Bed liner having enhanced frictional characteristics

Abstract

A motor vehicle bed or bed liner is vacuum formed from a single layer or two layer panel of thermoplastic material having a scuffed or roughened surface. The single layer panel is typically extruded and is homogeneous, being either a single material such as HDPE or a uniform mixture of materials. The two layer panel is co-formed of two layers of material which will typically be distinct compositions and characteristics. The upper surface of the panel is scuffed or roughened by a brush which contacts the surface. A bank of individually adjustable rollers supports the panel during the roughening operation and facilitates adjustment of the extent of contact or impingement of the brush on the surface of the panel at a plurality of transverse locations across the panel. The roughened panel is then vacuum formed into, for example, a truck bed or bed or cargo compartment liner.

1 .- 21 . (canceled)  
     
     
         22 . A method of fabricating a bed liner for a motor vehicle comprising: 
 co-forming a composite sheet having a first layer of a first thermoplastic material and a second layer of a second thermoplastic material distinct from said first thermoplastic material;    abrading at least a portion of one surface of said composite sheet with a brush having bristles, wherein tips of the bristle have a speed of from about 3,000 to about 6,000 feet per minute; and    thermoforming said composite sheet into a bed liner having said abraded surface.    
     
     
         23 . The method of  claim 22 , wherein the speed is at least 5,340 feet per minute.  
     
     
         24 . The method of  claim 22 , wherein said first layer is an upper layer selected from the group consisting of linear low density polyethylene and polyolefin.  
     
     
         25 . The method of  claim 22 , wherein said second layer is a lower layer of high density polyethylene.  
     
     
         26 . The method of  claim 22 , wherein said first and second layers are bonded together without an adhesive.  
     
     
         27 . The method of  claim 22 , wherein the brush rotates at about 1,700 revolutions per minute.  
     
     
         28 . The method of  claim 22 , wherein the abrading forms a plurality of irregular, generally aligned, arcuate depressions.  
     
     
         29 . The method of  claim 22 , wherein said co-forming is accomplished by co-extruding.  
     
     
         30 . The method of  claim 29 , wherein the brush rotates in a counter-current direction to a direction of travel of the extruded composite.  
     
     
         31 . A method of fabricating a liner for a motor vehicle comprising: 
 extruding a thermoplastic sheet;    passing the sheet through a water cooling station for cooling the sheet;    abrading at least a portion of one surface of the sheet with bristles on a wire brush; and    thermoforming the sheet into one of a bed liner or a cargo carrier, wherein the abraded surface is a cargo receiving surface.    
     
     
         32 . The method of  claim 31 , further comprising the step of abrading at least a portion of both surfaces of the thermoplastic sheet.  
     
     
         33 . The method of  claim 31 , wherein the liner is a bed liner.  
     
     
         34 . The method of  claim 31 , wherein the liner is a cargo carrier.  
     
     
         35 . The method of  claim 31 , wherein the passing step further includes the step of passing the sheet through rollers prior to the water cooling station.  
     
     
         36 . The method of  claim 31 , wherein the step of abrading, the bristles have tips moving at a speed of from about 3,000 to about 6,000 feet per minute.