| 摘要 |
A rigid, contoured insulating sheet is formed from a flexible, substantially uniform thickness mat (43) of loose fibers or open-cell foam, impregnated with an uncured, heat-activable adhesive, e.g., a phenol-formaldehyde resin, by: a) compressing the mat between a pair of complementary, contoured, preheated e.g., 375 DEG F.) dies (19 and 22) that have perforations (4, 18 and 33) across substantially their entire contact surfaces (30 and 50); b) simultaneously ejecting superheated vapor, preferably steam (lines 9, 14 and 40), through the perforations in both dies, the vapor being at a pressure and temperature e.g., 80 psig and 600 DEG F.) sufficient to heat the adhesive in the mat to its activation temperature e.g., 230-350 DEG F.); and c) applying vacuum (line 10) to the mat, so as to pull ambient air therethrough, until the adhesive is substantially set. The process is especially useful for forming contoured, fiberglass, insulation panels for automobiles, e.g., headliner shells. |
