A thermal/acoustic insulation product, such as for an aircraft, comprising a block of flexible, open-celled, cellular foam having a predefined shape and having a thermoformed amorphous film covering that completely envelops the foam block. A process for making the insulation product includes first cutting the block of foam to a predefined shape, such as a shape suitable for placement in an area of an aircraft in need of insulation. Then, a first sheet of film is heated to its melt point and conformed to a first surface area of the block, and a second sheet of film is heated to its melt point and conformed to a second surface area of the block, wherein the first film and the second film are joined to one another at one or more seams. The insulation product may then be installed in an aircraft.

A thermal/acoustic insulation product, such as for an aircraft, comprising a block of flexible, open-celled, cellular foam having a predefined shape and having a thermoformed amorphous film covering that completely envelops the foam block. A process for making the insulation product includes first cutting the block of foam to a predefined shape, such as a shape suitable for placement in an area of an aircraft in need of insulation. Then, a first sheet of film is heated to its melt point and conformed to a first surface area of the block, and a second sheet of film is heated to its melt point and conformed to a second surface area of the block, wherein the first film and the second film are joined to one another at one or more seams. The insulation product may then be installed in an aircraft.

To reliably perform partial decoration forming by avoiding crush deformation of a hollow structure due to a change into a pressure-reduced state even in a case where part of the hollow structure is included in a partial decoration forming range of a formed plate material. A surrounding frame body (33) is brought into contact with an upper portion of a body to be coated to surround the decoration forming range, and the body to be coated is accommodated, and an upper space (A) in a sealed state and a lower space in a sealed state are formed. A surrounded space in a sealed state whose top and bottom are surrounded by a decorative film and the body to be coated in the decoration forming range is formed after the lower space and the upper space (A) in the sealed state are brought into a predetermined first pressure state where the pressures in the lower space and the upper space (A) are equal to each other. By instantaneously increasing the pressures in the lower space and the upper space (A) around the surrounded space from the pressure-reduced state to a second pressure state where the pressures are equal to each other while keeping the surrounded space at the first pressure state, partial decoration forming is performed on the decoration forming range in the surrounded space with the decorative film.

To reliably perform partial decoration forming by avoiding crush deformation of a hollow structure due to a change into a pressure-reduced state even in a case where part of the hollow structure is included in a partial decoration forming range of a formed plate material. A surrounding frame body (33) is brought into contact with an upper portion of a body to be coated to surround the decoration forming range, and the body to be coated is accommodated, and an upper space (A) in a sealed state and a lower space in a sealed state are formed. A surrounded space in a sealed state whose top and bottom are surrounded by a decorative film and the body to be coated in the decoration forming range is formed after the lower space and the upper space (A) in the sealed state are brought into a predetermined first pressure state where the pressures in the lower space and the upper space (A) are equal to each other. By instantaneously increasing the pressures in the lower space and the upper space (A) around the surrounded space from the pressure-reduced state to a second pressure state where the pressures are equal to each other while keeping the surrounded space at the first pressure state, partial decoration forming is performed on the decoration forming range in the surrounded space with the decorative film.

A headliner includes a unitary body having a substrate with an A-surface and a B-surface, a secondary component carried on the B-surface and a laminated surface covering on the A-surface. That method of producing that headliner with a unitary body is also provided.

A method of producing a headliner with a unitary body includes the steps of thermoforming a blank into a headliner substrate, simultaneously injection molding a secondary component onto the headliner substrate and laminating a surface covering to the headliner substrate.

A vehicle interior component includes a base member, a cover member, and an adhesive layer applied to the base member or the cover member. The cover member and the base member are attached via the adhesive layer. On corners of the base member and in the vicinity of the corners, the base member includes non-adhesive portions where an adhesive is not applied.

Illustrated and described are a method and a device for laminating a profiled fibre moulding with a thermoplastic film. The film is laminated onto a surface of the fibre moulding to be coated by heat and differential pressure. To improve the lamination of the fibre moulding and to achieve uniform lamination thicknesses over the entire fibre moulding, the method includes the following steps: fixing at least an edge of the fed film to a base plate, heating the film, deforming the film via a moulding tool, feeding the fibre moulding, joining the fibre moulding to the pre-formed film, and removing the laminated fibre moulding.

A hot stamping apparatus and a hot stamping method are for collectively decorating a plurality of decoration objects using a decorative sheet. In a hot stamping apparatus, an upper chamber and a lower chamber are partitioned by a partition sheet and pressing bodies, so that decorative sheet pieces can be used instead of a decorative sheet having a large area. Then, by using the decorative sheet pieces, local thermal deformation can be prevented. A usage amount of the decorative sheet can be reduced, and three-dimensional decoration can be implemented as needed on a portion requiring decoration.

A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The polyurethane foam core has a density of 15-80 kg/m.sup.3. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article has a weight per unit area of 500-1000 g/m.sup.2 and a strength of greater than 17 N at a post-compression thickness of greater than 2 mm when tested in according with SAE J949 at 23 C.