METHOD OF MAKING A HEADLINER HAVING AN INTEGRATED ENERGY ABSORBING FOAM

摘要

A method of manufacturing a headliner assembly for use in the interior compartment of an automotive vehicle comprising the steps of: placing a mold release film (60) onto a concave mold surface (30) of a lower mold assembly (26) for providing a barrier against the mold surface; placing a fiber mat (62) on the mold release film; applying a foamable material (64) directly onto the fiber mat; expanding the foamable material around the fiber mat to embed the fiber mat therein; placing an adhesive film (66) onto a convex mold surface (16) of an upper mold assembly (14); positioning the lower mold assembly directly beneath the upper mold assembly; moving the upper mold assembly in mating engagement with the lower mold assembly to define a mold cavity between the convex mold surface and concave mold surface; curing the foamable material within the mold cavity; and bonding the mold release film and adhesive film to the foamable material with the fiber mat embedded therebetween. A layer of scrim (72) is then adhered to the mold release film and a layer of fabric (70) is adhered to the adhesive film for providing a decorative cover to the headliner assembly.