LAMINATED STRUCTURES WITH MULTIPLE DENIER POLYESTER CORE FIBERS, RANDOMLY ORIENTED REINFORCEMENT FIBERS, AND METHODS OF MANUFACTURE

摘要

A laminated panel-type structure (10), particularly suited for vehicle interior applications such as headliners and door panels, has a multiple denier polyester fiber core (12) and randomly oriented structural reinforcing fibers (14, 16) attached and intertwined with the core (12) on opposing major sides of the core. The core (12) of intertwined polyester fibers of differing deniers preferably has relatively large denier fibers on exterior areas of the core and some bicomponent fibers. The laminate structure also has an impervious polymer film (18) with a low melt layer, which retains the reinforcing fibers (14) against one side of the core (12), and a scrim layer (20) attached to said impervious film (18). Next to the reinforcing fiber layer (16) is a polymer web (19) and a cover stock (22). The invention further includes a method of manufacturing the laminated structure.