Sonic weld sunroof trim ring

• US 20050150930A1
• Filed: 01/08/2004
• Published: 07/14/2005
• Est. Priority Date: 01/08/2004
• Status: Active Grant

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: Lear Corporation
• Inventors: Tiesler, John M., Arnold, Scott D., Dykman, Michael C., Mestemaker, Jim
• Granted Patent: US 7,066,374 B2
• Time in Patent Office: Days
• US Class Current: 228/110.100
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 66/112 Single lapped joints
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/131 Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
• CPC Class Codes: B29C 66/21 said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
• CPC Class Codes: B29C 66/3022 said melt initiators being integral with at least one of the parts to be joined
• CPC Class Codes: B29C 66/474 said single elements being substantially non-flat
• CPC Class Codes: B29C 66/5344 said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends B29C66/5346 takes precedence
• CPC Class Codes: B29C 66/61 Joining from or joining on the inside for making tubes by bending sheets and joining from the inside B29C53/387
• CPC Class Codes: B29C 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/81427 comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29L 2007/002 Panels; Plates; Sheets
• CPC Class Codes: B29L 2012/00 Frames
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3011 Roof linings
• CPC Class Codes: B60R 13/0231 specially adapted for roofs with openings

Abstract

A method of installing trim rings to headliner trims systems in motor vehicles comprising a trim ring, a headliner, and a sonic horn and stack. The sonic horn vibrates to bond/weld headliner to trim ring. Energy directors can be added to facilitate bonding/welding process. Fasteners can also be added for attachment to the vehicle body. This bonding/welding of the headliner to trim ring creates a smooth, molded look for the trim ring and does so without gapping to or sliding within the headliner.

Claims

1. A method of installing a trim ring to a headliner of a motor vehicle comprising the steps of:

stacking a sonic horn with the headliner and the trim ring; and

vibrating the sonic horn such that the trim ring and the headliner bond and weld together in at least one weld area.

2. The method of installing a trim ring to a headliner in claim 1, further comprising the step of providing a nest and wherein said step of stacking the sonic horn with headliner and the trim ring occurs on the nest such that the trim ring, the headliner and the sonic horn are supported by the nest.

3. The method of installing a trim ring to a headliner in claim 1, wherein said step of vibrating the sonic horn such that the trim ring and the headliner bond and weld together in at least one weld area creates numerous weld areas around perimeter of said trim ring.

4. The method of installing a trim ring to a headliner in claim 1, wherein said step of stacking the trim ring, the headliner, and a sonic horn further comprises including at least one energy director between the trim ring and the headliner.

5. The method of installing a trim i ring to a headliner as in claim 4, wherein said energy directors comprise of plastic.

6. The method of installing a trim ring to a headliner as in claim 1, further comprising the step of fastening the headliner to a sunroof bracket with fasteners.

7. The method of installing a trim ring to a headliner as set forth in claim 1 wherein said step of stacking a sonic horn with the headliner and the trim ring includes stacking a band-shaped sonic horn with the headliner and the trim ring.

8. The method of installing a trim ring to a headliner as set forth in claim 1 wherein said step of stacking the sonic horn with the headliner and the trim ring includes positioning the headliner between the sonic ring and the trim ring.