Vehicle headliner and method of manufacture

• US 7,651,143 B2
• Filed: 10/11/2007
• Issued: 01/26/2010
• 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.
• Primary Examiner(s): Morrow; Jason S
• Application Number:
  US11/871,055
• Publication Number:
  US 20090096254A1
• Time in Patent Office: 838 Days
• Field of Search: 296/187.05, 296/187.06, 296/1.02, 296/214, 280/730.2, 280/728.2
• US Class Current: 296/1.02
• 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

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 is provided. 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.

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 with four corners dimensioned such that an assist grip attachment end can extend therethrough;

a weakened region within said substrate layer proximate said assist grip aperture, said weakened region having a plurality of slits and at least one of said plurality of slits extending from each of said four corners of said assist grip aperture in a generally outward direction; 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 is proximate a curtain side airbag region.

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

4. The headliner of claim 3, wherein said slit does not extend though said foam layer.

5. The headliner of claim 1, wherein said plurality of slits are formed using a water jet cutter.

6. 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, each of said pair of assist grip apertures having four corners and a weakened region within said substrate layer proximate said assist grip aperture, said weakened region having a plurality of slits and at least one of said plurality of slits extending from each of said four corners of said assist grip aperture in a generally outward direction.

7. The headliner of claim 6, further comprising a trim attached to said fabric layer proximate said pair of assist grip apertures.

8. 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;

each of said pair of assist grip apertures having four corners and a weakened region within said substrate layer proximate said assist grip aperture, said weakened region having a plurality of slits and at least one of said plurality of slits extending from each of said four corners of said assist grip aperture in a generally outward direction; 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.

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