United States Patent [191
`Donahue et al.
`
`I 111111111111111111111111111111111111 IIIII IIIII IIIII IIIII IIIIII Ill lllll llll
`US005298319A
`5,298,319
`[11] Patent Number:
`[45] Date of Patent: Mar. 29, 1994
`
`[54] MOLDABLE AUTOMOTIVE TRUNK LINER
`Inventors: John M. Donahue; Christopher H.
`[75]
`Gardner, both of Easley; John
`Owens, Seneca, all of S.C.
`(73] Assignee: Phillips Petroleum Company,
`Bartlesville, Okla.
`[21] Appl. No.: 850,755
`Mar. 13, 1992
`[22] Filed:
`Int. CJ.s ........................ B32B 27/36; B32B 5/06;
`[51]
`B32B 5/22
`[52] U.S. Cl ..................................... 428/284; 428/286;
`428/287; 428/300; 428/301; 428/298
`[58] Field of Search ................ 428/284, 286, 287, 300
`References Cited
`(56]
`U.S. PATENT DOCUMENTS
`4,269,884 5/1981 DellaVecchia et al. ............ 428/131
`4,320,167 3/1982 Wishman ............................. 428/288
`4,416,936 11/1983 Erickson et al. .................... 428/286
`4,673,207 6/1987 Reynolds et al. ................. 296/39 R
`4,695,501 9/1987 Robinson ............................ 428/287
`4,721,641 1/1988 Bailey .................................... 428/88
`4,801,169 1/1989 Queen et al. ....................... 296/39.1
`
`4,851,274 7/1989 D'Elia ................................. 428/113
`4,851,283 7/1989 Holtrop et al. ..................... 428/284
`
`Primary Examiner-George F. Lesmes
`Assistant Examiner-Kathryne Elaine Shelborne
`Attorney, Agent, or Firm-Richmond, Phillips,
`Hitchcock & Umphlett
`ABSTRACT
`[57]
`A moldable fibrous composite comprising a first layer
`comprising a non-woven fabric, a second intermediate
`layer comprising a thermoformable material, and a third
`layer comprising a non-woven fabric is provided. This
`moldable fibrous composite can be utilized to form a
`one-piece trunk liner for an automobile trunk compart(cid:173)
`ment. Additionally, the thermoformable material can be
`comprised of the same polymeric material as that of the
`staple fiber of the non-woven fabric of the first and third
`layer, thereby allowing recyclability of the moldable
`fibrous composite. A method is provided for the pro(cid:173)
`duction of the moldable fibrous composite, and, addi(cid:173)
`tionally, a method is provided for the production of a
`moldable automotive trunk liner.
`
`18 Claims, 3 Drawing Sheets
`
`34
`
`30
`
`EX1015
`Yita v. MacNeil
`IPR2020-01139
`
`

`

`US. Patent
`U.S. Patent
`
`Mar.29, 1994
`Mar. 29, 1994
`
`Sheet 1 0:3
`Sheet 1 of 3
`
`.
`
`5,298,319
`5,298,319
`
`IG.
`
`1 F
`
`

`

`U.S. Patent
`US. Patent
`
`Mar. 29, 1994
`Mar. 29, 1994
`
`Sheet 2 of 3
`Sheet 2 of 3
`
`5,298,319
`5,298,319
`
`0 n
`
`FIG.2
`
`

`

`U.S. Patent
`US. Patent
`
`Mar. 29, 1994
`Mar. 29, 1994
`
`Sheet 3 of 3
`Sheet 3 of 3
`
`5,298,319
`5,298,319
`
`co
`I{)
`
`FIG.3
`
`0
`'V
`
`

`

`1
`
`5,298,319
`
`2
`truded thermoplastic sheet comprised of polypropyl(cid:173)
`ene. In accordance with another aspect of this inven(cid:173)
`tion, a process is provided for producing a moldable
`fibrous composite comprising a first layer comprising a
`5 non-woven fabric, a second intermediate layer compris(cid:173)
`ing a thermoplastic resin, and a third layer comprising a
`non-woven fabric.
`In the drawings, further preferred embodiments and
`details of this invention are shown. These drawings
`10 should, however, not be interpreted to unduly limit the
`scope of this invention.
`
`MOLDABLE AUTOMOTIVE TRUNK LINER
`
`BACKGROUND OF THE INVENTION
`The present invention relates to moldable non-woven
`laminates and more particularly concerns moldable
`non-woven laminates that can be used for trunk liners
`for an automobile trunk compartment.
`In the fabrication of automotive trunk liners, it is
`common to utilize an integrally molded fibrous trunk
`liner wherein the trunk liner is molded in such a manner
`that the sidewalls thereof are formed so as to extend
`upwardly and outwardly in a diverging manner relative
`to the center floor cover panel so as to resiliently en(cid:173)
`gage the sidewalls of the trunk compartment when the 15
`sidewalls of the liner are biased inwardly toward an
`upright position when installed and mounted in a trunk
`compartment. This resilient engagement of the trunk
`liner with the walls of the trunk compartment facilitates
`the mounting of the trunk liner in the trunk compart- 20
`ment and the maintaining of the trunk liner in the in(cid:173)
`stalled position and engagement with the walls of the
`trunk compartment.
`Generally, such a trunk liner is formed from a mold(cid:173)
`able felt applied to the backside of a non-woven fabric. 25
`This felt serves to impart shape retention and stiffness to
`the overall molded body upon the molding operation
`being completed. The upper surface is formed of soft
`fibrous material for an aesthetically pleasing appear(cid:173)
`ance. The backside felt must be comprised of material 30
`that is capable of being thermoformed at temperatures
`that will not damage the look or feel of the upper sur(cid:173)
`face material. For this reason, the upper surface mate(cid:173)
`rial and the backside coating material are generally
`produced from dissimilar materials, thereby preventing 35
`trim or other waste from being reprocessed or recycled.
`It bas been estimated that between 20 and 40 percent of
`the material utilized to produce current trunk liners
`becomes waste material, which results in excessive pro-
`duction costs.
`It is an important object of the present invention to
`produce a thermoformable non-woven laminate in
`which all of the materials of the laminate are compatible
`and are thus capable of being recycled.
`It is another object of this invention to produce an 45
`integral molded trunk liner wherein the materials of the
`trunk liner are compatible and are thus capable of being
`recycled.
`It is a further object of this invention to produce an
`integral molded trunk liner with increased bulk thick- 50
`ness and increased acoustical value.
`Other and further objects, aims, purposes, features,
`advantages, embodiments, and the like will be apparent
`to those skilled in the art from the present specification,
`taken with the associated drawings, and the appended 55
`claims.
`More particularly, in one aspect, the present inven(cid:173)
`tion relates to a moldable fibrous composite comprising
`a first layer comprising a non-woven fabric, a second
`intermediate layer comprising a thermoformable mate- 60
`rial, and a third layer comprising a non-woven fabric. In
`accordance with another aspect of this invention, the
`three layers of the composite of the present invention
`are compatible with each other in order to provide for
`recyclability of the fibrous composite. In accordance 65
`with this aspect, the first and third layers of the compos-
`ite each comprise a non-woven fabric comprised of
`polypropylene fibers. A second layer comprises an ex-
`
`40
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a top perspective view of the trunk liner of
`the present invention substantially as the same appears
`when taken out of the mold.
`FIG. 2 is an isometric view of the moldable fibrous
`composite of the present invention showing the layered
`configuration.
`FIG. 3 is a schematic representation of a system for
`producing the moldable fibrous composite sheets of the
`present invention.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`Referring now to the drawings and to FIG. 1 in par(cid:173)
`ticular, the trunk liner 10 of the present invention is
`shown as removed from a typical pressure molding
`operation utilizing mating male and female molding
`components. The trunk liner 10 comprises a center floor
`cover panel 12 and a plurality of panels extending along
`the sides of said center floor cover panel 12 and inte(cid:173)
`grally connected thereto. These panels include a rear
`end panel 14 having lower end portions connecting rear
`most portions of the floor cover panel 12 and diver(cid:173)
`gently extending upwardly and outwardly therefrom. A
`first rear wheel housing cover panel 16 and a second
`rear wheel housing cover panel 18 are connected to
`opposite sides of the center floor cover panel 12 and
`divergently extend upwardly and outwardly therefrom.
`The molded trunk liner 10 is formed of a fibrous
`material that may readily be subjected to molding. FIG.
`2 iJiustrates the preferred construction of moldable fi(cid:173)
`brous composite from which the trunk liner 10 of this
`invention is manufactured. The moldable fibrous com(cid:173)
`posite is preferably a 3-ply laminate of a first non-woven
`fabric 20 having a first face 22 and a second face 24, a
`second non-woven fabric 26 having a first face 28 and a
`second face 30, and an extruded thermoformable mate(cid:173)
`rial 32 having a first face 34 and a second face 36. The
`first non-woven fabric 20 is bonded to the second non(cid:173)
`woven fabric 26 by the extruded thermoformable mate(cid:173)
`rial 32. The second face 24 of the first non-woven fabric
`20 is bonded in contact with the first face 34 of the
`extruded thermoformable material, while the first face
`28 of the second non-woven fabric 26 is bonded in
`contact with the second face 36 of the extruded thermo(cid:173)
`formable material 32 so that the first face 22 of the first
`non-woven fabric is exposed as the top surface of the
`moldable fibrous composite while the second face 30 of
`the second non-woven fabric is exposed as the bottom
`surface of the moldable fibrous composite.
`Because the first face 22 of the first non-woven fabric
`20 will be exposed within the trunk, it is important that
`the first non-woven fabric 20 comprise a material that
`has aesthetically pleasing look and feel as well as a
`material that is durable and tear resistant. The extruded
`
`

`

`25
`
`3
`thermoformable material 32 serves to impart shape re(cid:173)
`tention and stiffness to the overall molded body upon
`the molding operation being completed. The second
`non-woven fabric 26 serves to increase the bulk or
`thickness of the moldable fibrous composite in order to 5
`increase the rigidity or stiffness of the molded part.
`Additionally, the second non-woven fabric 26 aids in
`the overall acoustical value of the part by preventing
`the extruded thermoformable material from having
`intimate contact with the exposed sheet metal within 10
`the trunk. Further, the second non-woven fabric 26
`substantially improves the tear resistance of the com(cid:173)
`posite.
`In accordance with one aspect of this invention, the
`moldable fibrous composite utilized to form the auto- 15
`motive trunk liner of the present invention i-s com(cid:173)
`prised of a tri-laminate as shown in FIG. 2, wherein the
`first non-woven fabric 20, the second non-woven fabric
`26 and the extruded thermoformable material 32 are
`each comprised of the same polymeric material so that 20
`trim or other composite waste can be reprocessed or
`recycled. In a preferred embodiment, the first non(cid:173)
`woven fabric 20, the second non-woven fabric 26, and
`the extruded thermoformable material 32 are each com-
`prised of polypropylene.
`In such an embodiment, the first non-woven fabric 20
`and the second non-woven fabric 26 are each comprised
`of polypropylene staple fibers. Staple fibers suitable for
`use in the present invention can be selected from staple
`fibers having lengths ranging from about 2 to about 5 30
`inches. Good results have been attained employing a
`staple length ranging from about 3¼ to about 4 inches.
`Staple denier can be selected from a wide range of
`deniers. Normally the denier ranges from about 1 to
`about 20. The first non-woven fabric has a weight rang- 35
`ing from about 5 to about 7 ounces per square yard
`preferably about 5.5 to about 6.5 ounces per square
`yard. The second non-woven fabric 26 has a weight
`ranging from about 2 to about 4 ounces per square yard
`preferably about 2.5 to about 3.5 ounces per square 40
`yard. The extruded thermoformable material 32 must be
`compatible with the polypropylene staple fibers of the
`first non-woven fabric 20 and the second non-woven
`fabric 26 while also being capable of being thermo(cid:173)
`formed at temperatures that will not damage the look of 45
`feel of the first non-woven fabric 20 or the second non(cid:173)
`woven fabric 26. Accordingly, the extruded thermo(cid:173)
`formable material 32 is comprised of from about 50% to
`about 100% polypropylene, from about 0% to about
`10% ultra-low density polyethylene, from about 0% to 50
`about 20% particulate filler, from about 0% to about
`10% carbon black, and from about 0% to about 8%
`foaming agent, by weight.
`The addition of from about 0% to about 10% ultra(cid:173)
`low density polyethylene by weight to the polypropyl- 55
`ene helps the thermoforming operation by allowing the
`thermoformable material 32 to mold in process easier
`while also lowering the heat required to thermoform
`the material. The addition of this amount of ultra-low
`density polyethylene does not significantly decrease the 60
`recycling compatability of the thermoformable material
`32 and allows the thermoformable material 32 to remain
`compatible with the first non-woven fabric 20 and the
`second non-woven fabric 26.
`The addition of a particulate filler to the composition 65
`of the extruded thermoformable material 32 increases
`the modulus and stiffness of the resulting fibrous com(cid:173)
`posite while additionally providing a more economical
`
`5,298,319
`
`4
`composition. While calcium carbonate is presently pre(cid:173)
`ferred as a particulate filler in the present invention,
`such fillers may be selected from a wide variety of min(cid:173)
`erals, metals, metal oxides, siliceous materials, metal
`salts, and mixtures thereof. These fillers may optionally
`be treated with various coupling agents or adhesion
`promoters, as is known to those skilled in the art. Addi(cid:173)
`tionally, small amounts of carbon black can be added to
`this material in order to blacken the color of the mate(cid:173)
`rial. Foaming or blowing agents can also be added to
`the material in order to increase bulk and stiffness and
`result in greater thickness with less weight.
`Apparatus suitable for the manufacture of a non(cid:173)
`woven fabric such as first non-woven fabric 20 and
`second non-woven fabric 26, is described in detail in
`U.S. Pat. No. 4,042,655 issued to Platt et al and assigned
`to the assignees of the present invention, which patent is
`incorporated by reference herein. Such apparatus in(cid:173)
`cludes batt-forming means comprising two webb-form(cid:173)
`ing trains in which feed means, such as bale breakers,
`blender boxes, feed boxes, etc., feed fibers in the form of
`staple, such as polypropylene fiber staple, to breaker
`carding machines. The carding machines produce
`carded webs of intermixed fibers which are picked up
`by take-off aprons of crosslappers. The crosslappers
`also comprise lapper aprons which traverse a carrier
`means such as intermediate aprons in a reciprocating
`motion thus laying webs to form intermediate batts on
`the intermediate aprons. The intermediate batts are
`passed to finisher carding machines by the intermediate
`aprons. The carding machines produce carded webs
`which are picked up by additional take-up aprons asso(cid:173)
`ciated with additional crosslappers. The additional
`crosslappers also comprise additional lapper aprons
`which form a batt of fibers as the additional lapper
`aprons traverse a floor apron. The carded webs passing
`from the additional crosslappers are laid on the floor
`apron to build up several thicknesses to produce the
`previously mentioned batt.
`As used through the instant specification, the term
`"fill direction" means the direction transverse to the
`direction of movement of the batt on the floor apron.
`The term "warp direction" means the direction parallel
`to the direction the batt moves on the floor apron,
`which is sometimes referred to as the machine direction.
`First warp-drafting means, comprising at least two
`sets of nip rolls or an inlet apron in one set of nip rolls,
`is preferably used to draft the batt in the warp direction.
`As used herein, the term stretching, drawing, and draft(cid:173)
`ing are synonymous.
`The warp-drafted batt is then passed to a needle loom
`wherein the batt is needled at a suitable density, gener(cid:173)
`ally in the range of from about 100 to about 1,000
`punches per square inch (about 15 to about 155 punches
`per square centimeter) and more preferably in the range
`from about 300 to about 500 punches per square inch
`(about 46 to about 78 punches per square centimeter).
`The needle penetration distance during needle punch(cid:173)
`ing is generally in the range of from about 5 to about 10
`millimeters and more preferably in the range from about
`6 to about 8 millimeters. A penetration of less than 5
`millimeters is generally not sufficient to properly bind
`the staple fibers, however, a small needle penetration is
`desired in the present invention so that the resulting
`non-woven fabric will have greater thickness and there(cid:173)
`fore an appearance of more bulk. A needle penetration
`in the range of from about 6 to about 8 millimeters is
`sufficient to properly bind the staple fibers while main-
`
`

`

`5,298,319
`
`6
`the extruder 44 up to a certain percentage that would
`processable without harming final extrudate properties.
`This would result in lower extruder resin costs, while
`also lowering the trunk liner producers' costs by elimi(cid:173)
`nating the need for disposal of the waste.
`
`5
`taining maximum resulting thickness of the non-woven
`fabric.
`The warp-drafted and needled batt is then subjected
`· to additional drafting in the warp direction by second
`warp-drafting means. Generally, the needled batt of the 5
`first non-woven fabric 20 is warp-drafted with an over(cid:173)
`EXAMPLES
`all draft percentage ranging from about 7% to about
`The following examples are provided to further illus-
`15% and more preferably in the range from about 8% to
`about 10%. The needled batt of the second non-woven
`trate the invention and are not to be considered as un-
`fabric 26 is warp-drafted with an overall draft percent- 10 duly limiting the scope of this invention.
`age ranging from about 20% to about 35% and more
`The non-woven fabrics used in the following example
`preferably in the range of from about 22% to about
`were produced as described here. The first non-woven
`26%.
`fabric and the second non-woven fabric were prepared
`The batt is then preferably passed over a roll to fill-
`by using polypropylene staple fibers, 10 denier, 3¼
`drafting means, such as a tenter frame. A suitable tenter 15 inches long, carding the staple fibers to form a web,
`frame comprises a fill-drafting section and a tensioning
`feeding the thus formed web to a crosslapper to provide
`section. The tensioning section is not used to draft the
`additional thickness, stretching the web in a warp direc-
`batt, but is rather employed to subject the batt to tension
`tion, and needle punching the stretched web. The non-
`in the fill direction subsequent to the application of
`woven fabrics are needle-punched on a needle loom
`fill-drafting to the batt. The resulting fabric is then 20 using one barb needles with the barb located about 2½
`rolled onto storage rolls.
`mm above the point of the needles. The density of the
`A method of manufacturing the improved trunk liner
`needles used to make the non-woven fabrics are approx-
`of the present invention is illustrated in schematic form
`imately 300 needles per linear inch of needle board. The
`in FIG. 3. As shown therein, first non-woven fabric 20
`material formed for the first non-woven fabric was a
`from a supply roll 40 and second non-woven fabric 26 25 non-woven web of 6 ounces per square yard. This first
`from a supply roll 42 are brought in to juxtaposition and
`non-woven fabric was needle punched with a needle
`thermoformable material 32 from extruder 44 is depos-
`penetration of 7 millimeters. After needle punching, the
`ited uniformly therebetween to form the desired lami-
`first non-woven fabric was again stretched in the warp
`nated composite structure. Extruder 44 may be any of
`direction at a ratio of about 1.093/1. The material
`the commercially available extrusion devices which, in 30 formed for the second non-woven fabric was a non-
`known manner can, under beat and pressure soften the
`woven web of 3 ounces per square yard. This second
`thermoformable material and force it under control out
`non-woven fabric was needle punched with a needle
`of a die.
`penetration of 7 millimeters. After needle punching, this
`Pull rollers 46 move the composite structure after
`second non-woven fabric was again stretched in the
`lamination to a shearing station 48 where the composite 35 warp direction at a ratio of about 1.24/1. After needle
`structure is cut to predetermined dimensions. The cut
`punching and the subsequent warp drafting, the web of
`composition structure is preferably sized so that it will
`the first non-woven fabric and the web of the second
`overlie to a desired extent the trunk well of a particular
`non-woven fabric are each passed over a tenter frame to
`subject the batt to tension in the fill direction subsequent
`vehicle model.
`The cut composite structure 50 can then be trans- 40 to the application of fill-drafting to the batt. Each result-
`ported, e.g. on a pallet 52, to a preheating station where,
`ing fabric is then rolled onto storage rolls. The first
`after removal from the pallet, it is heated in an oven 54
`non-woven fabric and the second non-woven fabric are
`or equivalent structure to a temperature at which it is
`then brought into juxtaposition and thermoformable
`formable. The preheated composite structure is then
`material from an extruder is deposited uniformaly there-
`shaped by molding, preferably between a match set die 45 between to form the desired laminated composite struc-
`comprising a female vacuum die 56 and male plug die
`ture. In this example, four different composite struc-
`58. The dies are constructed so as to form the composite
`tures were prepared using the four different extrudates
`structure into the proper configuration as shown in
`as shown in Table 1.
`TABLE I
`
`%
`ULDPEC1)
`
`%
`Polypropylene
`
`%
`%
`Foaming(2)
`Calcium
`Agent
`Carbonate
`0
`0
`4
`94
`Extrudate A
`0
`0
`88
`10
`Extrudate B
`0
`Extrudate C
`4
`4
`90
`6
`4
`4
`84
`Extrudate C
`CIJulira low density polyethlene sqld under the trademark Attane by Dow Chemical Corp.
`(l.lfoaming agent 110Jd under the product designation 10104 from Ampacet Corp.
`
`Carbon
`Black
`
`2
`2
`2
`2
`
`FIG. 1. The molded structure is then allowed to cool
`and is then trimmed to produce the pre-shaped trunk 60
`liner 10 with the outstanding attributes described
`herein.
`All the waste; scraps, and off-quality goods from the
`composite structure could then be chopped or ground
`into smaller particles and heated, melted, extruded, and 65
`pelletized into a configuration readily able to be ex(cid:173)
`truded again. These reclaimed or recycled pellets could
`be added to the virgin resin pellets at the feed section of
`
`Each of the four resulting composites were heated
`and then thermoformed between a match set die com(cid:173)
`prising a female vacuum die and a male plug die. The
`composite comprising Extrudate A exhibited superior
`moldability with no degradation to the non-woven face
`material. The bending modulus for the composite com(cid:173)
`prising Extrudate A was considered superior while the
`thickness of this composite was considered adequate.
`
`

`

`5,298,319
`
`50
`
`55
`
`15
`
`7
`The composite compnsmg Extrudate B exhibited
`superior moldability with no thermal degradation to the
`non-woven face material. The thickness of the compos(cid:173)
`ite comprising Extrudate B was considered adequate;
`however, the bending modulus of this composite was 5
`considered unacceptable.
`The composite comprising Extrudate C exhibited
`superior moldability with no thermal degradation to the
`non-woven face material. The bending modulus and the
`thickness of this composite were both considered supe- lO
`rior.
`The composite comprising Extrudate D exhibited
`superior moldability with no thermal degradation to the
`non-woven face material. This composite also exhibited
`a superior bending modulus and thickness.
`That which is claimed is:
`1. A moldable fibrous composite comprising:
`a first layer having a first face and a second face
`wherein said first layer comprises a non-woven 20
`fabric consisting essentially of polypropylene sta(cid:173)
`ple fiber;
`a second layer having a first face and a second face
`wherein said first face of said second layer is adja(cid:173)
`cent to said second face of said first layer and 25
`wherein said second layer comprises an extruded
`thermoformable material comprising polypropyl(cid:173)
`ene; and
`a third layer having a first face and a second face
`wherein said first face of said third layer is adjacent 30
`to said second face of said second layer and
`wherein said third layer comprises a non-woven
`fabric consisting essentially of polypropylene sta(cid:173)
`ple fiber.
`2. A moldable fibrous composite in accordance with 35
`claim 1, wherein said extruded thermoformable material
`of said second layer comprises at least about 50% poly(cid:173)
`propylene.
`3. A moldable fibrous composite in accordance with
`claim 2, wherein said extruded thermoformable material 40
`of said second layer comprises in terms of weight less
`than about 10% ultra-low density polyethylene.
`4. A moldable fibrous composite in accordance with
`claim 2, wherein said extruded thermoformable material
`of said second layer comprises in terms of weight less 45
`than about 8% foaming agent.
`S. A moldable fibrous composite in accordance with
`claim 2, wherein said extruded thermoformable material
`of said second layer comprises less than about 20%
`particulate filler.
`6. A moldable fibrous composite in accordance with
`claim 2, wherein said extruded thermoformable material
`of said second layer comprises in terms of weight less
`than about 10% carbon black.
`7. A moldable fibrous composite in accordance with
`claim 1 wherein said first non-woven fabric bas a weight
`in the range of from about 5 ounces per square yard to
`about 7 ounces per square yard, and wherein said sec(cid:173)
`ond non-woven fabric has a weight in the range of from 60
`about 2 ounces per square yard to about 4 ounces per
`square yard.
`8. A moldable fibrous composite in accordance with
`claim 7, wherein said first non-woven fabric and said
`second non-woven fabric have been needle-punched 65
`with a needle penetration in the range of from about 5
`millimeters to about 10 millimeters.
`
`8
`9. A moldable fibrous composite in accordance with
`claim 7, wherein said first non-woven fabric bas been
`drafted in the longitudinal direction in the range of from
`about 7% to about 15% after said first non-woven fabric
`bas been needle-punched and said second non-woven
`fabric has been drafted in the longitudinal direction in
`the range of from about 20% to about 35% after said
`second non-woven fabric bas been needle-punched.
`10. A one-piece trunk liner for an automobile trunk
`compartment, said trunk liner comprising an integral
`molded relatively stiff fibrous body comprising a first
`layer having a first face and a second face wherein said
`first layer comprises a first non-woven fabric consisting
`essentially of polypropylene staple fiber;
`a second layer having a first face and a second face
`wherein said first face of said second layer is adja(cid:173)
`cent to said second face of said first layer and
`wherein said second layer comprises an extruded
`therrnoformable material comprising polypropyl(cid:173)
`ene; and
`a third layer having a first face and a second face
`wherein said first face of said third layer is adjacent
`to said second face of said second layer and
`wherein said third layer comprises a second non(cid:173)
`woven fabric consisting essentially of polypropyl(cid:173)
`ene staple fiber.
`11. A one-piece trunk liner in accordance with claim
`10, wherein said extruded thermoformable material of
`said second layer comprises at least about 50% polypro(cid:173)
`pylene.
`12. A one-piece trunk liner in accordance with claim
`11, wherein said extruded thermoformable material of
`said second layer comprises in terms of weight less than
`about 10% ultra-low density polyethylene.
`13. A one-piece trunk liner in accordance with claim
`11, wherein said extruded thermoformable material of
`said second layer comprises in terms of weight less than
`about 8% foaming agent.
`14. A one-piece trunk liner in accordance with claim
`11, wherein said extruded thermoformable material of
`said second layer comprises less than about 20% partic(cid:173)
`ulate filler.
`1S. A one-piece trunk liner in accordance with claim
`11, wherein said extruded thermoformable material of
`said second layer comprises in terms of weight less than
`about 10% carbon black.
`16. A one-piece trunk liner in accordance with claim
`10, wherein said first non-woven fabric has a weight in
`the range of from about 5 ounces per square yard to
`about 7 ounces per square yard, and wherein said sec(cid:173)
`ond non-woven fabric has a weight in the range of from
`about 2 ounces per square yard to about 4 ounces per
`square yard.
`17. A one-piece trunk liner in accordance with claim
`16, wherein said first non-woven fabric and said second
`non-woven fabric have been needle-punched with a
`needle penetration in the range of from about 5 millime(cid:173)
`ters to about 10 millimeters.
`18. A one-piece trunk liner in accordance with claim
`16, wherein first non-woven fabric has been drafted in
`the longitudinal direction i-n the range of from about
`7% to about 15% after said first non-woven fabric has
`been needle-punched and said second non-woven fabric
`has been drafted in the longitudinal direction in the
`range of from about 20% to about 35% after said sec(cid:173)
`ond non-woven fabric has been needle-punched.
`* * * * *
`
`

`

`UNITED STATES PATENT AND TRADEMARK OFFICE
`CERTIFICATE OF CORRECTION
`
`PATENT NO.: 5,298,319
`DATED: March 29, 1994
`INVENTOR($): John M. Donahue, Christopher H. Gardner, John Owens
`
`It is certified that error appears in the above-identified patent and that said Letters Patent is hereby
`corrected as shown below:
`
`Col.
`
`Line
`
`6
`
`7
`a
`a
`a
`
`55
`
`5 7
`
`2
`
`5
`a
`
`in the last line of Table I, patent reads:
`4
`2"
`"Extrudate C
`4
`84
`6
`patent should read:
`84
`--Extrudate D
`4
`6
`"non-woven fabric bas a weight"
`--non-woven fabric has a weight--
`"first non-woven fabric bas been"
`--first non-woven fabric has been--
`nbas been needle-punched"
`should read
`--has been needle-punched--
`"non-woven fabric bas been needle-punched"
`should read
`- -non-woven fabric has been
`needle-punched--
`
`2--
`4
`should read
`
`should read
`
`Signed and Sealed this
`
`Thirteenth Day of September, 1994
`
`Attest:
`
`Attesting Officer
`
`Commissioner of Parents and Trademarks
`
`BRUCE LEHMAN
`
`