Patent ID: 6409947
Filing Date: 2002-06-25
Classification: B29C,B60K,B60R

Abstract:
A method for making a headliner comprising a substrate configured to be mounted to a vehicle in a position at least partially covering a lower surface of a passenger compartment roof, the substrate comprising an upper substrate surface and a lower substrate surface disposed opposite the upper substrate surface, and a substrate peripheral edge, the substrate comprising a moldable material, and a cavity formed into the substrate between the upper substrate surface and the lower substrate surface; the method including the steps of:providing a blow mold having first and second opposing wall surfaces contoured to complement the exterior contours of the headliner substrate to be formed, including an enlarged region corresponding to a cavity position in the substrate to be formed; providing a molten parison into the blow mold between said first and second opposing wall surfaces, said molten parison being formed with opposed walls; expanding the molten parison with opposed walls into conforming contact with said first and second wall surfaces of the blow mold by injecting gas into the molten parison; forming a headliner substrate having a cavity formed within by pinching together said first and second opposed walls of said parison at a location within said peripheral edge; allowing the molten parison to harden; removing the headliner substrate from the blow mold; and providing a layer of foam on a lower surface of the substrate and providing a layer of cover material on the lower surface of the foam.