US5007976A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of making a headliner
Assignee: Findlay Industries Inc
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Filing: 1989-10-16
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Granted: 1991-04-16
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Expires: 2009-10-16
Abstract
Abstract A headliner for mounting in the passenger compartment of a vehicle is formed from a plurality of layers of materials including foamed polyurethane, fiber glass, scrim and remay. The layers are bonded together under heat and pressure which cures an incorporated adhesive.
Inventors
- 👤 Marshall G. Satterfield
- 👤 David M. Steinke
- 👤 Michael Blankenship
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 16:11
CPC Classifications
B; B32; B32B; B32B38/00; B32B38/08; B29; B29C; B29C70/00; B29C70/04; B29C70/28; B29C70/40; B29C70/42; B29C70/46; B29C70/68; B29C70/86; B60; B60R; B60R13/00; B60R13/02; B60R13/0212; B60R13/0225; B29C43/00; B29C43/02; B29C43/18; B29C2043/185; B29C67/00; B29C67/20; B29K; B29K2075/00; B29K2995/00; B29K2995/0037; B29K2995/0046; B29L; B29L2031/00; B29L2031/30; B29L2031/3005; B29L2031/3011; B60R2013/0287; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1043; Y10T156/1044; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249981; Y10T428/249982; Y10T428/249985
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
174 words
A process for forming a smooth contoured laminated panel from layers of compressible polyurethane foam, fiber glass, scrim and remay comprising, supplying a mold having an upper part and a lower part, said parts including facing substantially mirror image, curved surfaces, assembling on the curved surface of said mold lower part in sequence: (a) a first layer of adhesive impregnated scrim, (b) a first layer of open celled compressible polyurethane foam, said first polyurethane layer being impregnated with an adhesive in an amount to fill the open cells and make said polyurethane layer incompressible when heated to a curing temperature, (c) a first layer of adhesive impregnated fiber glass, (d) a second layer of open celled polyurethane foam, (e) an adhesive impregnated remay, and (f) a decorative layer, bringing the curved surfaces of the two mold parts together to cause the assembled layers to conform to the facing mold surfaces, heating the molds to cure the adhesive impregnating the layers, and retracting the molds and removing the formed panel from the lower mold part.
Claim 2
Dependent Claim
174 words
A process for forming a smooth contoured laminated panel from layers of compressible polyurethane foam, fiber glass, scrim and remay comprising, supplying a mold having an upper part and a lower part, said parts including facing substantially mirror image, curved surfaces, assembling on the curved surface of said mold lower part in sequence: (a) a first layer of adhesive impregnated scrim, (b) a first layer of open celled compressible polyurethane foam, said first polyurethane layer being impregnated with an adhesive in an amount to fill the open cells and make said polyurethane layer incompressible when heated to a curing temperature, (c) a first layer of adhesive impregnated fiber glass, (d) a second layer of open celled polyurethane foam, (e) an adhesive impregnated remay, and (f) a decorative layer, bringing the curved surfaces of the two mold parts together to cause the assembled layers to conform to the facing mold surfaces, heating the molds to cure the adhesive impregnating the layers, and retracting the molds and removing the formed panel from the lower mold part.
Claim 3
Dependent Claim
17 words
The process of claim 1 wherein the adhesive is a mixture of polyol, isocyanate and a catalyst.
Claim 4
Dependent Claim
33 words
The process of claim 2 including the further steps of assembling another layer of fiber glass, said other layer being placed below the first polyurethane foam layer and above the first scrim layer.
Claim 5
Dependent Claim
29 words
The process of claim 3 wherein the laminated molded panel is a headliner for a vehicle and the molds are pressed together at a pressure of about 1.5-29 psi.
Claim 6
Dependent Claim
23 words
The process of claim 4 wherein the upper mold is heated to a temperature above the temperature of the lower mold during curing.
Claim 7
Dependent Claim
33 words
The process of claim 5 wherein the first polyurethane foam layer and the fiber glass layers are impregnated with the same adhesive as the scrim layer, prior to assembly with the other layers.
Claim 8
Dependent Claim
37 words
The process of claim 6 wherein the polyol of the adhesive is hydroxyl terminated poly(oxyalkylene) and the isocyanate is aromatic, said polyol and isocyanate being combined in proportions with polyol in the range 60-75% and isocyanate 25-40%.
Claim 9
Dependent Claim
41 words
The process of claim 1 including the further steps of assembling a second layer of fiber glass below the first polyurethane foam layer and above the first scrim layer, the first fiber glass layer being above the first polyurethane foam layer.
Claim 10
Dependent Claim
29 words
The process of claim 1 wherein the laminated molded panel is a headliner for a vehicle and the molds are pressed together at a pressure of about 6-20 psi.
Claim 11
Dependent Claim
33 words
The process of claim 1 wherein the first urethane foam layer and the fiber glass layer are impregnated with the same adhesive as the scrim layer, prior to assembly with the other layers.
Claim 12
Dependent Claim
37 words
The process of claim 3 wherein the polyol of the adhesive is hydroxyl terminated poly(oxyalkylene) and the isocyanate is aromatic, said polyol and isocyanate being combined in proportions with polyol in the range 60-75% and isocyanate 25-40%.
Claim 13
Dependent Claim
27 words
The process of claim 11 wherein the upper mold is heated to about 275° F. and the lower mold is heated to less than about 200° F.
Claim 14
Dependent Claim
27 words
The process of claim 2 wherein the upper mold is heated to about 275° F. and the lower mold is heated to less than about 200° F.
Claim 15
Dependent Claim
33 words
The process of claim 13 wherein the first urethane foam layer and the fiber glass layer are impregnated with the same adhesive as the scrim layer, prior to assembly with the other layers.
Claim 16
Dependent Claim
19 words
The process of claim 1 wherein the polyurethane foam has a density of about 3 pounds per cubic foot.
Claim 17
Dependent Claim
19 words
The process of claim 2 wherein the polyurethane foam has a density of about 3 pounds per cubic foot.
Claim 18
Dependent Claim
19 words
The process of claim 3 wherein the polyurethane foam has a density of about 3 pounds per cubic foot.
Claim 19
Dependent Claim
19 words
The process of claim 4 wherein the polyurethane foam has a density of about 3 pounds per cubic foot.
Claim 20
Dependent Claim
23 words
The process of claim 1 wherein the upper mold is heated to a temperature above the temperature of the lower mold during curing.
Claim 21
Dependent Claim
27 words
The process of claim 19 wherein the upper mold is heated to about 275° F. and the lower mold is heated to less than about 200° F.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-04-15 | 1994-10-15 | 1995-04-16 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-04-15 | 1998-10-15 | 1999-04-16 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-04-15 | 2002-10-15 | 2003-04-16 | $7700.00 | Window Closed / Lapsed |