Abstract A foam headliner for a vehicle is provided which comprises a wire mesh support sandwiched between two laminated layers of cross-linked ethylene or propylene homopolymer or copolymer foam, one layer being thicker than the other. A composite of a polyvinyl chloride homopolymer or copolymer foam and a decorative solid polyvinyl chloride homopolymer or copolymer film layer is laminated to the thick layer of cross-linked foam. The crosslinked foam is for energy absorption and the vinyl foam is to prevent the vinyl film from developing creases when the headliner is flexed during handling or installation. The wire mesh is for keeping the headliner from sagging between points of support. The wire mesh may be designed to be more flexible about one axis than the one transverse thereto to prevent deforming premolded areas of the headliner when handling or installing the headliner.
The structure as recited in claim 1 wherein said cross-linked foam comprises a polymer selected from the group consisting of low density polyethylene, linear polyethylene, and stereoregular polypropylene and any of their copolymers.
Claim 2
Dependent Claim
15 words
The structure as recited in claim 1 wherein said cross-linked foam comprises low density polyethylene.
Claim 3
Dependent Claim
35 words
The structure as recited in claim 3 wherein the thickness of said first layer is between about 20 to 75 mils and the thickness of said second layer is between about 100 to 500 mils.
Claim 4
Dependent Claim
30 words
The structure as recited in claim 1 wherein said wire mesh is more flexible for bending about one axis than for bending about an axis transverse to said one axis.
Claim 5
Dependent Claim
18 words
The structure as recited in claim 4 wherein said first and second layers are of the same density.
Claim 6
Dependent Claim
30 words
The structure as recited in claim 4 wherein said wire mesh is more flexible for bending about one axis than for bending about an axis transverse to said one axis.
Claim 7
Dependent Claim
91 words
The structure as recited in claim 1 wherein said cross-linked foam comprises low density polyethylene, said third and fourth layers comprises polyvinyl chloride, and combined thickness range of said first and second layers is between 185 and 335 mils and the density thereof is between 1 and 6 pounds per cubic foot, the thickness range for the third layer is between 10 and 20 mils and the density thereof between 10 and 25 pounds per cubic foot, and the thickness range of the fourth layer is between 2 and 6 mils.
Claim 8
Dependent Claim
35 words
The structure as recited in claim 8 wherein the thickness range of said first layer is between 35 and 60 mils and the thickness range of said second layer is between 150 and 275 mils.
Claim 9
Dependent Claim
30 words
The structure as recited in claim 9 wherein said wire mesh is more flexible for bending about one axis than for bending about an axis transverse to said one axis.