Abstract:
A vehicle headliner attachment system for displaceable attachment of a headliner to a sunroof assembly frame. The attachment system includes at least one snap-in male connector including a distal insertion head adapted to be press fit into a corresponding elongated female acceptance slot disposed at a position adjacent to the perimeter of a sunroof opening. The male connector is releasably held at a support element secured to the headliner. The support element is oriented on the headliner such that the male connector is slideable along the elongated female acceptance slot without disengaging from the support element when the headliner is moved rearward relative to the assembly frame.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/161,557 filed Mar. 19, 2009, the contents of which are incorporated by reference as if set forth herein in their entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates generally to attachment systems and is more particularly directed to a system for attachment of a headliner in relation to a sunroof within a vehicle. In this regard, it is to be understood that by the term “sunroof” is meant any portal in the roof, including a moon roof, stationary vista port or the like. The attachment system incorporates a plurality of snap-in male fastening elements projecting away from support structures disposed in a pattern along portions of the headliner in adjacent relation to the sunroof opening. The male fastening elements engage slotted acceptors to permit longitudinal sliding displacement relative to the length dimension of the slot openings while substantially preventing transverse or vertical displacement during engagement. 
       BACKGROUND 
       [0003]    In many transportation vehicles, an opening is provided in the roof to permit the introduction of additional light and air during operation. Such openings are referred to generally as “sunroofs.” The sunroof typically includes an assembly frame surrounding an opening in which a sliding window is mounted. The assembly frame is secured to the underlying metal of the vehicle roof body. An aesthetic and noise damping headliner of a stabilized felt material or the like typically extends in surrounding relation to the sunroof in covering relation to the sunroof assembly frame and outboard portions of the roof. The headliner is required to be held in secure relation relative to the assembly frame. 
         [0004]    In the past, dual lock fastening systems requiring relatively high levels of installation force have been used to establish the connection of the headliner to the sunroof assembly frame. The relatively high force levels required for installation have required a worker to be positioned at the interior of the vehicle to provide adequate upward pushing force during assembly. The need for high installation forces may also lead to incidents of misalignment or partial engagement. Moreover, such systems may be prone to damage during disassembly. 
       SUMMARY 
       [0005]    The present invention provides an attachment system for a headliner relative to a sunroof assembly frame that facilitates secure attachment with low insertion force requirements. The attachment system utilizes an arrangement of male connectors arranged in a pattern across an upper surface of the headliner adapted to face upwardly away from the seating area such that the male connectors project towards the roof body. The male members are held within suitable support structures such as brackets, strips or the like that can accept and retain a male connector. By way of example only, the male connectors may be held at blocks referred to herein as “pucks” formed from a suitable material such as talc-filled polypropylene or the like. The pucks are glued or otherwise connected across the surface of the headliner facing towards the roof. 
         [0006]    In accordance with one exemplary aspect, the present invention provides a vehicle headliner attachment system for displaceable attachment of a headliner in at least partial covering relation to a sunroof assembly frame. The attachment system includes at least one snap-in male connector including a distal insertion head adapted to be press fit into a corresponding elongated female acceptance slot disposed at a position adjacent to the perimeter of a sunroof opening in the assembly frame. At least one support element is adapted to be secured to the headliner. The support element is further adapted to hold the male connector with the insertion head projecting outwardly away from the headliner. The support element includes a connector retention structure adapted to releaseably hold the male connector. The support element is oriented on the headliner such that the insertion head of the male connector is slideable along the elongated female acceptance slot adjacent to the perimeter of the sunroof opening without disengaging from the support element when the headliner is moved rearward relative to the assembly frame. 
         [0007]    In accordance with another exemplary aspect, the present invention provides a vehicle headliner attachment system for displaceable attachment of a headliner in at least partial covering relation to a sunroof assembly frame. The attachment system includes at least one snap-in male connector including a distal insertion head adapted to be press fit into a corresponding elongated female acceptance slot disposed at a position adjacent to the perimeter of a sunroof opening in the assembly frame. At least one puck element is adapted to be secured to the headliner. The puck element is further adapted to hold the male connector with the insertion head projecting outwardly away from the headliner. The puck element includes a connector retention structure adapted to slidingly receive the male connector such that the male connector is slidable along an insertion slot within the connector retention structure and is substantially blocked from movement in directions transverse to the insertion slot. The puck element is oriented on the headliner such that the insertion head of the male connector is slideable along the elongated female acceptance slot adjacent to the perimeter of the sunroof opening substantially without movement relative to the insertion slot when the headliner is moved rearward relative to the assembly frame. 
         [0008]    In accordance with another exemplary aspect, the present invention provides a vehicle headliner attachment system for displaceable attachment of a headliner in at least partial covering relation to a sunroof assembly frame. The attachment system includes at least one snap-in male connector including a “W” profile distal insertion head adapted to be press fit into a corresponding elongated female acceptance slot disposed at a position adjacent to the perimeter of a sunroof opening in the assembly frame. The snap-in male connector further includes a split level base including a lower level held by a post in spaced apart relation from an upper level. At least one puck element is adapted to be secured to the headliner. The puck element is further adapted to hold the male connector with the insertion head projecting outwardly away from the headliner. The puck element includes an integral raised doghouse structure including a pair of lateral stand-off legs and an upper platform extending between the stand-off legs, wherein the upper platform includes an insertion slot adapted to slidingly receive the male connector such that the upper platform of the doghouse is disposed between the lower level and the upper level of the split level base. The male connector is slideable along the insertion slot relative to the surface of the puck and is substantially blocked from movement in directions transverse to the insertion slot. The puck element is oriented on the headliner such that the insertion head of the male connector is slideable along the elongated female acceptance slot adjacent to the perimeter of the sunroof opening substantially without movement relative to the insertion slot when the headliner is moved rearward relative to the assembly frame. 
         [0009]    In accordance with one exemplary arrangement, male connectors attached to pucks oriented along lateral sides of the opening in the headliner may engage “C” channel acceptors facing downwardly away from the lateral sides of the sunroof assembly frame. The male connectors attached to pucks oriented along the base of the sunroof opening in the headliner may project through variable width slots in the rear rail of the assembly frame. Using this arrangement, assembly may be carried out by snap-in connection. Disassembly may be carried out by sliding the male fastening elements longitudinally out of the corresponding channel acceptors and slot openings. Engagement and disengagement may be carried out with low force requirements. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is an image illustrating an exemplary sunroof assembly frame showing positions for placement of “C” channel members or other channel acceptors along lateral sides and positions for slot openings along a side of the assembly frame; 
           [0011]      FIG. 2  is a plan view showing exemplary positions for placement of pucks holding male connectors across an upper surface of a headliner in adjacent relation to an opening within the headliner; 
           [0012]      FIG. 3  illustrates an exemplary configuration of a puck for attachment across a surface of the headliner, the puck includes a doghouse for acceptance and retention of an illustrated exemplary “W” head male connector; 
           [0013]      FIG. 4  is a cut-away assembly view taken generally along line  4 - 4  of  FIG. 3  illustrating attachment of the exemplary “W” head male connector within the doghouse of an exemplary attachment puck; 
           [0014]      FIG. 5  illustrates a first exemplary “C” channel member adapted to accept a “W” head male connector; 
           [0015]      FIG. 6  illustrates a second exemplary “C” channel member adapted to accept a “W” head male connector; and 
           [0016]      FIG. 7  illustrates an exemplary acceptance slot for placement along the rear rail of the sunroof assembly frame; 
       
    
    
       [0017]    Before the embodiments of the invention are explained in detail, it is to be understood that the invention is in no way limited in its application to the details of construction and/or the arrangements of the components set forth in the following description or illustrated in the drawings. Rather, the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for purposes of description only and should not be regarded as limiting. The use herein of “including”, “comprising”, and variations thereof is meant to encompass the items listed thereafter and equivalents, as well as additional items and equivalents thereof 
       DETAILED DESCRIPTION 
       [0018]    Reference will now be made to the drawings wherein like elements are designated by like reference numerals in the various views.  FIG. 1  illustrates an exemplary sunroof assembly frame  10  surrounding a sunroof opening  11  adapted to house a slideable panel of glass or other material in a manner as will be well known to those of skill in the art. In this regard, the illustrated surface of the assembly frame  10  is adapted to face downwardly away from a roof body panel and towards the interior of a vehicle passenger compartment (not shown). As illustrated through joint reference to  FIGS. 1 and 5 , the assembly frame  10  includes attachment points for a pair of first “C” channel members  12  disposed along lateral sides of the assembly frame  10  adjacent the forward cross rail of the assembly frame  10 . As illustrated through joint reference to  FIGS. 1 and 6 , the assembly frame  10  also includes attachment points for a pair of second “C” channel members  13  disposed along lateral sides of the assembly frame  10  at positions rearward of the first “C” channel members. Of course, a larger or smaller number of “C” Channel members may be used as desired. As shown, the “C” channel members  12 ,  13  are oriented generally longitudinally relative to the lateral sides of the assembly frame  10  and are also in substantial alignment with the length dimension of the vehicle. 
         [0019]    As best illustrated through joint reference to  FIGS. 1 and 7 , in the exemplary arrangement the assembly frame  10  also includes a number of variable width cut-out slots  14  disposed generally along a rear rail of the assembly frame  10 . As shown, one exemplary configuration for the variable width cut-out slots  14  includes a narrow finger segment  16  projecting away from a wider cut-out base segment  18 . The finger segment  16  preferably has a substantially constant width along its length dimension. In this arrangement the finger segment  16  projects generally towards the forward cross rail with the base segment  18  being disposed along a raised edge of the rear rail. Thus, the base segment  18  is angled upwardly relative to the finger segment  16  at a position rearward of the finger segment. In this regard, it will be understood that within this application the terms “forward” and “rearward” and counterparts refer to positions relative to the orientation of the vehicle compartment such that a front seated passenger is considered to be rearward of the windshield or other forward surface. 
         [0020]      FIG. 5  illustrates an exemplary construction for the first pair of “C” channel members  12 . As shown, the exemplary first “C” channel members  12  may each include a first support platform  20  of elongated, substantially rectangular geometry. Attachment openings  21  extend through the first support platform  20  for acceptance of screws or other attachment devises (not shown) for connection to the assembly frame  10 . A pair of spaced-apart first ramp members  22  extend in substantially parallel relation to one another in the length dimension inboard of lateral edges of the first support platform  20 . As shown through joint reference to  FIGS. 1 and 5 , the first ramp members  22  each have a rearward end and a forward end. The elevation relative to the first platform  20  increases from the rearward end to the forward end. The first ramp members  22  rise from the surface of the first support platform  20  to a corresponding pair of first elevated ledges  26 . The pair of first elevated ledges  26  have a generally flat, planar construction defining a pair of first overhang structures  28 . As shown, the inboard edges of the first overhang structures  28  project from the planes of the first ramp members  22  towards the centerline of the first support platform  20 . The inboard edges of the first overhang structures  28  define the sides of a first acceptance gap opening  30  disposed above a first platform opening  32  in the plane of the first support platform  20 . The first elevated ledges  26  in conjunction with the underlying first support platform  20  thus define a substantially “C” shaped cross-section which may be used to engage a “W” head male connector in a manner as will be described further hereinafter. 
         [0021]      FIG. 6  illustrates an exemplary construction for the pair of second “C” channel members  13 . As shown, the exemplary second “C” channel members  13  each include a second support platform  36  of elongated, substantially rectangular geometry. Attachment openings  37  extend through the second support platform  20  for acceptance of screws or other attachment devises (not shown) for connection to the assembly frame  10 . A pair of second spaced-apart ramp members  38  extends in substantially parallel relation to one another in the length dimension inboard of lateral edges of the second support platform  36 . As shown through joint reference to  FIGS. 1 and 6 , the second ramp members  38  each have a rearward end and a forward end. The elevation relative to the second support platform  36  increases from the rearward end to the forward end. The second ramp members  38  rise from the surface of the second support platform  36  to a pair of corresponding second elevated ledges  40  of generally flat, planar construction defining a pair of second overhang structures  42 . The inboard edges of the second overhang structures  42  project from the planes of the second ramp members  38  towards the centerline of the second support platform  36 . As shown, the inboard edges of the second overhang structures  42  define the sides of a second acceptance gap opening  44  disposed above a second platform opening  46  in the plane of second support platform  36 . The second elevated ledges  40  in conjunction with the underlying second support platform  36  thus define a substantially “C” shaped cross-section which may be used to engage a “W” head male connector in a manner as will be described further hereinafter. 
         [0022]    The “C” channel members  12 ,  13  and the cut-out slots  14  are each adapted to receive and retain a “W” head male connector  50  ( FIG. 3 ). Of course, it will be understood the “W” head male connector  50  is exemplary only, and any suitable male connector may likewise be used. Such male connectors may be formed from materials such as molded polymers or the like as will be known to those of skill in the art. In the exemplary illustrated embodiment, the “W” head male connector  50  includes a split base having a lower level  52  and an upper level  54  held in connected and spaced-apart relation by a generally centrally located pillar (not shown). In the illustrated exemplary construction, both the lower level  52  and the upper level  54  have a generally planar configuration although other configurations may likewise be used. The exemplary male connector  50  also includes an outwardly projecting insertion head  56 . As shown, the insertion head  56  has a generally “W” shaped profile defined by a substantially fixed position center post  58  with a pair of bendable wings  60  extending in angled relation downwardly from the distal end of the center post  58 . The bendable wings  60  preferably have a reduced thickness in the vicinity of the connection to the center post  58  so as to facilitate spring-like flexing of the wings  60  towards the center post  58  upon application of an applied inward compression force. 
         [0023]    As best illustrated through joint reference to  FIGS. 3 , and  4 , in the exemplary practice the male connector  50  is operatively connected to a puck  62  of generally block-like construction. The puck  62  may be formed from a suitable material such as talc-filled polypropylene or other material as may be desired. As shown, the exemplary puck  62  includes an integral raised profile doghouse  64  adapted to receive the male connector  50  such that the insertion head  56  of the male connector projects outwardly away from the puck  62 . As shown, in the exemplary embodiment, the doghouse  64  includes a pair of relatively narrow width lateral stand-off legs  66  running substantially along the length of the doghouse  64 . The stand-off legs extend away from the upper surface of the puck  62  to a doghouse upper platform  68 . As shown, portions of the doghouse upper platform  68  extend inwardly away from the lateral stand-off legs to define supported ledges held in raised and spaced-apart relation from the upper surface of the puck  62 . 
         [0024]    In the exemplary embodiment, the doghouse upper platform  68  includes an elongated insertion slot  70  adapted to slidingly receive and retain a central connection post (not shown) extending between the lower level  52  and the upper level  54  of the male connector base in substantial alignment with the center post  58  of the insertion head  56 . In the exemplary arrangement, the exemplary insertion slot  70  has a converging chute structure with a wide entrance  72  converging towards a post retention segment  74  of substantially constant width for housing the post connecting the lower level  52  and the upper level  54  of the male connector base. As will be appreciated, such a chute structure may be beneficial in promoting centered insertion of the male connector  50  into the doghouse  64 . 
         [0025]    As best seen in  FIG. 4 , in order to promote secure retention of the male connector  50  within the doghouse  64 , the thickness of the doghouse upper platform  68  is preferably substantially equivalent to the spacing distance between the lower level  52  and the upper level  54  of the male connector base. Likewise, the width of the post retention segment  74  is preferably substantially equivalent to the effective diameter of the connection post extending between the lower level  52  and the upper level  54  of the male connector  50 . Such an arrangement substantially secures the male connector  50  against displacement in the vertical direction as well as against displacement transverse to insertion slot  70  and the flex direction of the insertion head wings  60 . However, movement of the male connector  50  along the insertion slot  70  substantially in the flex direction of the insertion head wings  60  is nonetheless permitted. 
         [0026]    As shown, the exemplary puck  62  may also include a tab  76  projecting outwardly from the puck  62 . Such tabs may be used in conjunction with automated equipment to aid in locating and installing the pucks on the headliners. The tab  76  also may be grasped by a user to aid in manipulating the puck  62  and the attached male connector  50 . 
         [0027]    As best seen in  FIG. 2 , a plurality of pucks  62  as previously described may be arranged in a pattern along segments of a headliner  80  in surrounding relation to a headliner opening  82  which is adapted to be positioned in substantially aligned relation with the sunroof opening  11  in the assembly frame  10 . By way of example only, such a headliner may be formed from fusion bonded felt, pre-formed plastic or similar material. As will be appreciated, such headliner materials typically have some degree of stiffness and are molded by a thermal process to have a desired shape. However, other materials may likewise be used. The attachment of the pucks  62  to the headliner  80  may be by adhesive or other attachment mechanisms as may be desired. In this regard, the pucks  22  project away from the underside of the headliner  80  so as to face towards the surface of the assembly frame  10  which is illustrated in  FIG. 1 . As shown, the positions of the pucks  62  are arranged in a pattern to be substantially aligned with the positions of the corresponding “C” channel members  12 ,  13  and the cut-out slots  14 . 
         [0028]    During attachment of the headliner  80 , to the assembly frame  10 , the “W” head male connectors  50  extend outwardly from the pucks  62  and towards the illustrated surface of the assembly frame  10 . In this orientation, the “W” head male connectors  50  positioned along lateral sides of the headliner opening  82  may be press fit into the corresponding “C” channel members  12 ,  13  projecting downwardly from the lateral sides of the assembly frame  10 . Likewise, the “W” head male connectors positioned along the rearward edge of the headliner opening  82  may be press fit into the corresponding cut-out slots  14  disposed along the rear rail of the assembly frame  10 . 
         [0029]    During the press-fit operation, the “W” head male connectors  50  on pucks  62  disposed on the lateral sides at positions adjacent to the forward corners of the headliner opening  82  may be press-fit into first acceptance gap openings  30  in the first “C” channel members  12 . During this press-fit operation, the wings  60  of insertion heads  56  ( FIG. 3 ) will flex inwardly as they pass through the first acceptance gap openings  30  and will then snap behind the first overhang structures  28  such that they are held in place against vertical removal. Likewise, the “W” head male connectors  50  on pucks  62  disposed on the lateral sides at positions adjacent to the rear corners of the headliner opening  82  may be press-fit into corresponding second acceptance gap openings  44  in the second set of “C” channel members  13 . During this press-fit operation, the wings  60  of insertion heads  56  ( FIG. 3 ) will flex inwardly as they pass through the second acceptance gap openings  44  and will then snap behind the second overhang structures  42  such that they are held in place against vertical removal. 
         [0030]    The “W” head male connectors  50  on pucks  62  disposed along the rear edge of the headliner opening  82  may be press-fit into corresponding finger segments  16  of corresponding cut-out slots  14  ( FIG. 7 ). During this press-fit operation, the wings  60  of insertion heads  56  will flex inwardly as they pass through the openings defined by the finger segments  16  and then snap behind the edges of the finger segments  16 . 
         [0031]    As will be appreciated, in the illustrated and potentially preferred arrangement, the length dimensions of the “C” channel members  12 ,  13  and the cut-out slots  14  are substantially aligned with the length dimension of the vehicle. Thus, in the final assembly, each of the pucks  62  is preferably oriented such that the flex direction of the wings  60  and the orientation of the insertion slot  70  in the doghouse  64  is transverse to the length dimension of the vehicle as well as to the length dimensions of the “C” channel members  12 ,  13  and the cut-out slots  14 . Accordingly, following the snap-in attachment, the male connectors  50  may be moved in sliding relation along the “C” channel members  12 ,  13  and the cut-out slots while being held within the pucks  62 . This arrangement promotes ease of attachment and removal of the headliner  80 . 
         [0032]    By way of example only, during attachment of the headliner  80  to the assembly frame  10 , the headliner  80  may be inserted into the occupant compartment of a vehicle through the windshield opening. Hooks (not shown) may be used to provide attachment of the headliner to the front rail of the assembly frame  10  in a manner as will be known to those of skill in the art. The “W” head male connectors  50  projecting away from pucks  62  along lateral sides of the headliner opening  82  are then pressed into the corresponding “C” channel members  12 ,  13  arranged along the lateral sides of the assembly frame  10 . The “W” head male connectors projecting away from pucks  62  disposed along the lower edge of the headliner opening are then are pressed into the finger segments  16  of the cut-out slots  14  at the rear rail of the assembly frame  10 . Of course, this order of insertion may be reversed if desired. 
         [0033]    By way of example only, during disengagement of the headliner, the front hooks of the headliner are disengaged and the headliner is pushed towards the rear of the vehicle passenger compartment. The “W” head male connectors  50  projecting away from pucks  62  along lateral sides of the headliner opening slide out of the corresponding “C” channel members  12 ,  13  and the “W” head male connectors projecting away from pucks  62  disposed along the lower edge of the opening in the headliner slide from the narrow finger segments  16  to the wider base segments  18  of the cut-out slots. In this arrangement the headliner can fall away from the assembly frame  10  and be removed. Moreover, the components are not damaged during disassembly and may be reused. 
         [0034]    As will be noted through comparison of  FIGS. 5 and 6 , in the illustrated arrangement, the first elevated ledges  26  in the first “C” channel members  12  are shorter than the second elevated ledges  40  in the second “C” channel members  13 . Such an arrangement provides a degree of additional control during disengagement. Specifically, as the headliner  80  is pulled rearwardly, the shorter first elevated ledges  26  in the first set of “C” channel members  12  cause the forward portion of the headliner  80  to disengage before the portions held at the second “C” channel members  13 . Likewise, orienting the base segments  18  of cut-out slots  14  on a raised surface extending upwardly from the plane of the finger segments  16  may facilitate holding the rear edge of the headliner  80  in place until the final stage of disengagement. Thus, a staged, sequential disengagement of the headliner  80  may be achieved with the forward portions being released first, followed in order by the middle and rear sections. Of course, a substantially simultaneous disengagement may also be practiced if desired 
         [0035]    Of course, variations and modifications of the foregoing are within the scope of the present invention. Thus, it is to be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. the claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art.