Appeal No. 2005-2633 Page 3
Application No. 10/254,376
OPINION
Appellants’ invention generally relates to an injection molding method for making
a lightweight, thermoplastic, vehicle headliner having at least one integrally formed,
energy-absorbing, head-impact mechanism. (Brief, p. 3). Appellant further discloses
that vehicle headliners must meet head impact requirements such as HIC (Head Injury
Criteria) requirements. (Brief, p. 2). Claims 17 and 25, as presented in the Brief, are
reproduced below:
17. An injection molding method for making a lightweight, thermoplastic,
vehicle headliner having at least one integrally-formed, energy-absorbing,
head-impact mechanism, the method comprising:
providing an injection mold having first and second mold halves;
closing the mold so that the first and second mold halves define a mold
cavity;
injecting molten, thermoplastic resin into the mold cavity to form a
headliner including a stiff, self-supporting, thermoplastic sheet and a plurality
of spaced energy-absorbing, head-impact mechanisms formed on the sheet
and wherein each of the head-impact mechanisms includes a plurality of
spaced-apart, energy-absorbing thermoplastic structures which are integrally
molded and extend upwardly from an upper surface of the sheet and wherein
the number, spacing and size of the structures are predetermined based on
head-impact requirements;
cooling the headliner beneath the softening point of the molten resin; and
opening the mold and removing the headliner.
25. An injection molding method for making a lightweight, thermoplastic
vehicle headliner, the method comprising:
providing an injection mold having first and second mold halves;
closing the mold so that the first and second mold halves define a mold
cavity;
injecting molten, thermoplastic resin into the mold cavity to form a
headliner including a stiff, self-supporting, thermoplastic sheet adapted to be
mounted adjacent the roof so as to underlie the roof and completely shield
the roof from view, the sheet having an upper surface and a lower surface;
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