WO2013166009A1

WO2013166009A1 - Headliner and method of making headliner

Info

Publication number: WO2013166009A1
Application number: PCT/US2013/038855
Authority: WO
Inventors: Schuyler DEVRIES; Matt SLATER
Original assignee: Johnson Controls Technology Company
Priority date: 2012-05-01
Filing date: 2013-04-30
Publication date: 2013-11-07

Abstract

A headliner (110) comprising a panel; a fold (117) defining a folding portion (127) and a main portion (129) of the panel, the folding portion extending from an edge (115) of the panel to the fold; and an open-ended opening (123) provided completely through both the folding and main portions along a section of the fold, wherein the folding portion extends continuously around at least a portion of the open-ended opening, such that at least two layers of adjacent panel continuously surround the portion of the open-ended opening.

Description

HEADLINER AND METHOD OF MAKING HEADLINER

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 61/640,901, which was filed on May 1, 2012. The foregoing U.S. Provisional

Application is incorporated by reference herein in its entirety.

BACKGROUND

[0002] The present application relates generally to the field of headliners for use in vehicles. More specifically, the present application relates to headliner having an edge-fold with a member of supporting material.

[0003] A headliner typically includes one or more than one panel and is configured to be coupled to a roof of a vehicle, such as a support structure of the roof. Headliners generally include one or more than one peripheral edge, which may be configured to engage another component, such as the roof (e.g., a roof-rail). It may be desirable to provide a finished appearance (or improved aesthetics) of the peripheral edge, such as when the peripheral edge is visible in the vehicle. It may also be desirable to increase the strength of the peripheral edge. The headliner may include a fold to provide a finished appearance and to increase the strength of the peripheral edge. Often, a peripheral edge may include an opening (e.g., slot, notch, etc.) that is configured to provide access through the headliner. As shown in Figures 3-5, the headliner 10 may include an open notch 23 that extends inwardly from a forward peripheral edge 15 through the fold 17 of the peripheral edge 15 to provide access to route a wire harness to an electronic component, such as an overhead console having electronics for controlling the operation of a sunroof. In other words, the edge notch 23 has an open configuration before and after folding. This edge notch leads to a reduced strength local to the notch which has a tendency to lead to cracking of the headliner. This edge notch also leads to dimensional inaccuracy and inconsistency from part to part. Accordingly, there continues to be a need to improve the configuration of the headliners, particularly the peripheral edges of the headliners. SUMMARY

[0004] One embodiment relates to a headliner for covering an interior portion of a roof of a vehicle. The headliner includes a panel; a fold defining a folding portion and a main portion of the panel, the folding portion extending from an edge of the panel to the fold; and an open- ended opening provided completely through both the folding and main portions along a section of the fold. The folding portion extends continuously around at least a portion of the open-ended opening, such that at least two layers of adjacent panel continuously surround the portion of the open-ended opening.

[0005] Another embodiment relates to a method for making a headliner configured to cover an interior portion of a roof of a vehicle. The method of making the headliner includes the steps of: forming a panel; forming a closed-ended opening completely through the panel, such that the closed-ended opening is completely enclosed by the panel; and folding the panel along a fold that passes through the closed-ended opening to transform the closed-ended opening into an open-ended opening and to form a folding portion adjacent to a main portion of the panel. The folding portion extends from an edge of the panel to the fold, wherein the folding portion extends continuously around at least a portion of the open-ended opening, such that at least two layers of adjacent panel continuously surround the portion of the open- ended opening.

[0006] Yet another embodiment relates to a headliner for covering an interior portion of a roof of a vehicle. The headliner includes a panel including a fold defining a folding portion and a main portion of the panel, the folding portion extending from an edge of the panel to the fold; and a notch provided completely through both the folded and main portions along a section of the fold. The folding portion extends continuously around at least a portion of the notch, such that at least two stacked layers of adjacent panel continuously surround the portion of the notch.

[0007] The headliner may further include a stitch that secures the folding portion to the main portion of the panel. The stitch may be configured to completely penetrate both the folding and main portions of the panel. Alternatively, the stitch may be configured to completely penetrate the folding portion and may only partially penetrate the main portion, such that the stitch does not pass through an A-surface of the panel. The headliner may also include an end flange that is configured to extend upwardly from the folding portion away from the main portion to provide additional strength local to the notch.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a perspective view of an exemplary embodiment of a vehicle having a headliner.

[0009] Figure 2 is a perspective view of an interior of a vehicle, such as the vehicle of Figure 1 , having a headliner according to an exemplary embodiment.

[0010] Figures 3 and 4 are top plan views of a headliner according to the prior art.

[0011] Figure 5 is a cross-sectional view of the headliner of Figure 4 taken along line 5-5.

[0012] Figure 6 is a top plan view of a portion of an exemplary embodiment of a headliner.

[0013] Figure 7 is a top plan view of a portion of another exemplary embodiment of a headliner.

[0014] Figure 8 is a cross-sectional view of the headliner of Figure 7 taken along line 8-8.

[0015] Figure 9 is a top plan view of yet another exemplary embodiment of a headliner shown prior to folding.

[0016] Figure 10 is a top plan view of the headliner of Figure 9 shown after folding. [0017] Figure 11 is a cross-sectional view of an exemplary embodiment of a headliner. [0018] Figure 12 is a cross-sectional view of another exemplary embodiment of a headliner.

DETAILED DESCRIPTION

[0019] With general reference to the Figures, disclosed herein are headliners for use in vehicles having folded peripheral edges with openings having closed configurations, such as having closed edges or ends, prior to folding, and having open configurations, such as having an open edge or end, after folding in order to increase the strength of the headliner and provide improved aesthetics. The headliners may include an added portion of material, such as a bridge, a projection, or a tab, local to the hole to increase the strength of the headliner local to the opening. The headliner may also include an opening having a shape, such as an oval or an elongated shape, to help increase the strength of the headliner. The added strength of the headliner local to the opening(s) helps reduce the likelihood of cracking and reduce the dimensional instability of the headliner.

[0020] Figure 1 illustrates an exemplary embodiment of a vehicle 101 having a roof 105 with a sunroof 106 provided therein. It should be noted that the although a passenger vehicle is illustrated, the headliners as disclosed herein may be used within any vehicle, such as, for example trucks, SUVs, vans, mass transit vehicles, military vehicles, etc., and those embodiments disclosed herein are not limiting.

[0021] Figure 2 illustrates an exemplary embodiment of a portion of an interior 102 of a vehicle, such as the vehicle 101 of Figure 1. As shown, an overhead console 107 is provided on the interior (e.g., inside) of the roof 105 of the vehicle 101 and is configured having electronic controls for operating the sunroof 106 of the vehicle 101. Also shown, a rear- view mirror 108 is provided on the interior 102 of the vehicle 101. A headliner 110 is also provided on the interior of the roof 105 of the vehicle 101 and is configured to cover at least a portion of the interior of the roof 105 to improve the aesthetics inside the vehicle 101. The headliner 110 may be configured to extend between at least a portion of the overhead console 107 and the roof 105 to provide a finished appearance. A wiring harness (not shown in Figure 2) may be disposed in the roof 105 to communicate electric power to operate an interior component of the vehicle 101, such as the rear- view mirror 108 and/or the electronic controls of the overhead console 107. Accordingly, the headliner 110 may include an open- ended opening 123 (e.g., cutout, aperture, notch, etc.), such as in or along a portion of a peripheral edge 115 (e.g., forward peripheral edge), to provide access or routing of the wiring harness to the rear- view mirror 108 and/or overhead console 107.

[0022] The headliner 110 may include one or more than one panel made from any suitable material, such as a natural fabric, a synthetic fabric, or a combination thereof. Each panel of the headliner 110 may include a single layer or a plurality of layers. For example, the panel of the headliner 110 may include a substrate layer (e.g., a substrate, base, etc.) made from any suitable material, such as polypropylene (PP) or glass-reinforced PP, and a fabric layer (e.g., a cover, cover layer, etc.) wrapped around or provided over the substrate layer. The substrate layer of the panel may provide the strength (e.g., structure) to the headliner 110, and the fabric layer may provide improved aesthetics to the headliner 110, such as when viewed within the interior of the vehicle. As shown in Figure 8, the headliner 210 includes a bi- layered panel (e.g., a bi-laminate panel), where the panel includes a substrate 211 and a cover 212 disposed on an inside surface of the substrate 211, such that the cover 212 is visible from an interior of the vehicle. In other words, the cover 212 provides at least a portion of an A- surface of the headliner 210. A portion of the substrate 211 may also provide a portion of the A- surface or visible portion of the headliner 210.

[0023] Figure 6 illustrates an exemplary embodiment of a headliner 110 including a panel, a fold 117 defining a folding portion 127 (e.g., a first portion) of the panel and a main portion 129 (e.g., a second portion, an unfolded portion, etc.) of the panel, and an open-ended opening 123 (e.g., cutout, aperture, notch, etc.). As shown, the headliner 110 includes an edge 115 (e.g., a peripheral edge, an outside edge, etc.) that is configured to be folded about the fold 117 to provide a finished appearance of the headliner 110, such as along a new edge (e.g., periphery) that is formed along the fold 117. Thus, the folding portion 127 extends from the edge 115 to the fold 117, and the main portion 129 extends from the fold 117 along the panel in a direction away from the folding portion 127. As shown, the open-ended opening 123 extends completely through the panel. Accordingly, the open-ended opening 123 may be provided completely through both the folding portion 127 and the main portion 129 along a section of the fold 117. According to an exemplary method, the folding portion 127 of the headliner 110 may be folded back over onto the main portion 129 of the headliner 110, where the folding portion 127 is defined as the portion of the headliner 110 provided between the fold 117 and an outside periphery of the headliner 110, including the edge 115.

[0024] The headliner 1 10 may include a projection 125 (e.g., tab, bridge, ear, extension, protrusion, etc.) that extends away from the headliner 110, such as outwardly or away from the edge 115 of the panel. The projection 125 may include a web 125a (e.g., bridge, connection, etc.) that extends adjacent to the open-ended opening 123 to interconnect two spaced apart portions of the folding portion 127. As shown in Figure 6, the projection 125 has generally a U-shape with the web 125a extending between two legs 125b, where each leg 125b extends from the edge 115 of the panel, and where the open-ended opening 123 extends between the legs 125b. Thus, the web 125a of the projection 125 may include an outer periphery 125c that is offset from the edge 115 to allow an opening (e.g., the closed-ended opening 123') to extend beyond the edge 115, such as prior to folding. It is noted that the projection 125 may have other suitable shapes, such as semi-circular, C-shaped, or V-shaped.

[0025] Although the headliner 110 is configured to include a web 125 a that is part of the projection 125 that extends away from the edge 1 15 of the cushion, the web does not have to be provided on a projection. As shown in Figure 7, the headliner 210 includes a web that is provided between the edge 215 and the fold 217 extending between two spaced apart sections of the folding portion 227. Thus, the web of the headliner 210 is not provided on a projection.

[0026] Figure 6 illustrates the headliner 110 in both a pre-folded state and a post- folded state. Accordingly, the edge 115 corresponds to the post-folded configuration (e.g., location,) of the folding portion 127 and is illustrated in Figure 6 using solid lines, whereas the edge 115' corresponds to the pre-folded configuration and is illustrated using dashed lines. Thus, the projection 125 corresponds to the post-folded configuration and is illustrated using solid lines, whereas the projection 125' corresponds to the pre-folded configuration and is illustrated using dashed lines. Additionally, the fold 117 is illustrated using centerlines, since it is the fold line (i.e., line of symmetry between the projection 125 and the projection 125') about which the folding portion 127 is folded. However, it is noted that the fold 117 will define an edge, after folding the headliner 110, such as the edge defined along the fold 217 in Figure 8.

[0027] The open-ended opening 123 may be formed by a closed-ended opening 123 ', which may have any suitable configuration (e.g., size, shape) and location. As shown in Figure 6, the closed-ended opening 123 ' is configured as a generally rectangular opening with rounded corners. As shown in Figure 7, the closed-ended opening 223' of the headliner 210 is generally square shaped with radii provided at the corners. Even more preferably, the opening may be configured having a generally oval shape. These shapes (e.g., oval, square with radii corners, rectangular with rounded corners) may advantageously reduce the stress risers relative to those openings having generally sharp corners, such as with rectangular or square shaped openings. In other words, these shapes may advantageously increase the strength of the headliner 110, 210 local to the opening. The shape and size of the opening may be tailored based on the shape and size of the component in which the opening is to provide access or routing therethrough. For example, the size of the opening may be configured to be large enough for the wiring harness for the rear- view mirror 108 and/or the overhead console 107 to pass through the opening, and the size of the wiring harness may be different for different vehicles.

[0028] The closed-ended opening in the headliner is configured to be located along the fold, so that upon folding the folding portion onto the main portion, the closed-ended opening is configured as an open-ended opening providing access thereto by having an open edge (e.g., open end, open side, etc.), such as an open side along the fold. In other words, prior to folding the folding portion, the opening is closed-ended in that the opening is completely surrounded by the panel (e.g., all sides of the opening have adjacent portions of the panel), where after folding the folding portion, the opening is open-ended in that the opening is not completely surrounded by the panel (e.g., at least one side is open and does not have an adjacent portion of the panel).

[0029] As shown in Figure 6, the closed-ended opening 123 ' is located along the fold 117 of the headliner 110, so that the open-ended opening 123 is provided along a section of the fold 117. As shown in Figure 7, the closed-ended opening 223' in the headliner 210 overlaps with the fold 217, in order for the open-ended opening 223 to form a cutout along a section of the fold 217 to allow access into the open-ended opening 223. Although the openings 123', 223' are shown to be symmetric about their respective fold 117, 217, it is noted that the openings may be configured non-symmetric about their respective fold, such as where the opening includes a center (e.g., mid-portion) that is configured to be offset from the fold by a distance, which may be less than half of a length of the opening.

[0030] The projection 125 of the headliner 110 may have any suitable shape, configuration, and location. As shown in Figure 6, the projection 125 extends away from the edge 115 of the headliner 110 and continuously around at least a portion of the closed-ended opening 123'. For example, prior to folding the folding portion 127, the projection 125 may extend in an upward direction around an upper portion of the closed-ended opening 123', such that the headliner surrounds the closed-ended opening 123' to provide a closed configuration of the closed-ended opening 123'. After folding the folding portion 127, the projection 125 may extend in a downward direction around a lower portion of the open-ended opening 123 in order to provide an open configuration of the open-ended opening 123 to allow access thereto. Thus, the projection 125 may be configured such that the folding portion 127 extends continuously (e.g., in an uninterrupted manner) around at least a portion of the open- ended opening 123. Accordingly, once the folding portion 127 is folded onto the main portion 129, the headliner 110 includes at least two layers of adjacent panel (e.g., at least two layers of adjacent substrate) continuously surrounding the open-ended opening 123, which advantageously increases the strength around the open-ended opening 123 to prohibit damage (e.g., cracking) of the headliner 110. The size (e.g., width, extension or height) of the projection (e.g., the wall thickness around the opening) may be tailored, such as based on the location and/or size of the opening, to reduce the strength issues, such as cracking. The projection 125 also may advantageously provide improved dimensional accuracy and consistency (i.e., repeatability) of the edge.

[0031] According to an exemplary method, the headliner 110 may be made using a three step process. The first step involves forming a panel, which may include one or more layers. For example, the panel formed may include a substrate and a cover provided over an inside surface of the substrate. The second step involves forming a closed-ended opening 123' completely through the panel. For example, the opening may be configured to be completely enclosed by the panel, such as surrounded by the projection 125, the folding portion 127, and the main portion 129 of the panel. The third step involves folding the panel along a fold (e.g., the fold 117) that passes through the closed-ended opening 123' to transform the opening into an edge open-ended opening 123. The third step also forms the folding portion 127 that is provided adjacent to the main portion 129 of the panel and extends from an edge 115 of the panel to the fold 117. The folding portion 127 may include one or more than one layer of the panel. For example, the folding portion 127 may include only the substrate, the substrate and the cover, or any other layers of the panel and combinations thereof. The folding portion extends continuously around at least a portion of the notch, such that at least two layers of adjacent panel (e.g., substrate) continuously surround the portion of the notch. An A-surface of the headliner is provided, for example, by at least the cover.

[0032] The exemplary method of making the headliner 110 may include additional steps. For example, the method may include a fourth step that involves providing a stitch that is configured to secure the folding portion 127 to the main portion 129 of the panel at a location that is adjacent to the notch. The stitch may be configured to completely penetrate both the folding portion 127 and the main portion 129, or may be configured to completely penetrate the folding portion 127 and only partially penetrate the main portion 129, such as just the substrate and not the surface of the cover that provides the A- surface of the headliner 110.

[0033] Figures 7 and 8 illustrate another exemplary embodiment of a headliner 210 having a peripheral edge 215, 215' configured to be folded along a fold 217, where a folding portion 227 is folded back over onto a main portion 229 of the headliner 210. Figure 7 illustrates the folding portion 227 in both an unfolded configuration and a folded configuration. As shown, the edge 215' and the closed-ended opening 223' correspond to the unfolded configuration (e.g., location,) of the folding portion 227 and are illustrated using dashed lines, where the edge 215 and the open-ended opening 223 correspond to the folded configuration and are illustrated using solid lines. Further, the fold 217 is illustrated using centerlines, since it is the fold line or line of symmetry between the projection 125 and the projection 125'.

[0034] The headliner 210 includes an closed-ended opening 223' (e.g., cutout, notch, aperture, etc.) offset from the peripheral edge 215', such that a portion (e.g., a bridge 225) of the panel of the headliner 210 is disposed between the peripheral edge 215' and an outer edge of the opening. In other words, the bridge 225 interconnects the two portions of the panel that are provided on opposing sides of the closed-ended opening 223' and adjacent to the peripheral edge 215'. Thus, the bridge 225 extends between the edge 215' and the closed- ended opening 223' to increase the strength of the headliner 210 local to the closed-ended opening 223'. The bridge 225 may have any suitable shape, size, and configuration. For example, the size (e.g., width) of the bridge 225 may be tailored based on a predetermined desired strength.

[0035] The closed-ended opening 223' may have any suitable shape (e.g., oval, square, round, irregular, elliptical, etc.), configuration (e.g., size), and location. The closed-ended opening 223 ' may be located along the fold 217, such that at least a portion of the closed- ended opening 223' lies along the fold line. As shown, the bridge 225 forms a closed (e.g., closed edge) configuration around the closed-ended opening 223 ' prior to folding the folding portion 227 onto the main portion 229, and forms an open edge configuration around the open-ended opening 223 after folding the folding portion 227 to an adjacent position relative to the main portion 229 the headliner 210.

[0036] Figures 9 and 10 illustrate another exemplary embodiment of a headliner 310 that includes a folding portion 327 configured to strengthen the headliner 310 around an open- ended opening 323 provided along a fold 317. Figure 9 illustrates the folding portion in an unfolded configuration in solid lines with a forward periphery edge 315' having a projection 325' extending from the edge 315' in a forward direction. Figure 9 also illustrates the folding portion in a folded configuration in dashed lines. Figure 10 illustrates the folding portion 327 in a folded configuration adjacent to a main portion 329 in solid lines with the forward periphery edge 315 and projection 325 facing in a rearward direction. Figure 10 also illustrates the folding portion 327 is an unfolded configuration in dashed lines.

[0037] The forward peripheral edge 315 ' of the panel is configured to be folded along the fold 317 to reconfigure the closed-ended opening 323' from a closed configuration to an open configured open-ended opening 323. The open ended open-ended opening 323 may be located proximate to a location where an electronic component (e.g., the rear-view mirror 108, the overhead console 107, etc.) is configured to be provided. The edge 315 of the headliner 310 may then be folded upward and onto the portion of the headliner 310 that is adjacent to the fold, such as the main portion 329. After folding the folding portion 327 onto the adjacent portion of the headliner 310, the open-ended opening 323 has an open edge or open end configuration to allow access to the opening from the new open edge defined by the fold 317. For example, a wiring harness may be configured to route through the open-ended opening 323 of the headliner 310.

[0038] Figure 11 illustrates an exemplary embodiment of a cross-section of a headliner 410 having a folded edge 415. The headliner 410 may include a first layer 411 (e.g., a substrate) and a second layer 412 (e.g., a cover) provided on a surface of the first layer 411. The headliner 410 includes a folding portion 427, which may be configured having any suitable cross-sectional shape, such as arcuate, which may be similar to the shape of an adjacent lower portion (e.g., the main portion 429) of the headliner 410 (e.g., the non- folding portion). Thus, the folding portion 427 is provided above the main portion 429 of the headliner 410. [0039] The folding portion 427 may also be coupled to the main portion 429 at a connection 440 using stitching, an adhesive, or any suitable method. As shown, the folding portion 427 includes both the first layer 411 and the second layer 412, and the stitching 440 penetrates both layers (e.g., the first layer 411 and the second layer 412) of the folding portion 427 and both layers of the main portion 429. Alternatively, the stitching 440 may be configured to penetrate only the first layer 411 of the folding portion 427, such as where the folding portion 427 does not include the second layer 412. Additionally, the stitching 440 may be configured to penetrate only the first layer 411 of the main portion 429, such that the stitching 440 does not pass through an A- surface of the second layer 412.

[0040] Figure 12 illustrates another exemplary embodiment of a cross-section of a headliner 510 having a folded edge 515. As shown, the headliner 510 includes a folding portion 527 provided above the main portion 529, where the folding portion 527 and main portion 529 are coupled together using a stitching 540, which completely penetrates the folding portion 527 and only partially penetrates the main portion 529.

[0041] As shown, the folding portion 527 includes a first portion 527a that is substantially complimentary to the shape of the adjacent portion of the main portion 529 of the headliner 510. The folding portion 527 also includes a second portion 527b that extends away from (e.g., upwardly from) the adjacent portion of the headliner 510. As shown, the second portion 527b is configured as an end flange that is configured to extend upwardly away from the main portion 529 adjacent to a notch (e.g., the open-ended opening 323). The end flange may extend upwardly to a predetermined length or height to further strengthen the headliner 510 local to the notch. The height of the end flange may, for example, be greater than the thickness of the panel in order to provide at least three layers of adjacent panel (e.g., substrate) that continuously surrounds at least a portion of the notch.

[0042] It is noted that the folding portions of the headliners (e.g., 110, 210, 310 410, 510) may have any suitable cross-sectional shape and the embodiments disclosed herein are not limiting. Accordingly, the elements or features disclosed in one example of the headliner may be configured with any other example of the headliner. For example, any headliner disclosed herein may include a stitch, an end flange, or any other element or feature disclosed herein, even if that example does not disclose that specific feature or element. [0043] The headliners as disclosed herein, such as having folded peripheral edges with openings having closed configurations prior to folding and open configurations after folding help ameliorate strength issues (e.g., cracking) as well as provide access or routing of another component through the opening. In particular, the headliners having openings located centrally along the edge may gain an increase in strength and dimensional stability from the configurations as disclosed herein.

[0044] As utilized herein, the terms "approximately," "about," "substantially", and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0045] It should be noted that the term "exemplary" as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0046] The terms "coupled," "connected," and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0047] References herein to the positions of elements (e.g., "top," "bottom," "above," "below," etc.) are merely used to describe the orientation of various elements in the

FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. [0048] It is important to note that the construction and arrangement of the headliners as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

Claims

WHAT IS CLAIMED IS:

1. A headliner for covering an interior portion of a roof of a vehicle, the headliner comprising:

a panel;

a fold defining a folding portion and a main portion of the panel, the folding portion extending from an edge of the panel to the fold; and

an open-ended opening provided completely through both the folding and main portions along a section of the fold,

wherein the folding portion extends continuously around at least a portion of the open-ended opening, such that at least two layers of adjacent panel continuously surround the portion of the open-ended opening.

2. The headliner of claim 1, further comprising a projection extending outwardly from the edge of the panel, wherein the projection includes a web that extends adjacent to the open-ended opening.

3. The headliner of claim 2, wherein the projection has generally a U-shape with the web extending between two legs that extend away from the edge of the panel, and wherein the open-ended opening extends between the two legs.

4. The headliner of claim 3, wherein the projection includes an end flange that extends from both the web and the legs of the projection in an upward direction away from the main portion of the panel adjacent around the portion of the open-ended opening.

5. The headliner of claim 4, wherein the panel includes a substrate and a cover provided over an inside surface of the substrate, and wherein the folding portion includes only the substrate.

6. The headliner of claim 1, wherein the folding portion includes an end flange that is configured to extend upwardly away from the main portion adjacent to the open-ended opening a predetermined height to strengthen the headliner local to the open-ended opening.

7. The headliner of claim 6, further comprising a stich that secures the folding portion to the main portion of the panel at a location that is adjacent to the open-ended opening.

8. The headliner of claim 7, wherein the stitch is configured to completely penetrate the folding portion and only partially penetrate the main portion, such that the stitch does not pass through an A-surface of the main portion of the cover.

9. The headliner of claim 8, wherein the open-ended opening is configured to receive a wiring harness for either an overhead console or a rear- view mirror that is configured to attach to the roof of the vehicle.

10. A method for making a headliner configured to cover an interior portion of a roof of a vehicle, the method comprising the steps of:

forming a panel;

forming a closed-ended opening completely through the panel, such that the closed-ended opening is completely enclosed by the panel; and

folding the panel along a fold that passes through the closed-ended opening to transform the closed-ended opening into an open-ended opening and to form a folding portion adjacent to a main portion of the panel, the folding portion extending from an edge of the panel to the fold,

11. The method of claim 10, wherein the folding portion includes a projection extending outwardly from the edge of the panel, and wherein the projection has generally a web extending between two legs that extend away from the edge of the panel, and wherein the open-ended opening extends between the two legs and adjacent to the web.

12. The method of claim 11, wherein the projection includes an end flange that extends from both the web and the legs of the projection in an upward direction away from the main portion of the panel adjacent around the portion of the open-ended opening.

13. The method of claim 12, wherein the panel includes a substrate and a cover provided over an inside surface of the substrate, and wherein the folding portion includes both the substrate and the cover.

14. The method of claim 10, further comprising the step of providing a stich that secures the folding portion to the main portion of the panel at a location that is adjacent to the open-ended opening.

15. The method of claim 14, wherein the stitch is configured to completely penetrate the folding portion and only partially penetrate the main portion, such that the stitch does not pass through an A-surface of the main portion of the cover.