Vehicle Headliner And Method Of Manufacture

• US 20090096254A1
• Filed: 10/11/2007
• Published: 04/16/2009
• Est. Priority Date: 10/11/2007
• Status: Active Grant

• Current Assignee: Toyota Motor Corporation
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Spamer, Carl D.
• Granted Patent: US 7,651,143 B2
• Time in Patent Office: Days
• US Class Current: 296/214
• CPC Class Codes: B60R 13/0206 Arrangements of fasteners and clips specially adapted for attaching inner vehicle liners or mouldings devices for fastening or securing F16B
• CPC Class Codes: B60R 13/0225 self supporting head liners

Abstract

Disclosed is a headliner for preventing an assist grip located proximate a curtain side airbag (CSA) from detaching from a motor vehicle frame during deployment of the CSA. The headliner can include a substrate layer with an assist grip aperture dimensioned such that an assist grip attachment end can extend through the substrate layer and attach to sheet metal located adjacent to a back side of the headliner. Proximate to the assist grip aperture is a weakened region within the substrate layer that affords for headliner to bend and/or tear around the assist grip during deployment of the CSA. In addition, a fabric layer attached to and extending across the substrate layer is provided wherein the fabric layer covers the weakened region within the substrate layer. In some instances, the weakened region is a plurality of slits within the substrate layer, each of the slits extending in a generally outward direction from the assist grip aperture.

Claims

1. A headliner for enhancing an assist grip to remain attached to a motor vehicle frame during deployment of a curtain side airbag proximate said assist grip, said headliner comprising:

a substrate layer having an assist grip aperture dimensioned such that an assist grip attachment end can extend therethrough;

a weakened region within said substrate layer proximate said assist grip aperture; and

a fabric layer attached to and extending across said substrate layer, said fabric layer covering said weakened region within said substrate layer.

2. The headliner of claim 1, wherein said weakened region within said substrate layer proximate said assist grip aperture is a plurality of slits within said substrate layer, each of said plurality of slits extending in a generally outward direction from said assist grip aperture.

3. The headliner of claim 2, wherein said assist grip aperture has a rectangular shape, said rectangular shape having four corner regions.

4. The headliner of claim 3, wherein each of said four corner regions of said assist grip aperture has a slit extending therefrom in a generally outward direction.

5. The headliner of claim 1, further comprising a weakened region within said substrate layer proximate a curtain side airbag region.

6. The headliner of claim 5, wherein said weakened region is a plurality of slits within said substrate layer outlining said curtain side airbag region.

8. The headliner of claim 1, further comprising a foam layer between said substrate layer and said fabric layer.

9. The headliner of claim 8, wherein said slit does not extend through said foam layer.

10. The headliner of claim 2, wherein said plurality of slits are formed using a water jet cutter.

11. The headliner of claim 1, further comprising a pair of assist grip apertures in said substrate layer dimensioned such that a pair of assist grip attachment ends can extend therethrough.

12. The headliner of claim 11, further comprising a pair of weakened regions, each weakened region proximate one of said pair of assist grip apertures.

13. The headliner of claim 12, wherein said pair of weakened regions is a pair of plurality of slits, each of slits extending from one of said pair of assist grip apertures.

14. The headliner of claim 13, further comprising a trim attached to said fabric layer proximate said pair of assist grip apertures.

15. A headliner for enhancing an assist grip to remain attached to a motor vehicle frame during deployment of a curtain side airbag proximate said assist grip, said headliner comprising:

a substrate layer having a pair of assist grip apertures spaced apart from each other and dimensioned such that a pair of assist grip attachment ends can extend therethrough;

a pair of weakened regions within said substrate layer, one of said pair of weakened regions proximate each of said assist grip apertures; and

a fabric layer attached to and extending across said substrate layer, said fabric layer covering said pair of weakened regions within said substrate layer.

16. The headliner of claim 15, wherein each weakened region of said pair of weakened regions within said substrate is a plurality of slits within said substrate layer, each of said plurality of slits extending in a generally outward direction from one of said pair of assist grip apertures.

17. The headliner of claim 15, further comprising a foam layer between said substrate layer and said fabric layer.

18. A headliner for enhancing an assist grip to remain attached to a motor vehicle frame during deployment of a curtain side airbag proximate said assist grip, said headliner comprising:

a substrate layer having a pair of assist grip apertures spaced apart from each other and dimensioned such that a pair of assist grip attachment ends can extend therethrough, said substrate layer also having a curtain side airbag region dimensioned to conceal a curtain side airbag;

a pair of first plurality of slits within said substrate layer, one of said first plurality of slits proximate each of said assist grip apertures;

a second plurality of slits within said substrate layer proximate said curtain side airbag region; and

a fabric layer attached to and extending across said substrate layer, said fabric layer covering said pair of weakened region within said substrate layer.

19. The headliner of claim 18, wherein each of said pair of assist grip apertures has a rectangular shape, said rectangular shape having four corner regions.

20. The headliner of claim 19, each of said four corner regions of said rectangular shaped pair of assist grip apertures has a slit extending therefrom in a generally outward direction.