66) may then be inserted through the hole (12) to an exterior panel cavity (26). Insulation material (68), such as liquid polyurethane resin or other suitable materials, is injected into the panel cavity (26) and allowed to expand and harden. The hole (12) is then anodized or otherwise cleaned. A plug (62 or 64) may be used to cover the hole (12). The type of plug chosen depends on the location of the hole. A heat reflective cover (110) is secured on the exterior surface (112) of the windshield (114) to prevent heat from entering through the windshield (114). The cover (110) has a heat reflective coating (116) such as a metallic silver coating.

Abstract: The invention relates to a cover for shielding an article from incident heat energy and includes a first, non-heat reflective, sheet of material, a second sheet of material adapted to reflect heat, and a layer of non-abrasive sheet material. The sheets are superimposed and secured together to comprise a laminate, with the covering being tailored to provide a desired configuration. The covers are flexible thermal insulation covers tailored to fit and cover a particular shape of article which requires thermal insulation. The cover has spaced round its perimeter pockets or flaps into which are secured extensible members having a free end adapted to be hooked round a part of the article to maintain the cover securely in position.

Abstract: A panel system with variable light transmissiveness is formed of two essentially parallel transparent panels, and a seal encircling both panels. A cavity, defined by the panels and the seal, communicates with a liquid reservoir, from which liquid can be conveyed into the cavity by a transport element for the purpose of changing the distance between the panels by changing the thickness of the liquid layer between the panels. In order to render the panel system suitable for usage in a cover of a vehicle sliding/lifting roof, the liquid reservoir and the transport element, which is driven by a pole-reversible electric motor, are supported at an inner cover plate, which has an undercut in an edge portion in which an electrical contact element for establishing a conductive connection between the electric motor and the vehicle battery is disposed.

Abstract: A vehicle roof having a glass lid is framed by a two-part lid frame, a glass pane of which is coated on its lower face with a thin, lattice-like sunshield, preferably applied by the screen printing process. A multilayer closure plate, slidably guided at the lateral longitudinal members of the lid frame, bears from below against the sunshield, the thin closure plate layers of which possess a corresponding lattice-like structure. The closure plate layers are displaceable upon one another and can be displaced or set one after another to provide an infinitely variable cover or exposure of the light apertures of large area of the sunshield. A drive apparatus provides for a corresponding displacement drive of the individual closure plate layers.

Abstract: The specification discloses electrochemichromic solutions and devices based on the use of solvents comprising at least about 25% 3-hydroxypropionitrile, 3,3,'-oxydipropionitrile, 2-acetylbutyrolactone, 2-methylglutaronitrile, 3-methylsulfolane and mixtures thereof. The specification also discloses vacuum backfilling techniques for filling electrochemichromic cells and enhanced UV stability through solvent self-screening.

Abstract: A panel of glass or other transparent sheet material for use as a transparent sun roof for automobiles has a double-glazed structure formed by two sheets and a gap therebetween. A sealing bead holds the sheets together at a desired distance from each other. The holes through which the elements for fixing the sun roof to the roof of the vehicle extend are provided in only one of the sheets and to the outside of the gap between the sheets.

Abstract: The invention relates to a vehicle roof having a light-transmissive cover, which has at least one outside panel, and having a device for varying the light-transmissibility of the cover. A light-transmissive cover of flat construction and easy actuation, whose light transmissibility can be steplessly regulated over a wide range, is achieved by integrating a device of darkening elements into a transparent cover, which is of extremely flat construction, is lightweight, mechanically easy to activate, and has a short regulating distance. Especially advantageous is a device whose darkening elements are formed by two superposed polarization films that are movable relative to each other. Such a configuration facilitates a particularly flat construction, and the light transmissibility of the cover is practically steplessly adjustable in a range of 0%-100%.

Abstract: An improved removable shade for a vehicle moonroof, sunroof or other window assembly. The shade includes a relatively rigid panel having a size and shape configured to cover the window, a retainer button permanently attached to the window having a releasable retainer element on the opposed side and a connector button attached to the shade panel having a mating releasable retainer element, and a handle is attached to the shade panel, preferably coaxially aligned with the connector and retainer buttons. The retainer elements preferably comprise a plurality of resilient, generally linear connector elements projecting from each of the buttons having transverse end connector portions providing a releasable connection between the buttons and the connector button is preferably permanently adhesively bonded to the window.

Abstract: A honeycomb core panel structure for use for instance as a lining or roofing in an automobile. The panel structure has cavities or pockets for receiving lamps or other fittings and includes an upper support plate member, a lower support plate member and an intermediate support plate member interposed between the upper and lower plate members and defining a bottom wall of each pocket. The lower support plate member has reinforcing extensions extending a predetermined distance into the region of the pockets.

Abstract: A board structure used for the base material of a molded ceiling member of an automotive vehicle. The board structure includes a corrugated core board formed of a cardboard. Upper and lower surface boards are bonded respectively to the upper and lower surfaces of the corrugated core board. The upper and lower surface boards are formed of cork sheets, respectively, thereby improving the moldability and the physical properties of the board structure.

Abstract: A selective opacity, maximally transverse retracting sunroof system for a vehicle roof is retrofitted to a vehicle by removing most of the original vehicle roof side rails and attaching thereto a strut assembly capable of supporting a self-contained sunroof mechanism to be attached thereto. The sunroof panel of the mechanism then is capable of covering the vehicle roof aperture from side rail-to-side rail. To decrease the undesired effects of a large, clear roof, the sunroof panel opacity may be chosen by the operator. Opacity of the panel is electrically controlled and provision is made for supplying power to the sunroof panel throughout its range of movement. A second, selective opacity roof panel may be used in the vehicle roof structure to maximize the light transmitting area of the roof.

Abstract: A composite material is provided for use in a vacuum thermoforming process, which material is easily handled and presents an aesthetically pleasing fabric-like surface. The composite material comprises an outer layer of nonwoven fabric comprising thermoplastic fibers capable of elongation upon the application of heat and tensile force so as to be readily conformable to shaping in the vacuum thermoforming process. The composite material further comprises an inner layer of thermoplastic film.

Abstract: Vehicle roof with at least one cover that, alternatively, closes or at least partially opens an opening in a fixed roof surface of the vehicle, carries a solar power source for supplying power to at least one power consuming device that is separately located from the cover, and with a contact device for producing an electrical connection between the solar power source and the consuming device. The contact device is made as a switch arrangement that incorporates the cover so that the power consuming device is connected to the solar power source in one or more predetermined cover positions and is disconnected from the solar power source in all other cover positions.

Abstract: A vehicular roof structure which has no roof arches includes a roof panel having reinforcing frames on peripheral edges thereof and a curved lower surface having a radius R.sub.1 of curvature, a roof lining having a curved upper surface having a radius R.sub.2 of curvature, the roof lining being of a laminated structure comprising a support layer having a number of cells, a covering layer covering surfaces of the support layer, and a decorative layer disposed on a lower surface of the covering layer, and a vibration-damping layer having a substantially uniform thickness t and held between and closely against the upper surface of the roof lining and the lower surface of the roof panel, the radii R.sub.1, R.sub.2 of curvature and the thickness t meeting the relationship: R.sub.2 .ltoreq.R.sub.1 -t, the roof lining having peripheral edges fixed to the reinforcing frames of the roof panel.

Abstract: There are provided laminate structures comprising a reinforcing fibrous mat integrally bonded to a resilient fibrous batt. The mat is preferentially a porous mat of resin-bonded chopped glass fiber. The batt is preferentially a porous batt of natural or synthetic fibers. Preferentially, the laminate comprises a core of resilient fibrous batt sandwiched between two facing sheets of reinforcing fibrous mat, with a decorative cover layer being laminated to the exterior surface of one reinforcing fibrous mat, the whole being bonded together by a thermoset binder into a unitary structure.

Abstract: An automotive headliner comprised of a laminate of double corrugated paperboard. Perforations in all the sheets of the laminate except the back paperboard sheet improve the acoustical performance of the liner. A vapor barrier on the back sheet prevents entry of moisture into the laminate from the roof, and a layer of sound dampening material on the front face of the laminate improves the sound absorption of the laminate. The front corrugation is larger than the back corrugation. When molding the laminate it is first moisturized, then heat molded. Heat is applied until the laminate has regained its rigidity.

Abstract: The present disclosure is directed to a sun shade/shield substantially rectangular panel with upper and lower surfaces and having a first hinge extending along the entire length thereof, along a non-central axis dividing the panel width into two non-equal portions; a second hinge extending along a portion only of the entire width thereof along an axis substantially perpendicular to that of the first hinge with the remainder of the panel width being split (separated) along a line constituting an extension of the first hinge axis, the first and second hinges dividing the panel length equally into hinged and split portions of greater and lesser areas, respectively; plurality of first a cross bars each having at least one finger having an openly facing portion for attachment to a portion of a vehicle roof luggage rack, the first cross bars with finger(s) positioned on each of the panel portions of greater and lesser area; and an additional cross bar having at least one finger having an openly facing portion on th

Abstract: An improved conversion custom hard top or roof for vehicles is aerodynamic and provides greater headroom or interior vertical space for the occupants of the vehicle. The replacement roof comprises three separate levels distinguished by the three riser portions. Two of the riser portions are convex and the third riser portion is concave.

Abstract: A headlining laminate (10) is made up of a composite which includes two corrugated boards having corrugations which are arranged at right angles to each other and having a thermoplastic sheet interposed between the boards for adhesion. The board is covered with a fabric (15) and includes mounting holes. An advantage of the invention is that stretch lines do not occur on the fabric due to the corrugations of the board being at an angle to each other.

Abstract: A roof lining structure in a motor vehicle includes a roof lining base member and a vibration-damping layer interposed between an upper surface of the base member and a lower surface of a roof panel of the motor vehicle. The roof lining base member comprises a support layer having a cellular structure, and a reinforcing layer disposed at least partly in the roof lining base member. The upper surface of the vibration-damping layer is held in intimate contact with the lower surface of the roof panel. The vibration-damping layer is bonded to the roof panel by an adhesive layer. The vibration-damping layer is made of a material having such a mechanical strength that the vibration-damping layer will be torn apart vertically with a tearing force weaker than the bonding strength of the adhesive layer.

Abstract: Electrical connectors for providing direct connection of the output of a dedicated power supply to a movable sunroof panel when the panel is within a limited distance that extends from its fully closed position. Such connections are made and broken to a sunroof panel that utilizes electrically activated light transmittance control materials or light emitting elements. A first embodiment includes a ramped conducting surface on a relatively fixed block and a spring loaded contact element carried on the rear portion of the movable sunroof. A second embodiment contains a spring loaded contact within a bore formed in an insulator block. The block and contact are mounted in a relatively fixed position aligned with a conductive probe mounted on the rear portion of the movable sunroof. A circuit provides timing protection to the dedicated power supply by ensuring that the electrical connectors are in contact before allowing the power supply to be energized.

Abstract: A self-supporting sound barrier for the operator's cover of a construction type vehicle is supported within the operator's cover at the perimeter of the sound barrier only and is self-supporting throughout the major surface area of the sound barrier. The sound barrier has strengthening and supporting materials, such as a grid structure or oriented fibers, throughout the main body of the sound barrier which lengthen during sagging of the sound barrier. As the grid sturcture lengthens, it contacts portions of the operator's cover and the sound barrier is restrained from further sagging. Prior art sound barries utilize an elaborate system of parts and assembly procedures to secure a sound barrier in place within an operator's cover. The subject self-supporting sound barrier is simple to manufacture and is easy to install and/or remove from an operator's cover.

Abstract: A method of manufacturing a decorative automobile roof cap by forming a flat composite of a thermoplastic cover member laminated to a core layer foam sheet, thermoforming the composite to the desired shape and forming the edges of the roof cap by removing a portion of the core layer from the cover member and then wrapping the excess cover member around the edges of the core layer and securing it to the underside of the core layer to form an edge covered with the cover member.

Abstract: An automotive headliner comprised of a laminate of double corrugated paperboard. Perforations in all the sheets of the laminate except the back paperboard sheet improve the acoustical performance of the liner. A vapor barrier on the back sheet prevents entry of moisture into the laminate from the roof, and a layer of sound dampening material on the front face of the laminate improves the sound absorption of the laminate. The front corrugation is larger than the back corrugation. When molding the laminate it is first moisturized, then heat molded. Heat is applied until the laminate has regained its rigidity.

Abstract: A neutral, dark gray, nickel-free, soda-lime-silica glass having luminous transmittance less than 20 percent is produced with colorants consisting essentially of 0.55 to 1.0 percent by weight total iron (at least 15 percent in the ferrous state), 0.005 to 0.02 percent CoO, and 0.003 to 0.02 percent Se. The flat glass product having such a composition is particularly suitable for use in sun roofs.

Abstract: In a sliding roof for automobiles, comprising a sliding lid guided on guide rails in a roof opening, a lid liner, which participates in the lid displacements, is connected with the sliding lid by guide elements, which, during lowering movements of the sliding lid, simultaneously raise the lid liner and, during raising of the sliding lid into its closed position, simultaneously lower the lid liner until it lies flush with the fixed liner without any step. To prevent a gap from remaining in the closed position between the peripheral edges of the lid liner and fixed liner opening, which would make possible penetration of noise into the vehicle interior, it is provided that the peripheral edge of the lid liner possess a downwardly facing bearing surface, opposite which there is a correspondingly upwardly facing counter-surface at the peripheral edge of the fixed liner opening, in such a manner that the bearing surface and the counter-surface bear against each other without a gap in the closed position.

Abstract: The acoustical performance of automotive trim panels is improved, especially with respect to noise generated by structural vibration of an automobile and synchronous vibration of the trim panel itself, by positioning a dead, vibration-damping, foam material between the automobile frame and a semi-flexible support layer of the trim panel, the trim panel also including an open-celled, flexible, airborne sound-absorbing foam layer bonded to the opposing face of the support layer, and wherein the dead foam material has a substantially lower resilience value and a substantially higher recovery rate than the open-celled foam layer.

Abstract: A sliding liner for a sliding roof for automobiles, where a rigid, possibly transparent lid closes a roof opening in its closed position and is slidably guided on lateral guide rails mounted on the fixed roof portion, on which rails also guide channels are provided for the lateral edges of the sliding liner. The sliding liner is displaceable independently of the rigid sliding lid and is furnished with ventilation openings. The sliding liner is formed rigidly as a plate or frame and is equipped, in the region of its forward edge, with a grip depression, the adaptation of the sliding liner to different surface forms and constructions of the remaining lining of the automobile is facilitated in that, in the region of the forward edge of the sliding liner, a ventilation strip is detachably fixed, on which a grip is formed.

Abstract: A roof of corrugated sheet material having profiled cross-section of alternate troughs and ridges. The troughs have adhered therein a filler material to fill the troughs to at least a level flush with the level of the ridges on each side thereof. A waterproof sheet covering is located and adhered over the whole extent of the roof. The troughs may have a substantially greater width than the width of the ridges. The filler material may be in the form of elongated blocks or a panel of heat insulating material. The roof may be formed in sections, juxtaposed and attached to side walls of a structure such as a vehicle prior to the covering being adhered thereto.

Abstract: A sliding roof for motor vehicles having a transparent rigid sliding cover by means of which an opening in the roof can be selectively closed or can be exposed at least partially. A frameless sliding inside cover lining is provided that can be displaced at least in the cover sliding direction independently from the sliding cover and is guided at its lateral edges. The sliding inside cover lining is formed of a sandwich panel having a core layer and a cover layer that is applied to said core layer at least on one side. In the area of its lateral edges, the sandwich panel is squeezed together reducing the core thickness and increasing its density to form sliding guide edges.

Abstract: An insulated window insert or cover apparatus for use in motor vehicles having at least one window in the top or roof thereof which can be removed, tilted open, repositioned and the like to let in air. The insert apparatus includes a generally rectangular sheet of support material for blocking out the light from the sun which enters the roof window and insulation for absorbing the heat which enters the window to prevent the motor vehicle interior from becoming too hot and rendering the air conditioner inefficient and costly to run. The sheet and insulation are covered with a material whose interior-facing portion substantially matches the color, texture and fabric thereof for esthetic purposes. In particular cases, a resilient sheet of material may be used and the sheet may be eliminated and a relatively rigid sheet of plastic-foam material substituted in its place to serve a dual function.

Abstract: A sound insulating panel is provided having a support layer of honeycomb material, and a pair of covering layers, at least one of which is air-permeable. The support, honeycomb layer has a compressive strength greater than the compressive strength of each of the covering layers, in a direction transverse to the faces thereof, and has a tensile strength which is lesser, in the general direction parallel to the faces, than that each of the covering layers. The support layer is compacted over a part of its extent to a substantially closed layer of reduced thickness, this being, preferably, in the region of the border. A method of making an insulating construction element as described.

Abstract: A method for forming a laminate which is composed of a decorative layer and a carrier panel comprising applying a crosslinking plastic foam onto a decorative carrier web, subjecting the thus coated web to heat treatment to dry and partially crosslink the foam and then marrying the unfoamed side of the web to a carrier panel with the application of heat and pressure so as to further crosslink the foam. Laminates in accordance with the invention are described. Such laminates possess stability against delamination as well as relative freedom from gaseous inclusions.

Abstract: A novel automotive heat reflector shield comprising aesthetic-appearing, laminated, energy saving device for excluding sunrays, having a minimum angle of incidence of 45.degree., from penetrating automobile roofs equipped with sunroof and T-top roof configurations. The shield is insulative and thermally, acoustically non-conductive and thermal and light reflective. The shield is affixed by attachment means to interior of automobile equipped with sunroof or T-top roof inferior to said sunroof or T-top roof. Comprising a shield for providing automobiles, whether parked or during operation with passive cooling device thermally maintaining cooler interior so as to diminish air-conditioning requirements thereby reducing fuel consumption. It also excludes road noise and serves as a safety device capable of shielding occupants of automobile equipped with sunroof or T-top roof from being ejected through said sunroof or T-top roof during collision with other automobile or object.

Abstract: A rigid vehicle top of unitary construction and method of making the same is provided. The rigidity of the roof and headliner portions allows for the complete off-line assembly of lighting systems, switches, clocks, environmental control apparatus and decorations. Additionally, a method of converting an existing passenger vehicle is provided.

Abstract: The invention relates to a ceiling component which is formed by a curved panel and has a support which supports a layer of sound-proofing and heat insulating material. The support is made in one piece and is constituted by a metal sheet whose edges are bent back on itself and then to form a flange projecting from one surface of said panel. The bent edges alone provide the rigidity necessary for the panel without requiring the use of ribs and girders.

Abstract: An auto ceiling panel takes the form of a laminate composed of a permeable ceiling surface skin, a first layer of porous continuous bubble plastic foam attached to the skin, a second foamed plastic layer with numerous through holes attached to the first layer, and a third foamed plastic layer with through holes of a larger diameter than the holes in the second layer. A metal lath is between the second and third layers, and the second and third layers are fused to the metal lath.

Abstract: A rigid vehicle top of unitary construction and method of making the same is provided. The rigidity of the roof and headliner portions allows for the complete off-line assembly of lighting systems, switches, clocks, environmental control apparatus and decorations. Additionally, a method of converting an existing passenger vehicle is provided.