U.S. patent application number 14/172581 was filed with the patent office on 2014-11-13 for vehicle panel.
This patent application is currently assigned to JOHNSON CONTROLS TECHNOLOGY COMPANY. The applicant listed for this patent is JOHNSON CONTROLS TECHNOLOGY COMPANY. Invention is credited to BOBBY BAGBY, JULIE M. DEVRIES, ALBERT CHARLES HAAK, WILLIAM J. HOMIK, JACK LAWRENCE JOHNSON, CHRISTOPHER SCOTT KRING, RADE MILANOVIC, TODD D. NELLIS, PETER OOSTING, BRENT DONALD ROCKAFELLOW, BEN EDWARD SAPAK, JASON S. SCHOLTEN, KEVIN A. TOMASEK, DENNIS J. VANHOUTEN.
Application Number | 20140333097 14/172581 |
Document ID | / |
Family ID | 40239636 |
Filed Date | 2014-11-13 |
United States Patent
Application |
20140333097 |
Kind Code |
A1 |
KRING; CHRISTOPHER SCOTT ;
et al. |
November 13, 2014 |
VEHICLE PANEL
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.
Inventors: |
KRING; CHRISTOPHER SCOTT;
(ZEELAND, MI) ; NELLIS; TODD D.; (ZEELAND, MI)
; VANHOUTEN; DENNIS J.; (WYOMING, MI) ; BAGBY;
BOBBY; (ZEELAND, MI) ; DEVRIES; JULIE M.;
(ZEELAND, MI) ; SAPAK; BEN EDWARD; (WEST OLIVE,
MI) ; TOMASEK; KEVIN A.; (ZEELAND, MI) ;
OOSTING; PETER; (GRAND RAPIDS, MI) ; ROCKAFELLOW;
BRENT DONALD; (HOLLAND, MI) ; HAAK; ALBERT
CHARLES; (HOLLAN, MI) ; SCHOLTEN; JASON S.;
(HUDSONVILLE, MI) ; MILANOVIC; RADE; (HOLLAND,
MI) ; HOMIK; WILLIAM J.; (WEST OLIVE, MI) ;
JOHNSON; JACK LAWRENCE; (HOLLAND, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JOHNSON CONTROLS TECHNOLOGY COMPANY |
HOLLAND |
MI |
US |
|
|
Assignee: |
JOHNSON CONTROLS TECHNOLOGY
COMPANY
HOLLAND
MI
|
Family ID: |
40239636 |
Appl. No.: |
14/172581 |
Filed: |
February 4, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12672886 |
Feb 15, 2011 |
8641136 |
|
|
PCT/US08/09561 |
Aug 8, 2008 |
|
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14172581 |
|
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|
60935413 |
Aug 10, 2007 |
|
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Current U.S.
Class: |
296/214 ;
29/897.2 |
Current CPC
Class: |
B60R 13/0231 20130101;
B60R 13/0275 20130101; B32B 2605/003 20130101; B60R 13/0225
20130101; Y10T 29/49622 20150115; B21D 53/88 20130101; B60R
2013/0287 20130101 |
Class at
Publication: |
296/214 ;
29/897.2 |
International
Class: |
B60R 13/02 20060101
B60R013/02; B21D 53/88 20060101 B21D053/88 |
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.
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 a
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.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C.
.sctn.119(e) of U.S. Provisional Application No. 60/935,413, having
a filing date of Aug. 10, 2007, titled "Vehicle Headliner," the
complete disclosure of which is hereby incorporated by
reference.
BACKGROUND
[0002] The present disclosure relates generally to a panel for a
vehicle. More specifically, the present disclosure relates to a
panel, such as a headliner, having a wrapped or folded-over edge
and a method of manufacturing a panel with a wrapped or folded-over
edge.
[0003] Headliners are vehicle panels that are coupled to a support
structure or roof of a vehicle. Headliners may include one or more
peripheral edges that are visible to an occupant within the
vehicle. Headliners may also include one or more edges that define
an opening in the headliner, such as an opening for a sunroof. In
certain applications it may be desirable to provide one or more of
these edges with a finished appearance so as to improve the
aesthetics within the vehicle for the vehicle occupant. It may also
be desirable to provide one or more of these edges with a
structural or reinforcement member. For example, as sunroofs
increase in size (e.g., panoramic sunroofs, etc.), there is less
and less headliner material surrounding them, which may lead to
weaker headliners that have a tendency to fold or crack alongside
the sunroof opening. Secondary reinforcements may be added to the
headliner to strengthen the headliner around the sunroof opening.
Such reinforcements are generally manufactured separately with an
injection molding or vacuum-forming process and can be costly.
There continues to be a need to improve the configuration of
vehicle panels, including vehicle headliners, particularly the
edges of vehicle panels.
SUMMARY
[0004] One embodiment relates to a vehicle panel. 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.
[0005] Another embodiment relates to a method of manufacturing a
vehicle panel. The method comprises forming a main body portion
having a substantially rigid substrate and a substantially flexible
cover material coupled to the substrate. The substrate has an edge.
The method also comprises providing an area of reduced thickness in
the substrate. The area of reduced thickness defines a living
hinge. The method further comprises integrally forming a flap with
the main body portion. The flap is provided on a side of the living
hinge opposite the main body portion and comprises at least the
cover material. The method further comprises folding the flap about
the living hinge towards the substrate of the main body portion to
substantially conceal the edge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an isometric view of a vehicle according to an
exemplary embodiment.
[0007] FIG. 2 is an isometric view of the interior of the vehicle
of FIG. 1 showing a headliner according to an exemplary
embodiment.
[0008] FIG. 3 is a bottom plan view of a headliner according to an
exemplary embodiment and including an opening for a sunroof.
[0009] FIG. 4 is a partial bottom plan view of the headliner of
FIG. 3 showing an edge of the headliner around the opening before
it has been finished.
[0010] FIGS. 5A and 5B are cross-sections of a portion of a
headliner showing a flap according to an exemplary embodiment being
folded back onto the headliner.
[0011] FIGS. 6A and 6B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0012] FIGS. 7A and 7B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0013] FIGS. 8A and 8B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0014] FIGS. 9A and 9B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0015] FIGS. 10A and 10B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0016] FIGS. 11A and 11B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0017] FIGS. 12A and 12B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0018] FIGS. 13A and 13B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0019] FIGS. 14A and 14B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0020] FIGS. 15A and 15B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0021] FIGS. 16A and 16B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
[0022] FIGS. 17A and 17B are cross-sections of a portion of a
headliner showing a flap according to another exemplary embodiment
being folded back onto the headliner.
DETAILED DESCRIPTION
[0023] Referring generally to FIGURES, exemplary embodiments of a
panel for use in a vehicle (e.g., automobiles such as cars, trucks,
sport utility vehicles, minivans, buses, and the like; airplanes,
boats, etc.) are shown. The vehicle panel includes one or more
edges (e.g., peripheral edges, internal edges, etc.) that include a
folded-over or wrapped edge. The folded-over or wrapped edges may
be provided for aesthetic purposes and/or functional purposes. For
example, the folded-over or wrapped edges may function as a
reinforcement member that improves the strength and/or rigidity of
the vehicle panel. The folded-over or wrapped edge may also prevent
creases from propagating from the edge and further help to reduce
the chance of fabric fraying along an edge. Such vehicle panels may
be installed at any suitable location within a vehicle (e.g., side
walls, floors, headliners, etc.) and integrated with any other
vehicle component. The vehicle panels may be provided in a wide
variety of sizes, shapes, and configurations, and made from a wide
variety of materials and manufacturing processes according to
various exemplary embodiments. All such variations are intended to
be within the scope of the inventions.
[0024] Referring to FIGS. 1 and 2, the vehicle panel is shown
according to an exemplary embodiment as a headliner 100 that is
configured to be supported at or coupled to the roof of a vehicle
10. According to the embodiment illustrated, the headliner 100
includes an opening 102 for a sunroof (e.g., a panoramic sunroof,
vista roof, etc.). The portions of the headliner 100 surrounding
the opening 102 may be relatively narrow and/or may have a tendency
to crack or bend, especially if the opening 102 is for a larger
sunroof (e.g., a panoramic sunroof). According to the various
alternative embodiments, the headliner 100 may include additional
openings (e.g., for a second sunroof, for an attachment opening,
etc.) or may be a substantially continuous panel without any
openings.
[0025] FIG. 3 shows a plan view of the headliner 100 according to
an exemplary embodiment. The headliner 100 includes one or more
edges that define the periphery of the headliner 100. For example,
the headliner 100 is shown as including a first or front peripheral
edge 114, a second or rear peripheral edge 116, a third or
driver-side peripheral edge 118 and a fourth or passenger-side
peripheral edge 120. The opening 102 for the sunroof is defined by
a first boundary, shown as a front edge 104, a second boundary,
shown as a rear edge 106, a third boundary, shown as a driver-side
edge 108, and a fourth boundary, shown as a passenger-side edge
110. The front edge 104, the rear edge 106, the driver-side edge
108 and the passenger-side edge 110 cooperate to define a
substantially rectangular opening for the sunroof. The headliner
100 is also shown as including an number of additional openings for
receiving various components (e.g., fasteners, grab handles,
pillars, overhead consoles, etc.) upon installation of the
headliner 100. For example, the headliner 100 includes an opening
112 configured to receive a support member for a visor
assembly.
[0026] Referring to FIG. 4, the opening 102 for the sunroof may be
formed during a molding process or may be formed in a secondary
operation by removing a portion of the headliner material (e.g.,
scrap, offal, etc.). If the opening 102 is formed by removing a
portion of the headliner material, the material removed may be used
elsewhere in the vehicle. For example, the headliner material may
be used to construct seat backs, side panels for a floor console,
or door panel speaker enclosures. Further, a substrate of the
headliner material (i.e., fiberglass-reinforced polypropylene,
etc.) may make scrap material useful for other purposes such as
forming totes, outdoor storage cabinets, drink trays, sleds,
whiteboards or office panels. For such uses, the substrate may be
wrapped with other materials (e.g., vinyl, fabric, etc.) or may not
be wrapped with any covering. Such reuse of the scrap from the
headliner may help to reduce the amount of material that is
discarded.
[0027] According to an exemplary embodiment, one or more flaps
(e.g., extensions, strips, etc.), shown as a front flap 122, a
passenger side flap 124 and a corner flap 126, are provided after
the opening 102 has been formed. The flaps are coupled to the main
body of the headliner along the edges of the opening 102 and may be
folded back onto the headliner 100 to provide a folded-over or
wrapped edge for aesthetic purposes and/or to form a reinforcement
member or an integrated stiffener. According to an exemplary
embodiment, the flaps are integrally formed with a main body 128 of
the headliner 100 and formed of substantially the same material(s)
as the main body 128. According to the various alternative
embodiments, the flaps may be separate members that get attached to
the main body 128. For example, the flaps may be trimmed from the
main body 128 or any other panel and attached to the main body 128
near an edge with a suitable process (e.g., reheating the material,
adhesives, sewing, ultra-sonic welding, etc.).
[0028] In addition to providing reinforcement for the headliner
100, the flaps may provide further functional benefits. For
example, the flaps may be configured to provide a head impact
counter measure, an attachment area for other body panels, an
attachment area for coupling the panel to the vehicle framework or
structure, or an attachment area for various vehicle components
(e.g., overhead system components, etc.).
[0029] According to an exemplary embodiment, the flaps are provided
on each side of the headliner 100 that defines the opening 102
(e.g., around the entire periphery of the opening 102, etc.).
According to the embodiment illustrated, the flaps provided along
the lengths of the opening 102 (i.e., the front flap 122 and the
passenger side flap 124, etc.) are generally rectangular in shape
and have a depth sufficient to substantially wrap or conceal the
adjacent edge. For example, the flaps 122, 124 may have a depth
between approximately 15 and approximately 20 millimeters wide
after being trimmed, but according to the various alternative
embodiments, may be any suitable size depending on the particular
application. The corner flap 126 is shown as including a plurality
of sections or darts which will allow the combination of flaps to
provide the appearance of a substantially continuous edge when
folded back onto the headliner 100 and secured thereto.
[0030] Configuring the flaps 122, 124 and/or 126, referred to
hereunder as just the flap 122 for simplicity, as a reinforcement
member may minimize or eliminate cracking of the headliner 100
between the sides of the opening 102 and the peripheral edges of
the headliner 100. Configuring the flap 122 for aesthetic purposes
may provide the appearance of a substantially continuous and
cleanly wrapped (e.g., fabric wrapped, etc.) or finished edge.
According to various alternative embodiments, the flap may not be
configured to extend continuously around the opening 102. For
example, the flap may only be provide on one or more side or
lateral edges of the opening 102 (e.g., a driver-side flap and a
passenger side flap, etc.).
[0031] The flap 122 may be provided in other locations besides
around the opening 102 for the sunroof. For example, the headliner
100 may include the flap 122 on any exposed edges such as the front
peripheral edge 114, the rear peripheral edge 116, the driver-side
peripheral edge 118, the passenger-side peripheral edge 120, and/or
around pillar trim areas. According to such embodiments, the flap
122 may be folded back upon the headliner 100 and secured thereto
to form fabric-wrapped edges at the front peripheral edge 114, the
rear peripheral edge 116, the driver-side peripheral edge 118, the
passenger-side peripheral edge 120, and/or around pillar trim
areas. A similar folded-edge may be used along the periphery and/or
internally with other vehicle components or panels (e.g., trim
panels, such as those for a pillar or a door panel, etc.).
[0032] To achieve the folded-over or wrapped edge, the headliner
100 may be formed using a variety of processes including, but not
limited to, a thermofold process, an action in the molding tool to
complete the folding, scoring or machining the headliner 100,
overcompressing either face surface of the headliner 100, using a
heated tool, using a heated rollform tool, die trimming the
headliner 100, or shaping the flap to match the contours of the
back surface of the headliner 100 and folding the flap over onto
the back of the headliner 100.
[0033] Referring to FIGS. 5A and 5B, an exemplary embodiment of a
cross-section of a portion of the headliner 102 is shown before and
after the flap 122 has been folded against a main body 128 of the
headliner 100, respectively. As shown in FIG. 5A, the flap 122 may
include a contour that forms a structural shape that may be more
effective in reinforcing the headliner 100. According to the
embodiment illustrated, when the flap 122 is folded back onto the
main body 128, a space or channel 130 is provided between the flap
122 and the main body 128 of the headliner 100. For example, the
channel 130 is shown as a generally C-shaped channel. The channel
130 may also provide a conduit for one or more vehicle systems or
components (e.g., wiring harnesses, HVAC systems, etc.). It should
be noted that while the flap 122 is shown as providing a
reinforcement member for the headliner 100 to which the flap 122 is
integrally formed therewith, according to other exemplary
embodiments, the flap 122 may be removed and used as a reinforcing
member for another headliner.
[0034] Referring to FIGS. 6A through 17B, further exemplary
embodiments of cross-sections of a portion of the headliner 102 are
shown before and after the flap 122 has been folded against the
main body 128 of the headliner 100, respectively. According to the
embodiments illustrated, the headliner 100 is generally formed of a
first layer or portion, shown as a substrate 132, and a second
layer or portion, shown as a cover material 134 (e.g., coverstock,
etc.). According to an exemplary embodiment, the substrate 132 is
formed of a substantially rigid material that provides at least
some structural support for the headliner 100. For example, the
substrate 132 may be formed of a polymer (e.g., polyurethane,
polypropylene, etc), a composite such as a fiberglass-reinforced
polymer, or any other material known in the art. According to an
exemplary embodiment, the cover material 134 is formed of a
substantially flexible material (e.g., a fabric material, etc.)
that may be selected for its aesthetics.
[0035] The substrate 132 includes a first surface 136 and an
opposite second surface 138. The first surface 136 is configured to
face and/or be coupled to the vehicle structure, while the second
surface is configured to face the occupant compartment of the
vehicle. The cover material 134 is configured to be supported at
the second surface 138 of the substrate 132. According to an
exemplary embodiment, the cover material 134 is adhered to the
substrate 132, but alternatively, may be coupled to substrate 132
using any other suitable technique.
[0036] According to an exemplary embodiment, the headliner 100
includes one or more features that allow the flap 122 to be folded
back onto the main body 128 of the headliner 100 with a single step
after formation (e.g., molding, etc.) of the headliner 100.
According to the embodiments illustrated, such a feature is an area
of reduced thickness in the substrate 132, shown as a recess 140.
According to an exemplary embodiment, the recess 140 functions as a
hinge (e.g., a living hinge, etc.) that facilitates of the movement
of the flap 122. According to the various alternative embodiments,
the recess 140 may also be provided for ornamental applications.
For example, the recess 140 may allow the headliner 100 to include
fabric-wrapped ornamental features such as styling lines, logos or
other designs. The recess 140 may also be used for a functional
application. For example, the recess 140 may be used for forming
doors or panels that are configured to rupture to allow an airbag
to inflate into the interior of the vehicle.
[0037] The recess 140 may be formed during a molding process of the
substrate 132 or as a secondary operation after the substrate 132
has been formed. For example, the recess 140 may be formed during a
molding process of the headliner 100 by providing a projection with
a small radius or some other shape in a surface of the form tool.
Forming the recess 140 as a secondary operation may be achieved by
milling a portion of the substrate 132. For example, a portion of
the substrate 132 could be removed using a waterjet or some other
machining device. Another secondary operation technique that could
be used to form the recess 140 is overcompressing the substrate 132
in such an area. According to an exemplary embodiment, the
substrate 132 is thinned between approximately 20 percent to
approximately 30 percent relative to the thickness of the substrate
132 to form to form the hinge.
[0038] Referring to FIGS. 6A and 6B in particular, the recess 140
is in the form of a double hinge. According to an exemplary
embodiment, the recess 140 is formed during the molding process of
the substrate 132 and includes a stepped profile in the first
surface 136 of the substrate 132. Configuring the recess 140 as a
double hinge may simplify folding over the flap 122 and/or reduce
the likelihood of unwanted creases, bulges, and/or other
imperfections after the folding is complete. According to an
exemplary embodiment, the headliner 100 is configured to be trimmed
or cut at a trim line 142 before the flap 122 is folded over.
[0039] Referring to FIGS. 7A and 7B, the trim line 142 is within
the recess 140 or at a boundary of the recess 140. In such an
embodiment, when the flap 122 is folded back towards the substrate
132, the folded-over or wrap edge includes a portion of the
substrate 132 (i.e., the portion associated with the flap 122,
etc.) that functions as a reinforcement member for the headliner
100. The reinforcement member has a thickness that is less than the
thickness of the substrate 132 of the main body 128.
[0040] Referring to FIGS. 8A and 8B, the recess 140 is formed by
substantially removing all of the substrate 132 (e.g., via a
secondary operation, etc.) and, similar to the embodiment
illustrated in FIGS. 7A and 7B, the trim line 142 is within the
recess 140 or at a boundary of the recess 140. Such an embodiment,
results in a folded-over or wrapped edge that does not include a
portion of the substrate 132 acting a reinforcement member. It
should be noted that even without a portion of substrate 132
provided on the flap 122, the flap 122 may still provide
reinforcement for the headliner 100 with just the cover material
134. For example, the cover material 134 alone may provide some
reinforcement at the edge by being tensioned over the edge.
[0041] Referring to FIGS. 9A and 9B, the headliner 100 is similar
to that shown in FIGS. 8A and 8B, except that the trim line 142 is
located past the recess 140. In such an embodiment, when the flap
122 is folded back towards the substrate 132, the folded-over or
wrap edge includes a portion of the substrate 132 (i.e., the
portion associated with the flap 122, etc.) that functions as a
reinforcement member for the headliner 100. The reinforcement
member has a thickness that is substantially the same as the
thickness of the substrate 132 of the main body 128.
[0042] Referring to FIGS. 10A and 10B, the headliner 100 includes a
structural member, shown as a trim ring 144, to assist in moving
the flap 122 to the folded-over or wrapped position. According to
an exemplary embodiment, the trim ring 144 is added during a
molding process (e.g., insert molded, etc.) behind the first
surface 136 of the substrate 132. A free end (e.g., an upper end,
etc.) of the trim ring 144 defines that area about which the flap
122 is folded over.
[0043] Referring to FIGS. 11A and 11B, the recess 140 is formed by
overcompressing the substrate 132. Overcompressing the substrate
132 reduces the thickness of the substrate 132 thereby creating the
recess 140 and providing a hinge for folding over the flap 122. The
overcompressing process may be completed in a secondary operation
using a tool, shown as an indenter 146, that gets retracted after
the process is complete.
[0044] Referring to FIGS. 12A and 12B, the recess 140 is formed in
the second surface 138 of the substrate 132. According to an
exemplary embodiment, the recess 140 is formed during a molding
process. Similar to the embodiment shown in FIGS. 12A and 12B, the
trim line 142 is located past the recess 140 to provide a
reinforcement member for the headliner 100 after the flap 122 is
folded over.
[0045] Referring to FIGS. 13A and 13B, the flap 122 is shown as
being folded back using a roll form die tool 148. Referring to
FIGS. 14A and 14B, the recess 140 is formed in a secondary
operation using a waterjet 150 and the flap 122 is folded back
using a slide tool 152. Referring to FIGS. 15A and 15B and FIGS.
16A and 16B, in addition to the trim line 142, a second trim line
154 is provided. The second trim line 154 is a partial cut as it
does not extend through the cover material 134. The second trim
line 154 defines the point at which the flap 122 is configured to
be folded about. In FIGS. 16A and 16B, the substrate 132 on the
flap 122 is removed before the flap 122 is folded back towards the
substrate 132 of the main body 128. Referring to FIGS. 17A and 17B,
the recess 140 is formed in the second surface 138 of the substrate
132 similar to the embodiment illustrated in FIGS. 12A and 12B. In
such an embodiment, an additional recess is also provided in the
cover material 134 to further assist in folding the flap 122.
[0046] For purposes of this disclosure, the term "coupled" means
the joining of two members directly or indirectly to one another.
Such joining may be stationary in nature or moveable in nature
and/or such joining may allow for the flow of fluids, electricity,
electrical signals, or other types of signals or communication
between the two members. Such joining may be achieved with the two
members or the two members and any additional intermediate members
being integrally formed as a single unitary body with one another
or with the two members or the two members and any additional
intermediate members being attached to one another. Such joining
may be permanent in nature or alternatively may be removable or
releasable in nature.
[0047] It is important to note that the construction and
arrangement of the of the various embodiments of the vehicle panel
and the methods of manufacturing the vehicle panel provided herein
is illustrative only. Although only a few exemplary embodiments of
the present inventions have been described in detail in this
disclosure, those skilled in the art who review this disclosure
will readily appreciate that many modifications are possible in
these embodiments (such as variations in shape and size of the
panel, the flap(s), various locations for mounting within the
vehicle, etc.) without materially departing from the novel
teachings and advantages of the inventions. Further, elements shown
as integrally formed may be constructed of multiple parts or
elements, the position of elements may be reversed or otherwise
varied, and the nature or number of discrete elements or positions
may be altered or varied. Further, the vehicle panel and method of
manufacturing the vehicle panel may be used in any type of vehicle
such as trucks, recreational vehicles, minivans, sport utility
vehicles, passenger automobiles, etc. and at any suitable location
within the vehicle. Accordingly, all such modifications are
intended to be within the scope of the invention as defined in the
appended claims.
[0048] The order or sequence of any process or method steps may be
varied or re-sequenced according to alternative embodiments. In the
claims, any means-plus-function clause is intended to cover the
structures described herein as performing the recited function and
not only structural equivalents but also equivalent structures.
Other substitutions, modifications, changes and omissions may be
made in the design, operating configuration and arrangement of the
preferred and other exemplary embodiments without departing from
the spirit of the inventions as expressed in the appended
claims.
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