VEHICLE PANEL

• US 20110133522A1
• Filed: 08/08/2008
• Published: 06/09/2011
• Est. Priority Date: 08/10/2007
• Status: Active Grant

• Current Assignee: Adient Luxembourg Holding S..R.L.
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Oosting, Peter, Bagby, Bobby, Haak, Albert Charles, Tomasek, Kevin A., Sapak, Ben Edward, Devries, Julie M., Milanovic, Rade, Johnson, Jack Lawrence, Homik, William J., Scholten, Jason S., Nellis, Todd D., Kring, Christopher Scott, Vanhouten, Dennis J., Rockafellow, Brent Donald
• Granted Patent: US 8,641,136 B2
• Time in Patent Office: Days
• US Class Current: 296/214
• CPC Class Codes: B21D 53/88 other parts for vehicles, e.g. cowlings, mudguards
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B60R 13/0225 self supporting head liners
• CPC Class Codes: B60R 13/0231 specially adapted for roofs with openings
• CPC Class Codes: B60R 13/0275 comprising removable or hinged parts for accessing storage compartments B60R7/04; for airbag deployment B60R21/215
• CPC Class Codes: B60R 2013/0287 integrating other functions or accessories
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making

Abstract

A vehicle panel with a folded-over or wrapped edge is disclosed. The vehicle panel comprises a main body portion. The main body portion includes a first layer and a second layer. The first layer is formed of a substantially rigid material and has a first surface, a second surface and an edge. The second layer is coupled to the second surface of the first layer and formed of a substantially flexible material. The vehicle panel also comprises a flap integrally formed with the main body portion at the edge and comprises at least the second layer. The vehicle panel further comprises a hinge separating the flap from the main body portion, the hinge is defined by at least a portion of the first layer having a reduced thickness. The flap is folded back about the hinge towards the first surface of the first layer to substantially conceal the edge.

Claims

1. A vehicle panel comprising:

a main body portion including a first layer and a second layer, the first layer being formed of a substantially rigid material and having a first surface, a second surface and an edge, the second layer being coupled to the second surface of the first layer and formed of a substantially flexible material;

a flap integrally formed with the main body portion at the edge and comprising at least the second layer; and

a hinge separating the flap from the main body portion, the hinge being defined by at least a portion of the first layer having a reduced thickness,

wherein the flap is folded back about the hinge towards the first surface of the first layer to substantially conceal the edge.

2. The vehicle panel of claim 1 wherein the edge is at least one of a peripheral edge and an internal edge.

3. The vehicle panel of claim 1 wherein the vehicle panel is a headliner configured to be supported at a roof of a vehicle.

4. The vehicle panel of claim 3 wherein the edge defines an opening for a sunroof in the main body portion.

5. The vehicle panel of claim 1 wherein the flap further comprises the first layer which provides a reinforcement member at the edge when the flap is folded back towards the first surface of the first layer of the main body portion.

6. The vehicle panel of claim 1 wherein the portion of reduced thickness is formed by at least partially removing the first layer or by compressing the first layer.

7. The vehicle panel of claim 1 wherein the first layer is thinned from the second surface of the main body portion to provide the portion of the first layer having the reduced thickness and defining the hinge.

8. The vehicle panel of claim 1 wherein the first layer is thinned from the first surface of the main body portion to provide the portion of the first layer having the reduced thickness and defining the hinge.

9. The vehicle panel of claim 1 wherein a portion of the first layer is substantially removed to provide the portion of the first layer having the reduced thickness and defining the hinge.

10. The vehicle panel of claim 1 wherein the hinge is further defined by a portion of the second layer having a reduced thickness.

11. The vehicle panel of claim 10 wherein the second layer is thinned from a side opposite the first layer to provide the portion of the second layer having the reduced thickness and defining the hinge.

18. The vehicle panel of claim 1 wherein the flap provides an impact absorber for a vehicle occupant.

19. The vehicle panel of claim 1 wherein the flap provides an attachment area for a vehicle component.

20. The vehicle panel of claim 19 wherein the vehicle component comprises an overhead system component.

12. A method of manufacturing a vehicle panel, the method comprising:

forming a main body portion having a substantially rigid substrate and a substantially flexible cover material coupled to the substrate, the substrate having an edge;

providing an area of reduced thickness in the substrate, the area of reduced thickness defining a living hinge;

integrally forming a flap with the main body portion, the flap being provided on a side of the living hinge opposite the main body portion and comprising at least the cover material; and

folding the flap about the living hinge towards the substrate of the main body portion to substantially conceal the edge.

13. The method of claim 12 further comprising forming an opening in the main body portion and wherein the edge defines the opening.

14. The method of claim 12 further comprising configuring the flap to include both the substrate and the cover material, the substrate on the flap providing a reinforcement member adjacent to the edge when the flap is folded about the living hinge.

15. The method of claim 12 wherein providing an area of reduced thickness in the substrate comprises thinning the substrate from a surface opposite the cover material.

16. The method of claim 12 further comprising configuring the flap to provide an attachment area for a vehicle component.

17. The method of claim 12 further comprising configuring the flap to provide an impact absorber for a vehicle occupant.