Multi-layer composite vehicle headliner substrate with HIC provisions

• US 7,014,259 B2
• Filed: 04/29/2004
• Issued: 03/21/2006
• Est. Priority Date: 04/29/2004
• Status: Expired due to Term

• Current Assignee: FCA US LLC (Stellantis NV)
• Original Assignee: Daimler Chrysler Corporation (Mercedes-Benz Group AG)
• Inventors: Heholt, Susan
• Primary Examiner(s): Pedder, Dennis H.
• Application Number:
  US10/834,510
• Publication Number:
  US 20050242627A1
• Time in Patent Office: 691 Days
• Field of Search: 296/214
• US Class Current: 296/214
• CPC Class Codes: B60R 13/0225 self supporting head liners
• CPC Class Codes: B60R 13/0243 Doors
• CPC Class Codes: B60R 2013/0281 made of a plurality of visible parts
• CPC Class Codes: B60R 21/0428 associated with the side doors or panels, e.g. displaced towards the occupants in case of a side collision

Abstract

A combination of layered materials for producing a vehicle headliner is provided. The layers include a head impact countermeasure (HIC) layer of co-extruded thermoplastic and a rigid foam layer laid adjacent to the HIC layer and made of a thermoplastic. The layers are subsequently molded together to form the headliner.

Claims

1. A vehicle headliner having a combination of layered materials comprising:

a head impact countermeasure layer of co-extruded thermoplastic; and

a rigid foam layer laid adjacent to said head impact countermeasure layer and made of a thermoplastic, wherein said thermoplastic head impact countermeasure layers are and said rigid foam subsequently molded together to form the headliner free of glass fibers, adhesives and resins.

2. The vehicle headliner of claim 1 wherein said co-extruded thermoplastic comprises a polypropylene composite.

3. The vehicle headliner of claim 1 further comprising an acoustical scrim layer made of one of polyester and polypropylene.

4. The vehicle headliner of claim 1 further comprising a foam layer adjacent to a fabric layer with said fabric layer being positioned as an outer layer, wherein said foam layer and said fabric layers are made of one of polyester and polypropylene.

5. The vehicle headliner of claim 1 further comprising a light blocking layer made of one of polyester and polypropylene.

6. A vehicle headliner for positioning proximate the interior of a vehicle roof having substantially parallel beams at its outer edges, said headliner comprising:

a head impact countermeasure layer of co-extruded thermoplastic, said head impact countermeasure layer being formed to provide a crush space between at least one of the beams and the head impact countermeasure layer and;

a rigid foam layer fused to said head impact countermeasure layer to form the headliner free of glass fibers, adhesives and resins.

7. The vehicle headliner of claim 6 wherein said co-extruded thermoplastic comprises a polypropylene composite.

8. The vehicle headliner of claim 6 further comprising an acoustical scrim layer made of one of polyester and polypropylene.

9. The vehicle headliner of claim 6 further comprising a foam layer adjacent to a fabric layer with said fabric layer being positioned as an outer layer, wherein said foam layer and said fabric layers are made of one of polyester and polypropylene.

10. The vehicle headliner of claim 6 further comprising a light blocking layer made of one of polyester and polypropylene.