Abstract:
A headliner assembly ( 10 ) includes a layer of core material ( 16 ), a binding agent ( 26 ) adjacent to the core material ( 16 ), a first layer of chopped fiberglass ( 14 ) adjacent to the binding agent ( 26 ), a scrim ( 20 ) adjacent to the first layer of chopped fiberglass ( 14 ), a catalyst ( 38 ) adjacent to the scrim ( 20 ), a cover stock ( 22 ) adjacent to the catalyst ( 38 ). The catalyst ( 38 ) and the binding agent ( 26 ) are mixed together and impregnate the core material when pressure is applied to the headliner assembly ( 10 ), thereby resulting in a rigid headliner assembly. A method of forming the headliner assembly ( 10 ) is also disclosed.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to a laminated article and method for forming the laminated article. More particularly, the present invention relates to a laminated lightweight headliner assembly and method for forming the same.  
         [0003]     2. Description of the Related Art  
         [0004]     The headliner of a vehicle is a large lining that extends over the top of the passenger compartment to protect and aesthetically cover the vehicle roof. In some embodiments, the headliner consists of fabric that is stitched to a sheet of foam. Thus, the headliner is soft and pliable. Soft and pliable headliners are undesirable because an underlying support structure is required for the headliner to maintain its shape. Adding a support structure adds weight to the vehicle. Moreover, the support structure may create vibration noises that can be heard in the passenger compartment.  
       SUMMARY OF THE INVENTION  
       [0005]     In an illustrated embodiment of the invention, a headliner assembly includes a layer of core material, a binding agent adjacent to the core material, a first layer of chopped fiberglass adjacent to the binding agent, a scrim adjacent to the first layer of chopped fiberglass, a catalyst adjacent to the scrim, and a cover stock adjacent to the catalyst. The catalyst and the binding agent are mixed together and impregnate the core material when pressure is applied to the headliner assembly, thereby resulting in a rigid headliner assembly.  
         [0006]     A method of manufacturing the laminated headliner assembly is also disclosed. The method comprising the steps of: 
        applying a binding agent to one side of a core material;     applying a first layer of chopped fiberglass to said binding agent;     applying a scrim to said first layer of chopped fiberglass;     applying a catalyst to said scrim;     applying a cover stock to said catalyst; and     controlling an amount of said binding agent and said catalyst that penetrates said core material.       
 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:  
         [0014]      FIG. 1  is an exploded cross-sectional view of a partial laminated headliner assembly according to an embodiment of the present invention.  
         [0015]      FIG. 2  is a schematic view of a method for forming the laminated headliner assembly according to an embodiment of the present invention.  
         [0016]      FIG. 3  is an exploded cross-sectional view of a laminated headliner assembly according to an alternate embodiment of the present invention.  
         [0017]      FIG. 4  is an exploded cross-sectional view of a laminated headliner assembly according to another alternate embodiment of the present invention.  
         [0018]      FIG. 5  is a schematic view of an alternate method for forming a laminated headliner assembly according to an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]     Referring to  FIG. 1 , a laminated headliner assembly  10  is generally shown according to an embodiment of the present invention. The laminated headliner assembly  10  comprises a film  12 , a first layer of chopped fiberglass  14 , a layer of core material, such as a layer of foam  16 , a second layer of chopped fiberglass  18 , a hydrophilic scrim  20  and a cover stock  22 . The laminated headliner assembly  10  may also include an optional fabric covering  24  secured to the film  12  to provide an aesthetically pleasing finished surface to the laminated headliner assembly  10 . The film  12  may be made of any desirable material, such as a polyester material, or the like. In addition, the film  12  may be a scrim material. The fiberglass material of the first and second layers of chopped fiberglass  14 ,  18  may be of natural or synthetic fibers. The layer of foam  16  is bonded to the first and second layers of chopped fiberglass  14 ,  18  with a binding agent  26 , such as isocyanate, or the like. The layer of foam  16  may be made of any desirable material, for example, the layer of foam  16  may comprise a polyurethane, polyester material, or the like. A catalyst  38  is preferably applied to the hydrophilic scrim  20 . The catalyst  38  is discussed in greater detail below.  
         [0020]      FIG. 2  illustrates a method of manufacturing the laminated headliner assembly  10  according to the present invention. Initially, the first layer of chopped fiberglass  14  is applied to the film  12 . As the film  12  is fed along a main assembly line, a first fiberglass chopper  28  delivers random size fiberglass  14   a  onto the film  12 . The random size fiberglass  14   a  is generally evenly spread over the film  12  to form the first layer of chopped fiberglass  14 .  
         [0021]     A second assembly line feeds the layer of foam  16  through opposing sets of rollers  30 ,  32 . Preferably, the second assembly line runs concurrently in time with the main assembly line. One set of rollers  30  rolls over a top surface  16   a  of the layer of foam  16  while the second set of rollers  32  rolls over a bottom surface  16   b  of the layer of foam  16 . Each set of rollers  30 ,  32  includes a large roller  31   a  and a smaller roller  31   b . The set of rollers  30 ,  32  are used to apply the binding agent  26  to the top and bottom surfaces  16   a ,  16   b  of the layer of foam  16 . Alternatively, the binding agent  26  may be applied to only one surface of the layer of foam  16 , i.e., either the top surface  16   a  or the bottom surface  16   b.    
         [0022]     The amount of binding agent  26  applied to layer of foam  16  is controlled by the set of rollers  30 ,  32 . Moreover, saturation of the binding agent by the layer of foam  16  is also controlled by the set of rollers  30 ,  32 . Specifically, the distance between large roller  31   a  and small roller  31   b , and the position of the set of rollers  30 ,  32  with respect to the layer of foam  16 , controls the amount of binding agent  26  applied to the layer of foam  16  and the amount of absorption of the binding agent  26  by the layer of foam  16 . For instance, as the distance between large roller  31   a  and small roller  31   b  increases, the amount of binding agent  26  applied to the layer of foam  16  increases. Similarly, as the distance between set of rollers  30 ,  32  and the layer of foam  16  increases, the amount of binding agent  26  applied to the layer of foam  16  increases. Typically, the upper and the lower portions of the layer of foam  16  absorb the binding agent  26 . Absorption of the binding agent  26  into the layer of foam  16  preferably occurs within a range of twenty percent up to eighty five percent. It should be noted that the amount of absorption may vary depending upon the final product. Finally, the rigidity of the laminated headliner assembly  10  increases with the absorption of the binding agent  26 . However, the noise and vibration qualities of the headliner assembly  10  may decrease.  
         [0023]     Once the binding agent  26  has been applied to the layer of foam  16 , the agent-coated layer of foam  16   c  is introduced into the main assembly line. The agent-coated layer of foam  16   c  is placed over the first layer of chopped fiberglass  14 . A second fiberglass chopper  34  delivers random size fiberglass onto the main assembly line. The random size fiberglass  18   a  is generally evenly spread over the agent-coated layer of foam  16   c  to form the second layer of chopped fiberglass  18 .  
         [0024]     The hydrophilic scrim  20  is processed in a third assembly line. The hydrophilic scrim  20  is fed through a second set of rollers  36 . Second set of rollers  36  includes a large roller  36   a  and a small roller  36   b . As the hydrophilic scrim  20  passes through the second set of rollers  36 , a catalyst  38  is applied to the hydrophilic scrim  20 . In one embodiment of the present invention, the catalyst  38  is approximately ninety-five percent water in composition. The remaining approximate five percent composition of the catalyst  38  is a polyol. The polyol in the catalyst  38  facilitates a reaction between the water of catalyst  38  and the binding agent  26 . Thus, the catalyst  38  reduces the amount of time required for the binding agent  26  to bond the first and second layers of chopped fiberglass  14 ,  18  with the agent-coated layer of foam  16   c . Accordingly, the catalyst  38  reduces the cycle time to manufacture the laminated headliner assembly  10 .  
         [0025]     In an alternative embodiment, the catalyst  38  includes amines. The amines interact with the binding agent  26  to facilitate a reaction having a similar effect as the polyol. It can be noted that the catalyst  38  may be any desirable composition so long as catalyst  38  reduces the cycle time to manufacture the laminated headliner assembly  10 . Alternatively, the catalyst  38  may be substituted with a thermoset resin (not shown). The thermoset resin is heat activated to bond the first and second layers of chopped fiberglass  14 ,  18  with the agent-coated layer of foam  16   c . In a further alternate embodiment, the catalyst  38  may be applied to the hydrophilic scrim  20  by soaking the hydrophilic scrim  20  in a bath  50  of the catalyst  38  as described below.  
         [0026]     After the hydrophilic scrim  20  is fed through the second set of rollers  36 , the layer of cover stock  22  is placed over the layer of hydrophilic scrim  20 . The cover stock  22  is fed from a fourth assembly line (not shown). Upon joining, the cover stock  22  and the hydrophilic scrim  20  are fed to the main assembly line. A third set of rollers  40  rolls over the laminated headliner assembly  10 . The third set of rollers  40  includes rollers  40   a  and  40   b . As the laminated headliner assembly  10  is fed through the third set of rollers  40 , the third set of rollers  40  ensures that the layers of the laminated headliner assembly  10  are properly bonded together.  FIG. 2  illustrates rollers  40   a  and  40   b  as having approximately the same diameter. However, it can be appreciated that rollers  40   a  and  40   b  may vary in diameter with respect to each other.  
         [0027]     Additionally, the optional fabric covering  24  may be placed upon the film  12 . The addition of the fabric covering  24  is known by those skilled in the art and may be applied to the laminated headliner assembly  10  by any conventional means.  
         [0028]     After the laminated headliner assembly  10  passes through the third set of rollers  40 , the laminated headliner assembly  10  is cut to a desired length by a cutter  42 . The laminated headliner assembly  10  may be cut to any desired length. The length generally depends upon which vehicle the laminated headliner assembly  10  will be installed. Finally, the laminated headliner assembly  10  undergoes a process that presses together the layers of the laminated headliner assembly  10 . As shown in  FIG. 2 , a press  44  applies pressure to the laminated headliner assembly  10 . The press  44  includes, for example, an upper mold half  44   a  and a lower mold half  44   b . The force exerted by upper and lower mold halves  44   a ,  44   b  onto the laminated headliner assembly  10  assists in bonding together the film  12 , the first layer of chopped fiberglass  14 , the agent-based layer of foam  16   c , the second layer of chopped fiberglass  18 , the hydrophilic scrim  20 , the cover stock  22  and the optional fabric covering  24  of the laminated headliner assembly  10 . More specifically, the force exerted by upper and lower mold halves  44   a ,  44   b  mixes catalyst  38  with binding agent  26 . Primarily, the water component of catalyst  38  mixes with binding agent  26 . The mixture of the catalyst  38  and binding agent  26  diffuses through various layers of the laminated headliner assembly  10  and impregnates a portion of the layer of foam  16 , resulting in a rigid laminated headliner assembly  10 .  
         [0029]     Referring to  FIG. 3 , an alternative embodiment of the laminated headliner assembly  10 ′ is shown according to the present invention. Laminated headliner assembly  10 ′ incorporates substantially all of the features present in laminated headliner assembly  10 . Specifically, laminated headliner assembly  10 ′ includes a layer of polyurethane foam  16 ′ in which the binding agent  26  is partially absorbed. The laminated headliner assembly  10 ′ further includes an adhesive film or web  46  applied between the layer of film  12  and the first layer of chopped fiberglass  14 . The adhesive web  46  may be an interchangeable multi-layer adhesive that is tacky on one or both sides, indicated at  46   a  and  46   b.    
         [0030]      FIG. 4  is a further alternative embodiment of the laminated headliner assembly  10 ″ according to the present invention. The laminated headliner assembly  10 ″ is similar to and substantially incorporates the features of laminated headliner assembly  10  and laminated headliner assembly  10 ′. However, laminated headliner assembly  10 ″ includes a different core material, for example, a polyester batting  16 ″ in place of the layer of foam  16 . Moreover, the binding agent  26  is partially absorbed within the polyester batting  16 ″. The polyester batting  16 ″ may include various sized fibers  17  that blend with binding agent  26 .  
         [0031]      FIG. 5  illustrates a method of manufacturing laminated headliner assembly  10 ′ and  10 ″ of  FIGS. 3 and 4 . The method of manufacturing laminated headliner assembly  10 ′ and  10 ″ is similar to and substantially incorporates the method of manufacturing laminated headliner assembly  10  as illustrated in  FIG. 2 . However, the method of manufacturing laminated headliner assembly  10 ′ and  10 ″ includes an initial step of feeding the adhesive film  46  from a roller  52  into the main assembly line. The adhesive film  46  is placed over the layer of film  12 ′. Additionally, the hydrophilic film  20  enters a holding bin or bath  50  where catalyst  38  is applied.  
         [0032]     The method of manufacturing the laminated headliner assembly  10  according to the present invention results in advantages over conventional headliner assemblies. First, conventional headliner assemblies require the use of a thermoset resin to bind together the various layers of the headliner assembly. As a result, conventional headliner assemblies must be heated in order for the resin to properly bind the layers of the headliner assembly. Additionally, conventional headliner assemblies require an additional step of pre-mixing the thermoset resin and the catalyst together before applying the mixture to the headliner assembly. Further, conventional headliner assemblies require additional adhesive layers between each layer of fiberglass and the outermost layers of the headliner assembly.  
         [0033]     In contrast, the laminated headliner assembly of the present invention does not require the use of a thermoset resin. Thus, the laminated headliner assembly  10  does not have to be heated. Moreover, the binding agent  26  and the catalyst  38  do not have to be pre-mixed before application. Finally, the laminated headliner assembly  10  of the present invention does not require additional adhesive layers to bind the first and second layers of fiberglass  14 ,  18  or to bind the outermost layers of the laminated headliner assembly  10 . According, the laminated headliner assembly  10  of the present invention eliminates several steps in the conventional manufacturing process, resulting in a headliner assembly that is less expensive and easier to manufacture than conventional headliner assemblies. It should be noted that while the present invention is directed towards a headliner assembly, the present invention may be applied to various components within the vehicle, including, for example, a door trim, or a luggage trim, or the like.  
         [0034]     While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.