Method of forming corrugated paperboard automotive liner

• US 5,057,176 A
• Filed: 10/10/1989
• Issued: 10/15/1991
• Est. Priority Date: 05/10/1988
• Status: Expired due to Term

• Current Assignee: Jet Composites, Inc.
• Original Assignee: Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Bainbridge, William
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): YODER, MICHELE
• Application Number:
  US07/419,165
• Time in Patent Office: 735 Days
• Field of Search: 428/182, 428/184, 428/186, 428/179-181, 428/183, 428/185, 156/210, 156/205, 156/221, 156/212, 156/222, 156/224, 156/245, 156/292, 156/253, 296/211, 296/214, 181/286, 181/288, 181/290, 181/284, 181/291
• US Class Current: 156/222
• CPC Class Codes: B31F 1/0009 of plates, sheets or webs
• CPC Class Codes: B31F 1/0077 Shaping by methods analogous to moulding, e.g. deep drawing techniques
• CPC Class Codes: B31F 1/36 Moistening and heating webs to facilitate mechanical deformation and drying deformed webs during corrugating B31F1/28
• CPC Class Codes: B32B 29/08 Corrugated paper or cardboard
• CPC Class Codes: B60R 13/0225 self supporting head liners
• CPC Class Codes: B60R 13/0815 Acoustic or thermal insulation of passenger compartments wall or roof liners integrating the insulating function B60R13/02; insulating floor mats or carpets B60N3/04
• CPC Class Codes: B60R 13/0892 for humidity insulation sealing strips B60R13/06
• CPC Class Codes: Y10T 156/1044 of parallel stacked sheets only
• CPC Class Codes: Y10T 156/1048 to form dished or receptacle-like product
• CPC Class Codes: Y10T 156/1057 Subsequent to assembly of laminae
• CPC Class Codes: Y10T 428/24711 Plural corrugated components
• CPC Class Codes: Y10T 428/24727 with planar component

Abstract

An automotive headliner comprised of a laminate of double corrugated paperboard. Perforations in all the sheets of the laminate except the back paperboard sheet improve the acoustical performance of the liner. A vapor barrier on the back sheet prevents entry of moisture into the laminate from the roof, and a layer of sound dampening material on the front face of the laminate improves the sound absorption of the laminate. The front corrugation is larger than the back corrugation. When molding the laminate it is first moisturized, then heat molded. Heat is applied until the laminate has regained its rigidity.

Claims

1. A method of forming a self-supporting panel for lining the interior face of an automotive roof, comprising the steps of:

providing a paperboard laminate comprising front, back and median paperboard sheets spaced from each other in substantially planar parallel relationship, the distance between the front and median sheets being less than the distance between the median and back sheets, and further comprising corrugated paperboard mediums located between the median sheet and the front and back sheets and being adhered thereto;

perforating the paperboard laminate to form relatively small diameter perforations in the front and median sheets and in the corrugated mediums to improve the sound absorption of the paperboard laminate;

moisturizing the perforated paperboard laminate to substantially soften and reduce the rigidity thereof;

molding the moisturized and softened laminate in a nonplanar heated mold having curved portions to mold the laminate into a nonplanar configuration including curved portions, the curved portions of the molded laminate corresponding to the curved portions of the mold and comprising concave areas at the outer surface of the front sheet and convex areas at the outer surface of the back sheet, the molded laminate being of substantially uniform thickness;

adhering a layer of sound dampening material to the outer face of the front paperboard sheet, the sound dampening material permitting passage therethrough of ambient air; and

drying the molded laminate to increase the rigidity of the laminate.