LAMINATED STRUCTURES WITH MULTIPLE DENIER POLYESTER CORE FIBERS, RANDOMLY ORIENTED REINFORCEMENT FIBERS, AND METHODS OF MANUFACTURE

摘要

A laminated panel-type structure (10), particularly suited for vehicle interior applications such as headliners and door panels, has a multiple denier polyester fiber core (12) and randomly oriented structural reinforcin g fibers (14, 16) attached and intertwined with the core (12) on opposing majo r sides of the core. The core (12) of intertwined polyester fibers of differin g deniers preferably has relatively large denier fibers on exterior areas of t he core and some bicomponent fibers. The laminate structure also has an impervious polymer film (18) with a low melt layer, which retains the reinforcing fibers (14) against one side of the core (12), and a scrim layer (20) attached to said impervious film (18). Next to the reinforcing fiber layer (16) is a polymer web (19) and a cover stock (22). The invention furth er includes a method of manufacturing the laminated structure.