Headliner with Weakened Area and Method of Making Same

• US 20080115364A1
• Filed: 01/31/2008
• Published: 05/22/2008
• Est. Priority Date: 01/28/2005
• Status: Abandoned Application

• Current Assignee: Intier Automotive, Incorporated (Magna International Incorporated)
• Original Assignee: Intier Automotive, Incorporated (Magna International Incorporated)
• Inventors: Eichler, Gary, Verellen, Andre, Pelchat, Michael
• Application Number:
  US12/023,764
• Publication Number:
  US 20080115364A1
• Time in Patent Office: Days
• US Class Current: 29/897.2
• CPC Class Codes: B60R 13/0225 self supporting head liners
• CPC Class Codes: B60R 2013/0287 integrating other functions or accessories
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A method of manufacturing an interior trim panel disposable proximate vehicular sheet metal includes the steps of forming a multi-layer headliner by providing a substrate that includes a front surface, a back surface opposite the front surface, and a substrate thickness bound by the front and back surfaces; forming at least one slit that completely extends through the substrate, wherein the at least one slit defines at least one first opening in the substrate, and at least one second opening in the substrate, wherein the at least one first opening is formed in the front surface, wherein the at least one second opening is formed in the back surface; and concealing the at least one first opening by providing a covering adjacent the front surface.

Claims

1. A method of manufacturing an interior trim panel disposable proximate vehicular sheet metal, comprising the steps of:

forming a multi-layer headliner by

providing a substrate that includes

a front surface,

a back surface opposite the front surface, and

a substrate thickness bound by the front and back surfaces;

forming at least one slit that completely extends through the substrate,

wherein the at least one slit defines

at least one first opening in the substrate, and

at least one second opening in the substrate, wherein the at least one first opening is formed in the front surface, wherein the at least one second opening is formed in the back surface; and

concealing the at least one first opening by

providing a covering adjacent the front surface.

2. The method according to claim 1, wherein the providing a covering adjacent the front surface step includes

adhering the covering adjacent the front surface.

3. The method according to claim 1 further comprising the steps of

providing a component;

piercing the covering with the component;

passing the component through the at least one slit; and

attaching the component to the vehicular sheet metal.

4. The method according to claim 1, wherein the forming the at least one slit step includes

trimming the substrate with a water jet.

5. The method according to claim 1, wherein the forming the at least one slit step includes

trimming the substrate with a laser.

6. The method according to claim 1, wherein the forming the at least one slit step includes

in-molding the at least one slit into the substrate.

7. The method according to claim 1 further comprising the step of

reinforcing the substrate.

8. The method according to claim 7 further comprising the step of

defining the substrate to include a reinforced thermoset material.

9. The method according to claim 7 further comprising the step of

defining the substrate to include crushed urethane.

10. The method according to claim 7 further comprising the step of

defining the substrate to include fiber glass strands.

11. The method according to claim 7 further comprising the step of

defining the substrate to include crushed and reinforced cardboard.

12. A method of manufacturing an interior trim panel disposable proximate vehicular sheet metal, comprising the steps of:

manufacturing a multi-layer headliner by

extruding a substrate material;

defining the extruded substrate material to include

a front surface,

a back surface opposite the front surface, and

a substrate thickness bound by the front and back surfaces;

forming at least one slit that completely extends through the substrate,

wherein the at least one slit defines

at least one first opening in the substrate, and

at least one second opening in the substrate, wherein the at least one first opening is formed in the front surface, wherein the at least one second opening is formed in the back surface; and

concealing the at least one first opening by

adhering a covering adjacent the front surface.

13. The method according to claim 12 further comprising the steps of

providing a component;

piercing the covering with the component;

passing the component through the at least one slit; and

attaching the component to the vehicular sheet metal.

14. The method according to claim 12, wherein the forming the at least one slit step includes

trimming the substrate with a water jet.

15. The method according to claim 12, wherein the forming the at least one slit step includes

trimming the substrate with a laser.

16. The method according to claim 12, wherein the forming the at least one slit step includes

in-molding the at least one slit into the substrate.

17. A method of manufacturing an interior trim panel, comprising the steps of:

providing a multi-layer headliner by

extruding a substrate material;

defining the extruded substrate material to include

a front surface,

a back surface opposite the front surface, and

a substrate thickness bound by the front and back surfaces;

forming at least one slit that completely extends through the substrate,

wherein the at least one slit defines

at least one first opening in the substrate, and

at least one second opening in the substrate, wherein the at least one first opening is formed in the front surface, wherein the at least one second opening is formed in the back surface;

concealing the at least one first opening by

adhering a covering adjacent the front surface;

disposing the multi-layer headliner proximate vehicular sheet metal;

providing an assist grip;

piercing the covering with a portion of the assist grip;

passing the portion of the assist grip through the at least one slit; and

attaching the portion of the assist grip to the vehicular sheet metal.

18. The method according to claim 17, wherein the forming the at least one slit step includes

trimming the substrate with a water jet.

19. The method according to claim 17, wherein the forming the at least one slit step includes

trimming the substrate with a laser.

20. The method according to claim 17, wherein the forming the at least one slit step includes

in-molding the at least one slit into the substrate.