Modular vehicle headliner

• US 20080061604A1
• Filed: 09/12/2006
• Published: 03/13/2008
• Est. Priority Date: 09/12/2006
• Status: Abandoned Application

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: International Automotive Components Group North America (Lear Corporation)
• Inventors: Cauvin, David J., Mestemaker, Jim, Tiesler, John M.
• Application Number:
  US11/519,365
• Publication Number:
  US 20080061604A1
• Time in Patent Office: Days
• US Class Current: 296/214
• CPC Class Codes: B60H 1/0055 the housing or parts thereof being integrated in other devices, e.g. dashboard
• CPC Class Codes: B60R 13/0225 self supporting head liners
• CPC Class Codes: B60R 2013/0287 integrating other functions or accessories

Abstract

A modular vehicle headliner assembly includes a generally planar headliner substrate for mounting over an interior portion of a vehicle roof. An air duct is attached to one side of the substrate. An air-curtain assembly is attached to the air duct. The air duct supports the air-curtain assembly relative to the substrate.

Claims

1. A modular vehicle headliner assembly comprising:

a generally planar flexible headliner substrate for mounting over an interior portion of a vehicle roof;

a rigid air duct attached to one side of said substrate; and

an air-curtain assembly including an air curtain component attached relative to said substrate, said air duct engageable with said air curtain component to securely support and position said air-curtain component relative to said substrate.

2. The assembly of claim 1 wherein said substrate includes a perimeter support portion, said air duct attached to said substrate at said perimeter support portion.

3. The assembly of claim 1 wherein said air-curtain component is one of an inflatable air-curtain and an air canister for inflating said air-curtain.

4. The assembly of claim 1 wherein said one side is a first side opposite a second side of said substrate, the assembly further comprising:

a vehicle interior mounted to said substrate on said second side.

5. The assembly of claim 4 wherein said vehicle interior component is one of an assist handle, a visor and a cargo/coat hook.

6. The assembly of claim 1 further comprising:

a cross support extending along said one side of said substrate, a first end of said cross support attached to said air duct.

7. The assembly of claim 1 wherein said cross support includes a component mount for retaining a vehicle component relative to said substrate.

8. The assembly of claim 1 wherein said air duct is a multi-piece air duct.

9. The assembly of claim 1 wherein said air duct is attached to said substrate by one of welding, hot melting, adhesive bonding, and mechanical fastening.

10. A method for assembling a vehicle headliner module and installing the modular vehicle headliner assembly in a vehicle comprising:

a. providing a generally planar headliner substrate for mounting over an interior portion of a vehicle roof, the substrate defining first and second sides;

b. providing an air duct;

c. attaching the air duct to the first side of the substrate;

d. providing an air-curtain assembly;

e. attaching the air-curtain assembly to the air duct; and

f. mounting the modular vehicle headliner assembly including the substrate, the air duct and the air-curtain in a vehicle.

11. The method of claim 10 further comprising step g., before step f., of:

g. shipping the modular vehicle headliner assembly from a vehicle headliner assembly plant to a vehicle manufacturing plant.

12. The method of claim 10 further comprising steps g. and h., before step f., of:

g. providing a vehicle interior component; and

h. mounting the vehicle interior component to the substrate on a side of the substrate opposite the air duct.

13. The method of claim 10 further comprising steps g. and h., before step f., of:

g. providing a cross support; and

h. attaching a first end of the cross support to the air duct.

14. The method of claim 10 wherein the attaching in step c. is one of welding, hot melting, adhesive bonding, and mechanical fastening.