Automobile roof liner manufacture involves application of reinforcing layers onto a core to form a sandwich structure, then pressing an energy absorption member onto the sandwich

摘要

The multi-stage manufacturing process comprises: a) manufacturing a sheet-like core layer (3); b) applying a reinforcing layer (4) onto one or both sides of the core layer; and c) placing an energy absorbing crash pad (2) in a press tool (5) and joining to the core and/or reinforcing layer by compression. Initial core layers are cut from a prefabricated block or are foamed. Adhesive is applied (7) to the core layer (3) followed by water (21). Reinforcing layers (4) may comprise twin layers of reinforcing and covering fleeces. During the compression stage (13) the core layer is permanently shaped and retains this shape due to an application of a shape retention material. Further adhesive is applied (11) to the sandwich of core and reinforcing layers to enable a decorative layer (6) to be applied to one or both sides. The decorative layer is heated before application onto the sandwich. A bond is formed between decorative layer and sandwich in a press (27). An Independent claim is included for a roof liner incorporating an energy absorbing crash pad (2), a foamed core layer and a reinforcing layer of random fibers.