US20040222674A1 - Modular headliner assembly and method of making same - Google Patents
Modular headliner assembly and method of making same Download PDFInfo
- Publication number
- US20040222674A1 US20040222674A1 US10/867,128 US86712804A US2004222674A1 US 20040222674 A1 US20040222674 A1 US 20040222674A1 US 86712804 A US86712804 A US 86712804A US 2004222674 A1 US2004222674 A1 US 2004222674A1
- Authority
- US
- United States
- Prior art keywords
- headliner
- headliner assembly
- integration sheet
- component
- assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
- B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R13/0212—Roof or head liners
- B60R13/0225—Roof or head liners self supporting head liners
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0846—Insulating elements, e.g. for sound insulation for duct, cable or rod passages, e.g. between engine and passenger compartments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R2013/0287—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners integrating other functions or accessories
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R2013/0293—Connection or positioning of adjacent panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
- B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
- B60R21/04—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings
- B60R2021/0442—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings associated with the roof panel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
- B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
- B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
- B60R21/20—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components
- B60R21/213—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components in vehicle roof frames or pillars
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1028—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
- Y10T156/109—Embedding of laminae within face of additional laminae
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
- Y10T156/1092—All laminae planar and face to face
- Y10T156/1093—All laminae planar and face to face with covering of discrete laminae with additional lamina
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
Definitions
- the invention relates to a modular headliner assembly having an integration sheet, and a method of making such a headliner assembly.
- headliner assemblies with various components, such as energy absorbing members and wire harnesses, attached to preformed headliners.
- Such headliner assemblies which are known as modular headliner assemblies, are typically manufactured by individually attaching the components to the headliners with hot melt adhesives. Such a process, however, is time-consuming. Furthermore, the adhesives are expensive and increase the weight of the headliner assemblies.
- the invention addresses the shortcomings of the prior art by providing a modular headliner assembly that can be manufactured without hot melt adhesives.
- the headliner assembly includes a headliner having an appearance surface and a back surface. At least one component is disposed adjacent the back surface of the headliner. Furthermore, an integration sheet is attached to the back surface for securing the at least one component to the headliner
- FIG. 1 is a top perspective view of a headliner assembly according to the invention
- FIG. 2 is an exploded perspective view of the headliner assembly
- FIG. 3 is a top perspective view of a second embodiment of the headliner assembly.
- FIG. 4 is an exploded perspective view of the headliner assembly of FIG. 3, with the headliner assembly inverted to show a desired manufacturing orientation.
- FIGS. 1 and 2 show a modular headliner assembly 10 according to the invention for use with a motor vehicle.
- the headliner assembly 10 includes a headliner 12 having an appearance surface 13 and a back surface 14 .
- the appearance surface 13 is viewable from a passenger compartment of the vehicle when the headliner 10 is installed in the vehicle.
- the headliner 12 preferably, but not necessarily, includes a plurality of locating features or elements.
- the headliner 12 may include recesses 15 and 16 , projections such as bumps 17 , and an aperture 18 .
- the headliner assembly 10 may include a wire harness 19 , energy absorbing members such as head impact blocks 20 , acoustic members 20 such as acoustic mats 22 , and a light 23 . These components are preferably, but not necessarily, positioned on the headliner 12 using the recesses 15 and 16 , bumps 17 and aperture 18 as explained below in greater detail.
- the headliner assembly 10 further includes an integration sheet 24 attached to the back surface 14 for securing the components 19 , 20 , 22 and 23 to the headliner 12 .
- the integration sheet 24 is preferably relatively thin, with a thickness in the range of 0.1 millimeters (mm) to 1 mm, so that the integration sheet 24 may easily be attached to the headliner 12 .
- the integration sheet 24 may have any suitable thickness.
- the integration sheet 24 may comprise any suitable material that is bondable to the headliner 12 .
- the integration sheet 24 may comprise polypropylene, polyethylene, and/or acryl-butyl-styrene (ABS).
- the integration sheet 24 effectively secures the components 19 , 20 , 22 and 23 to the headliner 12 , additional adhesives may be eliminated from the headliner assembly 10 . Alternatively, adhesives may be used to further bond the integration sheet 24 to the headliner 12 , and/or to further bond the components 19 , 20 , 22 and 23 to the headliner 12 . Furthermore, because the integration sheet 24 encapsulates the components 19 , 20 , 22 and 23 , damage to and/or loss of the components 19 , 20 , 22 and 23 during shipping and handling can be significantly reduced.
- the headliner 12 is formed in any suitable manner and with any suitable materials.
- the headliner 12 may be formed by molding a polymer substrate or laminate assembly to a cover material such as a cloth layer. During such a molding process, the recesses 15 and 16 and bumps 17 are preferably formed as part of the back surface 14 .
- the aperture 18 is also preferably formed in the headliner 12 during the molding process. Alternatively, the aperture 18 may be formed after the molding process in any suitable manner, such as with a water jet or laser.
- the components 19 , 20 , 22 and 23 are positioned on the back surface 14 using the recesses 15 and 16 , bumps 17 and aperture 18 .
- the wire harness 19 may be snap fit between a plurality of bumps 17 .
- the head impact blocks 20 and acoustic mats 22 may also be placed in corresponding recesses 15 and 16 , respectively.
- the light 23 may be positioned in the aperture 18 .
- the components 19 , 20 , 22 and 23 may be positioned on the back surface 14 using any suitable locating elements.
- the wire harness 19 may be placed in a recess, and the head impact blocks 20 and acoustic mats 22 may be snap fit or otherwise positioned between projections.
- the headliner 12 may be provided with projections in specific locations that are configured as pins, and the head impact blocks 20 , acoustic mats 22 and/or other components may be pressed onto the pins so as to pin the head impact blocks 20 , acoustic mats 22 and/or other components to the headliner 12 .
- the components 19 , 20 , 22 and 23 may be positioned on the back surface 14 using a robotic arm or other automated positioning apparatus, such as a movable carriage mounted on a support member.
- the components 19 , 20 , 22 and 23 may also be temporarily held in position by application of localized vacuum pressure, such as by drawing air through localized areas of the headliner 12 .
- the headliner 12 may be provided with small holes (not shown) extending through the headliner 12 in areas where components 19 , 20 , 22 or 23 are to be positioned, so as to facilitate application of the vacuum pressure.
- the integration sheet 24 is then positioned over the back surface 14 and the components 19 , 20 , 22 and 23 .
- the integration sheet 24 may be configured to cover the entire back surface 14 , or only a portion of the back surface 14 .
- the integration sheet 24 is relatively flexible, such as a flexible film, so that the integration sheet 24 may be easily positioned over the back surface 14 and components 19 , 20 , 22 and 23 .
- the integration sheet 24 may be relatively rigid.
- the integration sheet 24 is formed around the components 19 , 20 , 22 and 23 , and is attached to the back surface 14 so as to secure the components 19 , 20 , 22 and 23 to the headliner 12 .
- the integration sheet 24 may be heated in any suitable manner such as by blowing heated air over the integration sheet 24 .
- the integration sheet 24 may then be vacuum formed to the headliner 12 by drawing air through the headliner 12 such that the integration sheet 24 is drawn toward the back surface 14 .
- the integration sheet 24 may be cooled so as to effectively secure the components 19 , 20 , 22 and 23 to the headliner 12 .
- the integration sheet 24 fuses or bonds directly to the headliner 12 .
- An adhesive such as glue, however, may be applied to the integration sheet 24 and/or headliner 12 to further attach the integration sheet 24 to the headliner 12 .
- the integration sheet 24 may be attached to the headliner 12 by heating the integration sheet 24 , and allowing the integration sheet 24 to form around the components 19 , 20 , 22 and 23 and to bond to the headliner 12 .
- the integration sheet 24 may be configured to shrink upon application of heat so as to encapsulate the components 19 , 20 , 22 and 23 .
- an adhesive such as glue may be applied to the integration sheet 24 and/or headliner 12 to further attach the integration sheet 24 to the headliner 12 .
- FIGS. 3 and 4 show a second embodiment 110 of the headliner assembly that includes a headliner 112 having an appearance surface 114 and a back surface 116 .
- the headliner assembly 110 also includes a plurality of components disposed on the back surface 116 of the headliner 112 .
- the headliner assembly 110 may include a wire harness 118 , head impact blocks 120 , acoustic mats 122 and a light 123 .
- the headliner assembly 110 may include one or more air bag modules such as air curtain modules 124 disposed on the back surface 116 .
- the headliner assembly 110 further includes an integration sheet 126 for positioning the components 118 - 124 on the back surface 116 , and for securing the components 118 - 124 to the headliner 112 .
- the integration sheet 126 preferably includes suitable locating features or elements for positioning the components 118 - 124 .
- the integration sheet 126 may include grooves 128 for receiving the wire harness 118 ; recesses 130 , 131 and 132 for receiving the head impact blocks 120 , acoustic mats 122 and light 123 , respectively; and channels 133 for receiving the air curtain modules 124 .
- the grooves 128 , recesses 130 - 132 and channels 133 may also be configured to provide an interference fit with the corresponding components 118 - 124 .
- the opening of the grooves 128 may be slightly smaller than the diameter of the wire harness 118 such that the wire harness 118 may be snapped into the grooves 128 .
- the channels 133 are preferably relatively rigid and are configured to facilitate deployment of the air curtain modules 124 by inhibiting upward deployment.
- the integration sheet 126 may be provided with any suitable locating elements, such as dimples and apertures, for positioning the components 118 - 124 .
- the headliner 112 may also be provided with locating elements such as described above with respect to the headliner 12 .
- the integration sheet 126 also has a plurality of integrally formed reinforcement ribs 134 for increasing stiffness of the headliner assembly 110 .
- the ribs 134 are relatively rigid and are especially useful for providing additional support if the headliner assembly 110 includes numerous heavy components.
- the ribs 134 may have any suitable configuration.
- each rib 134 may be solid, hollow, or include fused portions such as fused side wall portions.
- the integration sheet 126 also includes a plurality of integrally formed energy absorbing members 136 . While the energy absorbing members 136 may have any suitable configuration, each energy absorbing member 136 preferably has an egg crate or honeycomb configuration that is collapsible upon impact so as to absorb energy. As shown in FIG. 3, the energy absorbing members 136 also preferably extend upwardly. Alternatively, the energy absorbing members 136 may extend downwardly toward the headliner 112 . Furthermore, the integration sheet 126 has a plurality of cavities 138 that form acoustic chambers 140 when the integration sheet 126 is attached to the headliner 112 .
- the integration sheet 126 is preferably relatively thin, with a thickness in the range of 0.5 mm to 2 mm. Alternatively, the integration sheet 126 may have any suitable thickness. Furthermore, the integration sheet 126 may comprise any suitable material that is bondable to the headliner 112 . For example, the integration sheet 126 may comprise any suitable thermoplastic material such as polypropylene, polyethylene, and/or ABS.
- the headliner 112 is formed in any suitable manner and with any suitable materials, such as described above with respect to the headliner 12 .
- the headliner 112 may be provided without any recesses or dimples.
- the integration sheet 126 is formed in any suitable manner.
- the integration sheet 126 may be formed by vacuum molding or compression molding.
- electrical wiring such as flat printed cable may be incorporated into the integration sheet such that some or all of the wire harness 118 may be eliminated.
- the components 118 - 124 may then be positioned on the integration sheet 126 using the grooves 128 , recesses 130 - 132 and channels 133 .
- the integration sheet 126 and the headliner 112 are positioned adjacent each other so that the integration sheet 126 is proximate the back surface 116 of the headliner 112 . If the integration sheet 126 is configured to provide an interference fit with the components 118 - 124 , then the integration sheet 126 may be positioned above the headliner 112 . Alternatively, the headliner 112 may be positioned above the integration sheet 126 , as shown in FIG. 4.
- the integration sheet 126 is then attached to the headliner 112 in any suitable manner.
- the integration sheet 126 may be vacuum formed, heat sealed, and/or sonically welded to the headliner 112 .
- the integration sheet 126 fuses or bonds directly to the headliner 112 .
- An adhesive such as glue, however, may also be applied to the integration sheet 126 and/or the headliner 112 to further attach the integration sheet 126 to the headliner 112 .
- the integration sheet 126 can be used to locate the components 118 - 124 on the headliner 112 .
- the integration sheet 126 is used to secure the components 118 - 124 to the headliner 112 , the use of additional adhesives such as hot melt adhesives can be eliminated.
- the air curtain modules 124 are preferably also secured to a roof structure or side structure of the vehicle.
- each air curtain module 124 may be sandwiched between a grab handle and the roof structure so as to secure the air curtain modules 124 to the vehicle.
Abstract
Description
- 1. Field of the Invention
- The invention relates to a modular headliner assembly having an integration sheet, and a method of making such a headliner assembly.
- 2. Background Art
- It is desirable to provide headliner assemblies with various components, such as energy absorbing members and wire harnesses, attached to preformed headliners. Such headliner assemblies, which are known as modular headliner assemblies, are typically manufactured by individually attaching the components to the headliners with hot melt adhesives. Such a process, however, is time-consuming. Furthermore, the adhesives are expensive and increase the weight of the headliner assemblies.
- The invention addresses the shortcomings of the prior art by providing a modular headliner assembly that can be manufactured without hot melt adhesives. The headliner assembly includes a headliner having an appearance surface and a back surface. At least one component is disposed adjacent the back surface of the headliner. Furthermore, an integration sheet is attached to the back surface for securing the at least one component to the headliner
- FIG. 1 is a top perspective view of a headliner assembly according to the invention;
- FIG. 2 is an exploded perspective view of the headliner assembly;
- FIG. 3 is a top perspective view of a second embodiment of the headliner assembly; and
- FIG. 4 is an exploded perspective view of the headliner assembly of FIG. 3, with the headliner assembly inverted to show a desired manufacturing orientation.
- FIGS. 1 and 2 show a
modular headliner assembly 10 according to the invention for use with a motor vehicle. Theheadliner assembly 10 includes aheadliner 12 having anappearance surface 13 and aback surface 14. Theappearance surface 13 is viewable from a passenger compartment of the vehicle when theheadliner 10 is installed in the vehicle. In addition, theheadliner 12 preferably, but not necessarily, includes a plurality of locating features or elements. For example, theheadliner 12 may includerecesses bumps 17, and anaperture 18. - A plurality of components are disposed on the
back surface 14 of theheadliner 12. For example, theheadliner assembly 10 may include awire harness 19, energy absorbing members such ashead impact blocks 20,acoustic members 20 such asacoustic mats 22, and alight 23. These components are preferably, but not necessarily, positioned on theheadliner 12 using therecesses bumps 17 andaperture 18 as explained below in greater detail. - The
headliner assembly 10 further includes anintegration sheet 24 attached to theback surface 14 for securing thecomponents headliner 12. Theintegration sheet 24 is preferably relatively thin, with a thickness in the range of 0.1 millimeters (mm) to 1 mm, so that theintegration sheet 24 may easily be attached to theheadliner 12. Alternatively, theintegration sheet 24 may have any suitable thickness. Furthermore, theintegration sheet 24 may comprise any suitable material that is bondable to theheadliner 12. For example, theintegration sheet 24 may comprise polypropylene, polyethylene, and/or acryl-butyl-styrene (ABS). - Because the
integration sheet 24 effectively secures thecomponents headliner 12, additional adhesives may be eliminated from theheadliner assembly 10. Alternatively, adhesives may be used to further bond theintegration sheet 24 to theheadliner 12, and/or to further bond thecomponents headliner 12. Furthermore, because theintegration sheet 24 encapsulates thecomponents components - A method of manufacturing the
headliner assembly 10 will now be described. First, theheadliner 12 is formed in any suitable manner and with any suitable materials. For example, theheadliner 12 may be formed by molding a polymer substrate or laminate assembly to a cover material such as a cloth layer. During such a molding process, therecesses bumps 17 are preferably formed as part of theback surface 14. Theaperture 18 is also preferably formed in theheadliner 12 during the molding process. Alternatively, theaperture 18 may be formed after the molding process in any suitable manner, such as with a water jet or laser. - Next, the
components back surface 14 using therecesses bumps 17 andaperture 18. For example, thewire harness 19 may be snap fit between a plurality ofbumps 17. The head impact blocks 20 andacoustic mats 22 may also be placed incorresponding recesses light 23 may be positioned in theaperture 18. Alternatively, thecomponents back surface 14 using any suitable locating elements. For example, thewire harness 19 may be placed in a recess, and the head impact blocks 20 andacoustic mats 22 may be snap fit or otherwise positioned between projections. As another example, theheadliner 12 may be provided with projections in specific locations that are configured as pins, and thehead impact blocks 20,acoustic mats 22 and/or other components may be pressed onto the pins so as to pin thehead impact blocks 20,acoustic mats 22 and/or other components to theheadliner 12. - As yet another alternative or in addition to the above approaches, the
components back surface 14 using a robotic arm or other automated positioning apparatus, such as a movable carriage mounted on a support member. Thecomponents headliner 12. Under such an approach, theheadliner 12 may be provided with small holes (not shown) extending through theheadliner 12 in areas wherecomponents - The
integration sheet 24 is then positioned over theback surface 14 and thecomponents integration sheet 24 may be configured to cover theentire back surface 14, or only a portion of theback surface 14. Preferably, theintegration sheet 24 is relatively flexible, such as a flexible film, so that theintegration sheet 24 may be easily positioned over theback surface 14 andcomponents integration sheet 24 may be relatively rigid. - Next, the
integration sheet 24 is formed around thecomponents back surface 14 so as to secure thecomponents headliner 12. For example, theintegration sheet 24 may be heated in any suitable manner such as by blowing heated air over theintegration sheet 24. Theintegration sheet 24 may then be vacuum formed to theheadliner 12 by drawing air through theheadliner 12 such that theintegration sheet 24 is drawn toward theback surface 14. Next, theintegration sheet 24 may be cooled so as to effectively secure thecomponents headliner 12. Preferably, theintegration sheet 24 fuses or bonds directly to theheadliner 12. An adhesive such as glue, however, may be applied to theintegration sheet 24 and/orheadliner 12 to further attach theintegration sheet 24 to theheadliner 12. - Alternatively, the
integration sheet 24 may be attached to theheadliner 12 by heating theintegration sheet 24, and allowing theintegration sheet 24 to form around thecomponents headliner 12. For example, theintegration sheet 24 may be configured to shrink upon application of heat so as to encapsulate thecomponents integration sheet 24 to theheadliner 12. Again, however, an adhesive such as glue may be applied to theintegration sheet 24 and/orheadliner 12 to further attach theintegration sheet 24 to theheadliner 12. - FIGS. 3 and 4 show a
second embodiment 110 of the headliner assembly that includes aheadliner 112 having anappearance surface 114 and aback surface 116. Theheadliner assembly 110 also includes a plurality of components disposed on theback surface 116 of theheadliner 112. For example, theheadliner assembly 110 may include awire harness 118, head impact blocks 120,acoustic mats 122 and a light 123. Furthermore, theheadliner assembly 110 may include one or more air bag modules such asair curtain modules 124 disposed on theback surface 116. - The
headliner assembly 110 further includes anintegration sheet 126 for positioning the components 118-124 on theback surface 116, and for securing the components 118-124 to theheadliner 112. Theintegration sheet 126 preferably includes suitable locating features or elements for positioning the components 118-124. For example, theintegration sheet 126 may includegrooves 128 for receiving thewire harness 118;recesses acoustic mats 122 and light 123, respectively; andchannels 133 for receiving theair curtain modules 124. Thegrooves 128, recesses 130-132 andchannels 133 may also be configured to provide an interference fit with the corresponding components 118-124. For example, the opening of thegrooves 128 may be slightly smaller than the diameter of thewire harness 118 such that thewire harness 118 may be snapped into thegrooves 128. Furthermore, thechannels 133 are preferably relatively rigid and are configured to facilitate deployment of theair curtain modules 124 by inhibiting upward deployment. Alternatively, theintegration sheet 126 may be provided with any suitable locating elements, such as dimples and apertures, for positioning the components 118-124. As yet another alternative, theheadliner 112 may also be provided with locating elements such as described above with respect to theheadliner 12. - The
integration sheet 126 also has a plurality of integrally formedreinforcement ribs 134 for increasing stiffness of theheadliner assembly 110. Theribs 134 are relatively rigid and are especially useful for providing additional support if theheadliner assembly 110 includes numerous heavy components. Furthermore, theribs 134 may have any suitable configuration. For example, eachrib 134 may be solid, hollow, or include fused portions such as fused side wall portions. - The
integration sheet 126 also includes a plurality of integrally formedenergy absorbing members 136. While theenergy absorbing members 136 may have any suitable configuration, eachenergy absorbing member 136 preferably has an egg crate or honeycomb configuration that is collapsible upon impact so as to absorb energy. As shown in FIG. 3, theenergy absorbing members 136 also preferably extend upwardly. Alternatively, theenergy absorbing members 136 may extend downwardly toward theheadliner 112. Furthermore, theintegration sheet 126 has a plurality ofcavities 138 that formacoustic chambers 140 when theintegration sheet 126 is attached to theheadliner 112. - The
integration sheet 126 is preferably relatively thin, with a thickness in the range of 0.5 mm to 2 mm. Alternatively, theintegration sheet 126 may have any suitable thickness. Furthermore, theintegration sheet 126 may comprise any suitable material that is bondable to theheadliner 112. For example, theintegration sheet 126 may comprise any suitable thermoplastic material such as polypropylene, polyethylene, and/or ABS. - A method of manufacturing the
headliner assembly 110 will now be described. First, theheadliner 112 is formed in any suitable manner and with any suitable materials, such as described above with respect to theheadliner 12. For theheadliner assembly 110, however, theheadliner 112 may be provided without any recesses or dimples. - Next, the
integration sheet 126 is formed in any suitable manner. For example, theintegration sheet 126 may be formed by vacuum molding or compression molding. During this step, electrical wiring such as flat printed cable may be incorporated into the integration sheet such that some or all of thewire harness 118 may be eliminated. - The components118-124 may then be positioned on the
integration sheet 126 using thegrooves 128, recesses 130-132 andchannels 133. Next, theintegration sheet 126 and theheadliner 112 are positioned adjacent each other so that theintegration sheet 126 is proximate theback surface 116 of theheadliner 112. If theintegration sheet 126 is configured to provide an interference fit with the components 118-124, then theintegration sheet 126 may be positioned above theheadliner 112. Alternatively, theheadliner 112 may be positioned above theintegration sheet 126, as shown in FIG. 4. Theintegration sheet 126 is then attached to theheadliner 112 in any suitable manner. For example, theintegration sheet 126 may be vacuum formed, heat sealed, and/or sonically welded to theheadliner 112. Preferably, theintegration sheet 126 fuses or bonds directly to theheadliner 112. An adhesive such as glue, however, may also be applied to theintegration sheet 126 and/or theheadliner 112 to further attach theintegration sheet 126 to theheadliner 112. - Because the components118-124 are first positioned on the
integration sheet 126, theintegration sheet 126 can be used to locate the components 118-124 on theheadliner 112. In addition, because theintegration sheet 126 is used to secure the components 118-124 to theheadliner 112, the use of additional adhesives such as hot melt adhesives can be eliminated. - When the
headliner assembly 110 is installed in a vehicle, theair curtain modules 124 are preferably also secured to a roof structure or side structure of the vehicle. For example, eachair curtain module 124 may be sandwiched between a grab handle and the roof structure so as to secure theair curtain modules 124 to the vehicle. - While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.
Claims (24)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/867,128 US20040222674A1 (en) | 2000-06-08 | 2004-06-14 | Modular headliner assembly and method of making same |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US21019500P | 2000-06-08 | 2000-06-08 | |
US10/297,116 US6783624B2 (en) | 2000-06-08 | 2001-03-27 | Modular headliner assembly and method of making same |
US10/867,128 US20040222674A1 (en) | 2000-06-08 | 2004-06-14 | Modular headliner assembly and method of making same |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/297,116 Division US6783624B2 (en) | 2000-06-08 | 2001-03-27 | Modular headliner assembly and method of making same |
PCT/US2001/009728 Division WO2001094155A1 (en) | 2000-06-08 | 2001-03-27 | Modular headliner assembly and method of making same |
Publications (1)
Publication Number | Publication Date |
---|---|
US20040222674A1 true US20040222674A1 (en) | 2004-11-11 |
Family
ID=22781946
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/297,116 Expired - Fee Related US6783624B2 (en) | 2000-06-08 | 2001-03-27 | Modular headliner assembly and method of making same |
US10/867,128 Abandoned US20040222674A1 (en) | 2000-06-08 | 2004-06-14 | Modular headliner assembly and method of making same |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/297,116 Expired - Fee Related US6783624B2 (en) | 2000-06-08 | 2001-03-27 | Modular headliner assembly and method of making same |
Country Status (3)
Country | Link |
---|---|
US (2) | US6783624B2 (en) |
DE (1) | DE10196327T1 (en) |
WO (1) | WO2001094155A1 (en) |
Families Citing this family (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6783624B2 (en) * | 2000-06-08 | 2004-08-31 | Lear Corporation | Modular headliner assembly and method of making same |
US6652021B1 (en) | 2002-11-06 | 2003-11-25 | Lear Corporation | Integrated headliner assembly |
US20070046054A1 (en) * | 2005-08-31 | 2007-03-01 | Hinman David T | Interior trim accessory attachment apparatus |
US7798566B2 (en) * | 2007-12-14 | 2010-09-21 | Toyota Motor Engineering & Manufacturing North America, Inc. | Molded headliner reinforcement |
DE102010036795A1 (en) | 2010-08-02 | 2012-02-02 | International Automotive Components Group Gmbh | Covering device for a motor vehicle with integrated lighting system |
DE102010046244A1 (en) * | 2010-09-22 | 2012-03-22 | Trw Automotive Electronics & Components Gmbh | Component for securing electronic parts between metal sheet of door of vehicle i.e. motor car, and car body, has adaptor plate cooperating attachment members provided at inner side of interior trim part |
US20120294670A1 (en) * | 2011-05-16 | 2012-11-22 | First Dome Corporation | Pivot pin securing structure |
DE102015104299A1 (en) | 2015-03-23 | 2016-09-29 | International Automotive Components Group Gmbh | Interior trim part for a motor vehicle |
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2001
- 2001-03-27 US US10/297,116 patent/US6783624B2/en not_active Expired - Fee Related
- 2001-03-27 WO PCT/US2001/009728 patent/WO2001094155A1/en active Application Filing
- 2001-03-27 DE DE10196327T patent/DE10196327T1/en not_active Withdrawn
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2004
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US4848829A (en) * | 1987-10-26 | 1989-07-18 | General Motors Corporation | Door trim panel assembly |
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US6120091A (en) * | 1998-06-09 | 2000-09-19 | Lear Automotive Dearborn, Inc. | Molded headliner with relatively rigid frame in combination with a less rigid mat |
US6086145A (en) * | 1998-07-16 | 2000-07-11 | Textron Automotive Company Inc. | Blow molded headliner |
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Also Published As
Publication number | Publication date |
---|---|
US6783624B2 (en) | 2004-08-31 |
DE10196327T1 (en) | 2003-05-22 |
US20030211290A1 (en) | 2003-11-13 |
WO2001094155A1 (en) | 2001-12-13 |
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