METODO PER PRODURRE UN PANNELLO DI FINITURA SAGOMATO PERFORATO.

摘要

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. The compacted and contoured smooth sheet thereafter is cooled to effect rigidification and retention of the contoured configuration thereof. The process further contemplates the application of a decorative layer to the sheet prior to or subsequent to the heating and molding operation.