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WO2001054949A1 - Roof module assembly having a foam-in-place headliner - Google Patents

Roof module assembly having a foam-in-place headliner Download PDF

Info

Publication number
WO2001054949A1
WO2001054949A1 PCT/CA2001/000080 CA0100080W WO0154949A1 WO 2001054949 A1 WO2001054949 A1 WO 2001054949A1 CA 0100080 W CA0100080 W CA 0100080W WO 0154949 A1 WO0154949 A1 WO 0154949A1
Authority
WO
WIPO (PCT)
Prior art keywords
module assembly
roof
roof panel
set forth
trim layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CA2001/000080
Other languages
French (fr)
Inventor
Wolfgang K. Rohn
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Intier Automotive Inc
Original Assignee
Intier Automotive Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Intier Automotive Inc filed Critical Intier Automotive Inc
Priority to AU2001228242A priority Critical patent/AU2001228242A1/en
Publication of WO2001054949A1 publication Critical patent/WO2001054949A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/06—Fixed roofs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212—Roof or head liners
    • B60R13/0225—Roof or head liners self supporting head liners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
    • B62D65/14—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components the sub-units or components being passenger compartment fittings, e.g. seats, linings, trim, instrument panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R11/00—Arrangements for holding or mounting articles, not otherwise provided for
    • B60R11/02—Arrangements for holding or mounting articles, not otherwise provided for for radio sets, television sets, telephones, or the like; Arrangement of controls thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0206—Arrangements of fasteners and clips specially adapted for attaching inner vehicle liners or mouldings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/06—Sealing strips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R11/00—Arrangements for holding or mounting articles, not otherwise provided for
    • B60R2011/0001—Arrangements for holding or mounting articles, not otherwise provided for characterised by position
    • B60R2011/0003—Arrangements for holding or mounting articles, not otherwise provided for characterised by position inside the vehicle
    • B60R2011/0028—Ceiling, e.g. roof rails
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R11/00—Arrangements for holding or mounting articles, not otherwise provided for
    • B60R2011/0042—Arrangements for holding or mounting articles, not otherwise provided for characterised by mounting means
    • B60R2011/0043—Arrangements for holding or mounting articles, not otherwise provided for characterised by mounting means for integrated articles, i.e. not substantially protruding from the surrounding parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R11/00—Arrangements for holding or mounting articles, not otherwise provided for
    • B60R2011/0042—Arrangements for holding or mounting articles, not otherwise provided for characterised by mounting means
    • B60R2011/0043—Arrangements for holding or mounting articles, not otherwise provided for characterised by mounting means for integrated articles, i.e. not substantially protruding from the surrounding parts
    • B60R2011/0045—Arrangements for holding or mounting articles, not otherwise provided for characterised by mounting means for integrated articles, i.e. not substantially protruding from the surrounding parts with visible part, e.g. flush mounted
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R2013/0287—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners integrating other functions or accessories

Definitions

  • the subject invention generally relates to a roof module assembly for a vehicle having a foam-in-place headliner. More specifically, the invention relates to a foam headliner integrally formed with a roof panel.
  • Motor vehicle headliners typically comprise a trim layer, or outer, layer that presents a major exterior appearance of the vehicle ceiling, a foam intermediate layer, and some form of a structural component.
  • the structural component provides the headliner with structural integrity so that the headliner will maintain its installation configuration without sagging when attached to the roof panel of the vehicle.
  • a typical example of a prior art headliner is described in United States patent nos. 5,683,796 and 5,721,038.
  • the headliner is typically fastened to the roof panel of the vehicle through the use of fasteners or adhesives. Magnets are also commonly used to attach the headliner to the roof panel.
  • roof panel must also be reinforced to prevent sagging.
  • Bows are commonly used with the headliner to provide structural support for the headliner and at the same time, the roof panel.
  • the disadvantages of the prior art may be overcome by providing a roof module assembly which is molded to the roof panel, thereby providing structural support to both the headliner and the roof panel.
  • a roof module assembly for a passenger vehicle having a foam substrate including an upper surface and a lower surface.
  • a decorative trim cover layer is molded to the lower surface of the foam substrate.
  • the upper surface of the foam substrate is molded to an exterior roof panel for providing structural support to the exterior roof panel.
  • a method of making a roof module assembly comprising the steps of providing a trim layer in a contoured mold, positioning an exterior roof panel in spaced relation with the trim cover layer defining a foaming cavity therebetween, providing a foaming composition between the roof panel and the trim cover layer, expanding the foaming composition to fully occupy the foaming cavity and cured to formed a foam substrate self bonded between the roof panel and trim cover layer, and removing roof module assembly from the mold.
  • Figure 1 is a partial cross-sectional view of the roof module assembly having overhead components molded therein;
  • Figure 2 is a partial cross-sectional view of the roof module assembly showing an interface with a vehicle door
  • Figure 3 is a front view of a mold associated with the method of making the roof module assembly.
  • FIG. 1 a sectional view of a roof module assembly 10 for use in an automotive vehicle is generally shown in Figures 1 and 2.
  • the roof module assembly 10 includes an exterior roof panel 12 having a generally planar underside 14 with an upper surface of a polyurethane foam substrate 16 bonded thereto.
  • a trim layer 18 of headliner fabric or trim cover material is adhered to the lower surface of the foam 16 such that the foam 16 is disposed between the roof panel 12 and the trim layer 18.
  • the trim layer 18 forms an interior overhead surface and comprises either woven or non-woven material, such as cloth, or any other material commonly used in an automotive interior as may be desired, including felt type materials. Additionally, the trim layer 18 could comprise a multi layer laminate composite having a fabric layer, a soft foam layer and a film layer.
  • the foam substrate 16 is molded to complement the aesthetic, and dimensional requirements of the interior overhead surface.
  • a generally U-shaped structural support beam 19 is affixed to the underside 14 of the roof panel 12 along a longitudinal periphery 20 of the roof panel 12.
  • the outer peripheral edge of the roof panel 12 is curled around a portion of the support beam 19 and forms a flange 22 with the support beam 19 for securing the support beam 19 to the roof panel 12.
  • spot welds may be added between the support beam 19 and the roof panel 12, if necessary.
  • the support beam 19 provides structural support to the roof module assembly 10 during assembly operations and thereafter.
  • the roof panel 12 is typically a solid, planar stamped piece of sheet metal. Roof panel 12 is preferably primed and painted with a polyurethane based paint. As an alternative, however, the roof panel 12 can be formed, or molded, out of a composite material such as, for example an organic plastic material. A plastic roof panel 12 would provide an additional mass savings to the vehicle, while the foam substrate 16 provides sufficient structural support to the plastic roof panel 12 eliminating the need for structural cross car beams.
  • the plastic roof panel 12 may be affixed to the support beam 19 with a structural adhesive or an equivalent.
  • a lamp 24 may be molded into the foam 16.
  • the lamp 24 can be positioned in the roof module assembly 10 at any location, such as, for example, adjacent the support beam 19, above the driver's seat and passenger's seat, and the rear seat.
  • One or more electrical wiring harnesses 26 may also be molded into the roof module assembly 10 for providing electrical current to the lamp 24 and to any other electrical component disposed upon the roof module assembly 10.
  • the wiring harness 26 includes a free hanging connector for connecting to the vehicle electrical harness as is known in the art of vehicle electrical circuits.
  • the connector is typically located along a side panel of the vehicle.
  • the roof module assembly 10 may further include a heating, venting and air conditioning duct 28 (HVAC) disposed within the foam 16 for meeting HVAC requirements for the vehicle passenger compartment.
  • HVAC heating, venting and air conditioning duct 28
  • the roof module assembly 10 may include any of the components typically associated with vehicle overhead systems such as, for example, head impact protection panels, head impact protection air bags, tear seams for air bag deployment, a sun roof, coat hooks, assist grips, overhead consoles, speakers and sun visors.
  • vehicle overhead systems such as, for example, head impact protection panels, head impact protection air bags, tear seams for air bag deployment, a sun roof, coat hooks, assist grips, overhead consoles, speakers and sun visors.
  • the vehicle includes a structural roof rail 30 concealed by an exterior sheet metal flange 32 which is fixedly attached to the structural roof rail 30.
  • the exterior flange 32 forms a surface to which the roof module assembly 10 is affixed.
  • a structural adhesive 34 is disposed between the exterior flange 32 and the support beam 19 for securing the roof module assembly 10 to the roof rail 30, and thus, to the vehicle.
  • other methods of attachment are contemplated as a particular design may require.
  • the foam 16 and the trim layer 18 is formed to define a lip 36 presenting a channel
  • the body side trim panel 38 covers and conceals the structural roof rail 30 and other body components from view within the interior compartment of the vehicle.
  • the lip 36 extends from the A-pillar of the vehicle to the side panel for providing alignment for the full length of the passenger compartment.
  • the body side trim panel 38 is aligned and attached at an opposite second end 41 to the lip 36 by a mounting clip 40 having a bulb seal 42 adjacent a vehicle door 44 for sealing and preventing outside elements from entering the passenger compartment as is known in the art of vehicle weather proofing.
  • the roof module assembly 10 of the present invention is manufactured by providing a molding apparatus.
  • the molding apparatus utilized to carry out the method of the present invention is more particularly described in United States patent nos. 5,683,796 and 5,721,038.
  • a reaction injection molding (RIM) apparatus could also be utilized.
  • Trim layer 18 is placed on a movable upper mold 54.
  • the upper mold 54 includes a contoured mold surface 47 for supporting the trim layer 18.
  • the upper mold 54 is provided with vacuum ports connected to a source of vacuum to draw the trim layer 18 into contact with the mold surface 47.
  • the roof panel 12 is mounted in cavity 50 of a lower mold 48. Magnets or clips are provided to retain the roof panel 12 in the lower mold 48.
  • the roof panel 12 is positioned in a spaced relation with the trim layer 18 defining a foaming cavity 52 therebetween.
  • the desired accessory components such as the interior lamp 24, HVAC ducts 28 and/or wiring harness 26, are then positioned on the roof panel 12.
  • a polyurethane foaming composition is poured or sprayed into the foaming cavity 52 and between the roof panel 12 and the trim layer 18 and allowed to expand or free rise as the upper mold 54 is closed.
  • the foaming composition continues until it fully occupies the foaming cavity 52 and cures to form the polyurethane foam substrate 16.
  • the polyurethane foam cures the upper surface forms a tacky skin.
  • the skin rises until it contacts the roof panel 12, which restricts further rising and adheres thereto.
  • the substrate 16 will become integrally or self bonded to the roof panel 12 and the trim layer 18, forming a composite or sandwich construction.
  • the polyurethane foam substrate 16 is a closed cell rigid material in the range of 4 to 7 pounds per cubic foot.
  • the roof module assembly 10 is removed from the lower mold 46 and may then be assembled into a partially assembled vehicle.
  • the roof module assembly 10 is presented to the structural adhesive 34 disposed on the exterior flange 32.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Manufacturing & Machinery (AREA)
  • Body Structure For Vehicles (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

A roof module assembly (10) for a passenger vehicle has a polyurethane foam substrate (16) having an upper surface and a lower surface. A decorative trim cover layer (18) is molded to the lower surface of the foam substrate. The upper surface of the foam substrate (16) is molded to an exterior roof panel (12) for providing structural support to the exterior roof panel (12).

Description

ROOF MODULE ASSEMBLY HAVING A FOAM-IN-PLACE HEADLINER
Field of the Invention The subject invention generally relates to a roof module assembly for a vehicle having a foam-in-place headliner. More specifically, the invention relates to a foam headliner integrally formed with a roof panel.
Background Of The Invention Motor vehicle headliners typically comprise a trim layer, or outer, layer that presents a major exterior appearance of the vehicle ceiling, a foam intermediate layer, and some form of a structural component. The structural component provides the headliner with structural integrity so that the headliner will maintain its installation configuration without sagging when attached to the roof panel of the vehicle. A typical example of a prior art headliner is described in United States patent nos. 5,683,796 and 5,721,038.
The headliner is typically fastened to the roof panel of the vehicle through the use of fasteners or adhesives. Magnets are also commonly used to attach the headliner to the roof panel.
Additionally, the roof panel must also be reinforced to prevent sagging. Bows are commonly used with the headliner to provide structural support for the headliner and at the same time, the roof panel.
The use of fasteners and bows is cumbersome and time consuming. Additionally, as the headliner is made more rigid, it becomes more difficult to insert it through a window of a partially assembled vehicle since the width of the headliner often exceeds the width of the front or rear window opening.
Summary Of The Invention
The disadvantages of the prior art may be overcome by providing a roof module assembly which is molded to the roof panel, thereby providing structural support to both the headliner and the roof panel.
According to one aspect of the invention, there is provided a roof module assembly for a passenger vehicle having a foam substrate including an upper surface and a lower surface. A decorative trim cover layer is molded to the lower surface of the foam substrate. The upper surface of the foam substrate is molded to an exterior roof panel for providing structural support to the exterior roof panel.
According to another aspect of the invention, there is provided a method of making a roof module assembly comprising the steps of providing a trim layer in a contoured mold, positioning an exterior roof panel in spaced relation with the trim cover layer defining a foaming cavity therebetween, providing a foaming composition between the roof panel and the trim cover layer, expanding the foaming composition to fully occupy the foaming cavity and cured to formed a foam substrate self bonded between the roof panel and trim cover layer, and removing roof module assembly from the mold.
Brief Description Of The Drawings
Figure 1 is a partial cross-sectional view of the roof module assembly having overhead components molded therein;
Figure 2 is a partial cross-sectional view of the roof module assembly showing an interface with a vehicle door; and
Figure 3 is a front view of a mold associated with the method of making the roof module assembly.
Detailed Description Of The Preferred Embodiment Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a sectional view of a roof module assembly 10 for use in an automotive vehicle is generally shown in Figures 1 and 2.
The roof module assembly 10 includes an exterior roof panel 12 having a generally planar underside 14 with an upper surface of a polyurethane foam substrate 16 bonded thereto. A trim layer 18 of headliner fabric or trim cover material is adhered to the lower surface of the foam 16 such that the foam 16 is disposed between the roof panel 12 and the trim layer 18. The trim layer 18 forms an interior overhead surface and comprises either woven or non-woven material, such as cloth, or any other material commonly used in an automotive interior as may be desired, including felt type materials. Additionally, the trim layer 18 could comprise a multi layer laminate composite having a fabric layer, a soft foam layer and a film layer. The foam substrate 16 is molded to complement the aesthetic, and dimensional requirements of the interior overhead surface. A generally U-shaped structural support beam 19 is affixed to the underside 14 of the roof panel 12 along a longitudinal periphery 20 of the roof panel 12. The outer peripheral edge of the roof panel 12 is curled around a portion of the support beam 19 and forms a flange 22 with the support beam 19 for securing the support beam 19 to the roof panel 12. However, spot welds may be added between the support beam 19 and the roof panel 12, if necessary. Additionally, the support beam 19 provides structural support to the roof module assembly 10 during assembly operations and thereafter.
The roof panel 12 is typically a solid, planar stamped piece of sheet metal. Roof panel 12 is preferably primed and painted with a polyurethane based paint. As an alternative, however, the roof panel 12 can be formed, or molded, out of a composite material such as, for example an organic plastic material. A plastic roof panel 12 would provide an additional mass savings to the vehicle, while the foam substrate 16 provides sufficient structural support to the plastic roof panel 12 eliminating the need for structural cross car beams. The plastic roof panel 12 may be affixed to the support beam 19 with a structural adhesive or an equivalent.
As shown in Figure 1, a lamp 24 may be molded into the foam 16. The lamp 24 can be positioned in the roof module assembly 10 at any location, such as, for example, adjacent the support beam 19, above the driver's seat and passenger's seat, and the rear seat. One or more electrical wiring harnesses 26 may also be molded into the roof module assembly 10 for providing electrical current to the lamp 24 and to any other electrical component disposed upon the roof module assembly 10. The wiring harness 26 includes a free hanging connector for connecting to the vehicle electrical harness as is known in the art of vehicle electrical circuits. The connector is typically located along a side panel of the vehicle.
The roof module assembly 10 may further include a heating, venting and air conditioning duct 28 (HVAC) disposed within the foam 16 for meeting HVAC requirements for the vehicle passenger compartment.
The roof module assembly 10 may include any of the components typically associated with vehicle overhead systems such as, for example, head impact protection panels, head impact protection air bags, tear seams for air bag deployment, a sun roof, coat hooks, assist grips, overhead consoles, speakers and sun visors.
As shown in Figures 1 and 2, the vehicle includes a structural roof rail 30 concealed by an exterior sheet metal flange 32 which is fixedly attached to the structural roof rail 30. The exterior flange 32 forms a surface to which the roof module assembly 10 is affixed. A structural adhesive 34 is disposed between the exterior flange 32 and the support beam 19 for securing the roof module assembly 10 to the roof rail 30, and thus, to the vehicle. However, other methods of attachment are contemplated as a particular design may require. The foam 16 and the trim layer 18 is formed to define a lip 36 presenting a channel
37 for aligning, receiving and attaching a first end 39 of an interior body side trim panel 38 with the roof module assembly 10. The body side trim panel 38 covers and conceals the structural roof rail 30 and other body components from view within the interior compartment of the vehicle. The lip 36 extends from the A-pillar of the vehicle to the side panel for providing alignment for the full length of the passenger compartment.
As shown in Figure 2, the body side trim panel 38 is aligned and attached at an opposite second end 41 to the lip 36 by a mounting clip 40 having a bulb seal 42 adjacent a vehicle door 44 for sealing and preventing outside elements from entering the passenger compartment as is known in the art of vehicle weather proofing. Referring to Figure 3, the roof module assembly 10 of the present invention is manufactured by providing a molding apparatus. Preferably, the molding apparatus utilized to carry out the method of the present invention is more particularly described in United States patent nos. 5,683,796 and 5,721,038. Alternatively, a reaction injection molding (RIM) apparatus could also be utilized. Trim layer 18 is placed on a movable upper mold 54. The upper mold 54 includes a contoured mold surface 47 for supporting the trim layer 18. Optionally, the upper mold 54 is provided with vacuum ports connected to a source of vacuum to draw the trim layer 18 into contact with the mold surface 47.
The roof panel 12 is mounted in cavity 50 of a lower mold 48. Magnets or clips are provided to retain the roof panel 12 in the lower mold 48. The roof panel 12 is positioned in a spaced relation with the trim layer 18 defining a foaming cavity 52 therebetween.
The desired accessory components, such as the interior lamp 24, HVAC ducts 28 and/or wiring harness 26, are then positioned on the roof panel 12.
A polyurethane foaming composition is poured or sprayed into the foaming cavity 52 and between the roof panel 12 and the trim layer 18 and allowed to expand or free rise as the upper mold 54 is closed. The foaming composition continues until it fully occupies the foaming cavity 52 and cures to form the polyurethane foam substrate 16. As the polyurethane foam cures the upper surface forms a tacky skin. The skin rises until it contacts the roof panel 12, which restricts further rising and adheres thereto. The substrate 16 will become integrally or self bonded to the roof panel 12 and the trim layer 18, forming a composite or sandwich construction. Preferably, the polyurethane foam substrate 16 is a closed cell rigid material in the range of 4 to 7 pounds per cubic foot.
The roof module assembly 10 is removed from the lower mold 46 and may then be assembled into a partially assembled vehicle. The roof module assembly 10 is presented to the structural adhesive 34 disposed on the exterior flange 32. The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that the invention may be practiced otherwise than as specifically described.

Claims

What is claimed is:
1. A roof module assembly for a vehicle comprising: a decorative trim layer; an exterior roof panel; and a polyurethane foam substrate disposed between said decorative trim layer and said exterior roof panel; said foam substrate self bonded to said exterior roof panel and said trim layer providing structural support to said exterior roof panel.
2. A roof module assembly as set forth in claim 1 further including a pair of spaced structural support beams attached along side edges of said roof panel for mounting and supporting said roof module assembly on the vehicle.
3. A roof module assembly as set forth in claim 2 further including at least one accessory component molded in said foam substrate between said exterior roof panel and said trim layer.
4. A roof module assembly as set forth in claim 3 wherein said accessory component includes a lamp.
5. A roof module assembly as set forth in claim 3 wherein said accessory component includes an electrical wiring harness.
6. A roof module assembly as set forth in claim 3 wherein said accessory component includes an HVAC duct.
7. A roof module assembly as set forth in claim 3 further wherein an outer peripheral portion of said foam substrate and said trim layer include a lip defining a longitudinal channel in said roof module assembly adapted to receive, align and attach an interior trim panel thereto.
8. A roof module assembly as set forth in claim 1 wherein said roof panel is pre-painted with a polyurethane based paint.
9. A method of making a roof module assembly comprising the steps of: providing a trim layer in a contoured mold; positioning an exterior roof panel in spaced relation with the trim layer defining a foaming cavity therebetween; providing a polyurethane foaming composition between the roof panel and the trim layer; expanding the foaming composition to fully occupy the foaming cavity and curing the foaming composition to form a foam substrate self bonded between the roof panel and trim layer; and removing roof module assembly from the mold.
10. A method as set forth in claim 9 further including position at least one accessory component in the mold adjacent the trim layer and expanding the foaming composition about the component secured between the trim layer and roof panel.
11. A method as set forth in claim 10 wherein said step providing a foaming composition includes pouring a polyurethane foaming composition between the roof panel and the trim layer.
12. A method as set forth in claim 10 wherein said step providing a foaming composition includes injecting a polyurethane foaming composition between the roof panel and the trim layer.
13. A method as set forth in claim 10 wherein said step providing a foaming composition includes spraying a polyurethane foaming composition between the roof panel and the trim layer.
14. A method as set forth in claim 9 wherein said method includes a pre-step of painting the panel with a polyurethane based paint.
PCT/CA2001/000080 2000-01-25 2001-01-24 Roof module assembly having a foam-in-place headliner Ceased WO2001054949A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2001228242A AU2001228242A1 (en) 2000-01-25 2001-01-24 Roof module assembly having a foam-in-place headliner

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US17797000P 2000-01-25 2000-01-25
US60/177,970 2000-01-25

Publications (1)

Publication Number Publication Date
WO2001054949A1 true WO2001054949A1 (en) 2001-08-02

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1334878A3 (en) * 2002-02-08 2004-11-17 ArvinMeritor GmbH Roof unit for vehicle and method for manufacturing the same
DE10158961B4 (en) * 2001-12-03 2007-08-16 Webasto Ag Flat outer part for vehicle bodies
EP2070806A2 (en) 2007-12-13 2009-06-17 Schmitz Cargobull AG Vehicle roof for a van body, and van body with such a vehicle roof
US7776174B2 (en) 2004-04-19 2010-08-17 Intier Automotive Inc. Embossed headliner and method of making same
US8133419B2 (en) 2005-12-19 2012-03-13 Dow Global Technologies Llc Method for making automotive headliners
CN107487396A (en) * 2016-09-22 2017-12-19 宝沃汽车（中国）有限公司 Instrument board alignment schemes and instrument method of plate installation
WO2019009851A3 (en) * 2017-02-23 2019-03-28 Pimsa Otomotiv Anonim Sirketi Roof insulation material for vehicles and production method
US11511610B2 (en) 2018-11-12 2022-11-29 Shape Corp. Vehicle door carrier with integrated edge seal and method of manufacture

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Publication number Priority date Publication date Assignee Title
EP0300889A1 (en) * 1987-07-20 1989-01-25 Automobiles Peugeot Car roof and ceiling unit
US5683796A (en) 1995-10-05 1997-11-04 Atoma International Inc. Spray urethane method of making a headliner assembly
EP0960802A2 (en) * 1997-03-06 1999-12-01 Meritor Automotive GmbH Vehicle roof

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0300889A1 (en) * 1987-07-20 1989-01-25 Automobiles Peugeot Car roof and ceiling unit
US5683796A (en) 1995-10-05 1997-11-04 Atoma International Inc. Spray urethane method of making a headliner assembly
US5721038A (en) 1995-10-05 1998-02-24 Atoma International Inc. Spray urethane headliner assembly
EP0960802A2 (en) * 1997-03-06 1999-12-01 Meritor Automotive GmbH Vehicle roof
EP0960803A2 (en) * 1997-03-06 1999-12-01 Meritor Automotive GmbH Vehicle roof

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10158961B4 (en) * 2001-12-03 2007-08-16 Webasto Ag Flat outer part for vehicle bodies
EP1334878A3 (en) * 2002-02-08 2004-11-17 ArvinMeritor GmbH Roof unit for vehicle and method for manufacturing the same
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