Abstract:
The multi-segmented headliner for a vehicle includes an elongated intermediate segment, an elongated first side segment, and an elongated second side segment. In one configuration the segments are separate and form the complete headliner on assembly inside the roof of the vehicle. In another configuration the segments are joined together in a single piece, with the side segments being movable relative to the intermediate segment. Both configurations permit the replacement of the headliner of a van or sport utility by moving the headliner either in separate segments, or folded if a single piece, through the opening defined by the rear door or liftgate of the vehicle.

Description:
TECHNICAL FIELD 
     The embodiments of the disclosed invention relate generally to headliners for vehicles. More particularly, the embodiments relate to a multi-segmented headliner for a vehicle which can be readily installed on the roof of the vehicle. 
     BACKGROUND OF THE INVENTION 
     Vehicle headliners are used to both cover the bare material (usually metal) of the vehicle roof and to provide protection to the vehicle occupant in a crash event. Headliners are typically composed of multiple layers which include a relatively rigid or semi-rigid backing and an outer cover of a woven or non-woven material which is color-coordinated to the rest of the vehicle for aesthetic purposes. 
     Headliners are typically composed of a single molded piece of material. The outer cover may be added to the molded piece after formation or may be molded with the backing in a single mold during a single or multi-stepped process. The headliner of a vehicle must be wide enough not only to provide coverage for the roof, but also must be wide enough to cover the area between the roof and the side walls. In vans and in sport utility vehicles the headliner is both wide and long, usually long enough to cover the entire area of the roof from the windshield opening to the rear door or liftgate opening. Ordinarily the considerable width prohibits passage of the headliner through the rear opening of the van or sport utility vehicle. On initial vehicle assembly this prohibition is not usually a problem as the windshield has not yet been installed and the headliner can be passed through the windshield opening. However, replacement of a van or sport utility headliner after the vehicle has been assembled is a time-consuming task. In the modern vehicle the windshield is maintained in position by a weather sealing strip that is attached by very strong adhesives to the walls that define the windshield opening. This makes removal of the windshield anticipatory to the removal of the old headliner and installation of the replacement headliner very difficult and costly. 
     As an alternative to removing the windshield, attempts have been made to pass the single piece headliner through the rear opening of the van and the sport utility vehicle. However, this opening is most ordinarily narrower than is the windshield opening and, as a consequence, the single piece headliner is too wide to permit the passage of the headliner through the rear opening without bending the piece and creating a permanent crease mark in the outer cover. Complicating this procedure is the fact that rear door and tailgate components (such as the doors and tailgates themselves as well as the liftgate struts) interfere with the procedure. 
     Accordingly, as in so many areas of vehicle technology, there is room in the art of vehicle headliner design for providing a headliner arrangement which may be installed or replaced in a vehicle&#39;s interior without the need to remove the vehicle&#39;s windshield. 
     SUMMARY OF THE INVENTION 
     The headliner assembly for a vehicle is set forth herein in its different configurations. In general, the disclosed headliner assembly includes a headliner which has three segments. The headliner has a long axis. One of the three segments is an intermediate segment that has a first longitudinal edge that is substantially parallel to the long axis of the headliner. The intermediate segment also includes a second longitudinal edge that is substantially parallel to the long axis of the headliner. The other two segments are side segments which include a first side segment and a second side segment. The first side segment has a longitudinal edge that is fittable to the first longitudinal edge of said intermediate portion. Similarly, the second side segment has a longitudinal edge that is fittable to the second longitudinal edge of the intermediate portion. 
     In one configuration the intermediate and side segments are initially provided separate from one another and form the complete headliner assembly on the roof of the vehicle. Once the three segments are positioned within the interior of the vehicle, they may either be joined and then installed on the vehicle roof as a joined assembly or the segments may be individually attached to the roof. If individually attached to the roof the intermediate segment may be attached to the roof first with the side segments entirely or partially holding the intermediate segment in place. Alternatively the side segments can be installed first followed by installation of the intermediate segment. 
     In another configuration the intermediate and side segments are joined together when manufactured, with the side segments being movable relative to the intermediate segment. Both configurations permit the replacement of the headliner of a van or sport utility by moving the headliner either in separate segments or folded if a single piece through the opening defined by the rear door or liftgate of the vehicle. 
     Other features of the various embodiments of the invention will become apparent when viewed in light of the detailed description of the preferred embodiments when taken in conjunction with the attached drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein: 
         FIG. 1  illustrates a partial perspective view of the headliner assembly in relative position as it would appear prior to placement in a vehicle, also shown in partial perspective view; 
         FIG. 2  is a sectional view of a portion of a joint of two panels connected by a clip according to the first embodiment of the panel-connecting arrangement of the invention; 
         FIG. 3  is a sectional view of a portion of a joint of two panels connected by a clip according to the second embodiment of the panel-connecting arrangement of the invention; 
         FIG. 4  is a sectional view of a portion of two panels illustrating an arrangement for attaching the panels to the roof of a vehicle according to the first embodiment of the panel-attaching arrangement of the invention; 
         FIG. 5  is a sectional view of a portion of two panels illustrating an arrangement for attaching the panels to the roof of a vehicle according to the second embodiment of the panel-attaching arrangement of the invention; 
         FIG. 6  is a perspective view of an alternate embodiment of the headliner of the invention; 
         FIG. 7  is a sectional view of the headliner of  FIG. 6  taken along lines  7 - 7  of that figure; and 
         FIG. 8  is a sectional view of the alternate embodiment of the headliner of the invention similar to that shown in  FIG. 7  showing the side panels in their folded positions for fitting through an area defined by the inside edge of a vehicle liftgate. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for plural constructed embodiments. These specific parameters and components are included as examples and are not meant to be limiting. 
     With reference to  FIG. 1 , a partial perspective view of an embodiment of the headliner assembly of the disclosed invention, generally illustrated as  10 , is shown. The headliner assembly  10  is shown in its general position prior to installation in the roof of a vehicle of which a partial vehicle, generally illustrated as  12 , is shown. While the present invention finds particular utility in a passenger van or in a sports utility vehicle, it is to be understood that the headliner of the present invention may well be fitted in other vehicles while still achieving the general goal of the present invention which is to provide a headliner which can be readily installed in a vehicle interior without the need to remove the vehicle&#39;s windshield. By providing a headliner of the disclosed invention which can be reduced from its installed dimension to a pre-installation dimension, the headliner can be passed through openings of the vehicle including the tailgate and door opening for replacement. This arrangement also allows for added flexibility at the installation stage. 
     The headliner assembly  10  includes a first side panel  14 , a second side panel  16  positioned opposite said first side panel  14 , and an intermediate panel  18 . The panels  14 ,  16  and  18  are shown spaced apart from one another as they would appear prior to installation according to the present embodiment of the invention. While three panels  14 ,  16  and  18  are disclosed, it is to be understood that as few as two panels and more than three may be used while keeping within the spirit of the present invention. 
     The panels  14 ,  16  and  18  may be made from materials known in the art. In general the panels  14 ,  16  and  18  include an inner structural layer and an outer cover layer. Other layers may be included as desired for both structural and acoustic enhancement. Preferably, but not exclusively, the side panels  14  and  16  are composed of a structural, impact-absorbing material while the intermediate panel  18  is an acoustic panel. The acoustic material may be any of a variety of materials, including a sound absorbing foamed layer or a fibrous polyethylene terephthalate material. The structural, impact absorbing material may also be of any of a variety of materials, including ABS plastic and fiberglass. The outer cover layer (or the A surface) is generally composed of a fabric which is attached to the inner layer either during the formation process or after each layer is prepared individually. The outer cover layer may also be composed of a variety of materials, including woven and non-woven cloth. 
     The suggested layering of the panels  14 ,  16  and  18  are illustrated in  FIGS. 2 through 8 . Referring first to  FIG. 2 , a portion of the intermediate panel  18  is shown. The intermediate panel  18  includes an inner acoustic layer  20  and an outer cover layer  22 . Also shown in  FIG. 2  is a portion of the side panel  14  which includes an inner impact absorbing layer  24  and the outer cover layer  22 . 
     The panels  14 ,  16  and  18  of the present invention may be joined to one another and to the roof of the vehicle  12  by different methods. Such methods are disclosed in  FIGS. 2 through 5  which are intended as being illustrative rather than limiting. In addition to showing the possible layering of the outer panel  14  and the intermediate panel  18 ,  FIG. 2  also illustrates an embodiment of the method of joining two adjacent panels. According to this embodiment, the side panel  14  includes a joining end  26  which is angled relative to the rest of the outer panel  14 . Similarly, the intermediate panel  18  includes a joining end  28  which is angled relative to the rest of the intermediate panel  18 . The joining end  26  and the joining end  28  are positioned so that they abut one another as illustrated. A spring clip  30  is provided to maintain the abutment illustrated in  FIG. 2 . The spring clip  30  may be a long, continuous clip that is fitted substantially along the length of the abutment defined by the joining end  26  and the joining end  28  or may be one of several of the same clips positioned at spaced intervals along the length of the abutment. A visually pleasing appearance is formed at the abutment of the two panels  14  and  18 . 
     An alternative method of joining two adjacent panels is illustrated in  FIG. 3  which shows two sectional views of a side panel  40  and an intermediate panel  42 . The panels  40  and  42  are similar respectively to the panels  14  and  18  in configuration and composition. However, the arrangement for joining the two panels varies from the arrangement illustrated in  FIG. 2 . Specifically, the side panel  40  includes an attachment end  44  which includes a channel  46  that is formed substantially along the entire length of the attachment end  44 . The attachment end  44  also includes a fastener attachment surface  48  and a fastener-passing aperture  50  formed therethrough. The intermediate panel  42  includes an attachment end  52  which has a flange  54  formed substantially along the entire length of the attachment end  52 . As illustrated, the attachment end  52  nests substantially within the channel  46 . A visually pleasing appearance is formed along the seam of the mated panels  40  and  42 . 
     The attachment end  52  of the intermediate panel  42  also includes a fastener surface  56  to which the base of a fastener  58  is attached by an adhesive or by mechanical attachment. The fastener  58  has a stud portion  60  extending therefrom and through the fastener-passing aperture  50  of the attachment end  44  of the side panel  40 . The attachment end  44  of the side panel  40  is drawn tight against the attachment end  52  of the intermediate panel  42  by fitting of a nut such as a pal nut  62  on the stud portion  60  as illustrated in  FIG. 3 . Alternate fasteners may be employed other than the arrangement illustrated provided that the side panel  40  is snugly mated with the intermediate panel  42 . 
     The panels  14  and  18  shown in  FIG. 2  and the panels  40  and  42  shown in  FIG. 3  may be attached to the roof of the vehicle  12  by any of a number of known methods of attachment including mechanical fasteners or adhesives. Possible methods of attaching the panels to the vehicle ceiling as well as to one another are shown in  FIGS. 4 and 5 . 
     With reference to  FIG. 4 , a sectional view of a portion of two panels, a side panel  70  and in intermediate panel  72  is shown in relation to a portion of a vehicle, generally illustrated as  74 . The vehicle  74  includes an outer roof structural portion  76  having an outer edge  78 , an inner roof structural portion  80  having an outer edge  82 , and an intermediate roof structural portion  84  having an outer edge  86 . The outer edges  78 ,  82  and  86  convene along a common edge  88  and are fastened to one another to form the common edge  88  by spot welding or by other known joining techniques. The structural roof portions  76 ,  80  and  84  are shown for illustrative purposes only and are not intended as being limiting as other configurations could be adapted for use as well. 
     The side panel  70  includes an inner edge  90 , an outer edge  92 , and a body  93 . The outer edge  92  is held in place adjacent to the common edge  88  by a polymerized weather strip  94  having a channel  96  formed therein which is held in place along the common edge  88  by friction. The weather strip  94  also has a lip  98  which extends vehicle inward. 
     The inner edge  90  generally defines an area of the side panel  70  that is inwardly folded back onto itself as illustrated in  FIG. 4 . 
     The intermediate panel  72  includes a body  100  which generally defines a first plane and an outer edge  102  which generally defines a second plane, the first and second planes being different. The body  100  and the outer edge  102  are joined by a wall  104 . The outer edge  92  of the outer panel  70  is held in position relative to the roof of the vehicle  74  by tension of the lip  98  of the weather strip  94 . The inner edge  90  substantially nests along the wall  104  and the outer edge  102  of the intermediate panel  72  and thereby holds the intermediate panel  72  in place against the inner roof structure portion  80 . Fasteners or adhesives, while usable for this fitting, are thus rendered unnecessary in holding the intermediate panel  72  in place. 
     In addition to the lateral support provided by the lip  98  of the weather strip  94 , the side panel  70  is held in place by one or more mechanical fasteners which may be of a variety of different configurations. A preferred fastener is a spring fastener  106 . The spring fastener  106  may be a stand-alone fastener or, as illustrated, may be part of a grab handle assembly  108 . As illustrated, the grab handle assembly  108  includes a grommet  110  having a peripheral flange  112 . A fastener aperture  114  is formed through the body  93  of the side panel  70  through which the spring fastener  106  extends. The peripheral flange  112  abuts the outer area surrounding the fastener aperture  114  and thus assists in holding the side panel  70  in place against the inner roof structural portion  80 . 
     While the spring fastener  106  as part of the grab handle assembly  108  is illustrated as the method of attaching the side panel  70  to the inner roof structural portion  80 , it is to be understood that other methods of attachment may be employed. Such arrangements for attachment include nylon “Christmas tree” style fasteners and other spring fasteners which are attached to the inner layer of the side panel  70  so as not to be seen by the vehicle passenger. 
     A variation of the arrangement for attaching the intermediate and side panels to the roof of a vehicle is shown in  FIG. 5 . With respect to that figure, a sectional view of a portion of two panels, a side panel  120  and an intermediate panel  122 , is shown in relation to a portion of a vehicle, generally illustrated as  124 . The vehicle  124  includes an outer roof structural portion  126  having an outer edge  128 , an inner roof structural portion  130  having an outer edge  132 , and an intermediate roof structural portion  134  having an outer edge  136 . The outer edges  128 ,  132  and  136  convene along a common edge  138  and are fastened to one another to form the common edge  138  by spot welding or by other known joining techniques. As shown, the inner roof structural portion  130  does not extend as far vehicle inward as does the inner roof structural portion  80  of the embodiment shown in  FIG. 4 . 
     With reference still to  FIG. 5 , the side panel  120  includes an inner edge  140 , an outer edge  142 , and a body  143 . The inner edge  140  is angled back slightly toward the body  143 . The outer edge  142  is held in place adjacent to the common edge  138  by a polymerized weather strip  144  having a channel  146  formed therein which is held in place along the common edge  138  by friction. The weather strip  144  also has a lip  148  which extends vehicle inwardly. 
     The intermediate panel  122  includes a body  200  which generally defines a first plane and an outer edge  202  which generally defines a second plane, the first and second planes being different. The body  200  and the outer edge  202  are joined by a wall  204 . The outer edge  142  of the outer panel  120  is held in position relative to the roof of the vehicle  124  by tension of the lip  148  of the weather strip  144 . A portion of the inner edge  140  substantially nests along the wall  204  and the outer edge  202  of the intermediate panel  122  and thereby holds the intermediate panel  122  in place against the underside of the outer roof structural portion  126 . Consistent with the method of holding the intermediate panel  72  in place as set forth in  FIG. 4 , fasteners or adhesives, while usable for this fitting, are thus rendered unnecessary in holding the intermediate panel  122  in place. 
     In addition to the lateral support provided by the lip  148  of the weather strip  144 , the side panel  120  is held in place by one or more mechanical fasteners of which the illustrated fastener is a spring fastener  206 . The spring fastener  206  may be a stand-alone fastener or, as illustrated, may be part of a grab handle assembly  208 . The grab handle assembly  208  includes a grommet  210  having a peripheral flange  212 . A fastener aperture  214  is formed through the body  143  of the side panel  120  through which the spring fastener  206  extends. The peripheral flange  212  abuts the outer area surrounding the fastener aperture  214  and thus assists in holding the side panel  120  in place against the inner roof structural portion  130 . 
     While the spring fastener  206  as part of the grab handle assembly  208  is illustrated as the method of attaching the side panel  120  to the inner roof structural portion  120 , it is to be understood that other methods of attachment may be employed as set forth above with respect to  FIG. 4 . 
     Also as set forth above, one object of the disclosed invention is to provide a practical and time-efficient approach to replacing or repairing the headliner of a vehicle without the need to remove the windshield. The embodiment disclosed in  FIGS. 1 through 5  is a multi-piece headliner. On assembly or repair, the intermediate panel is brought into the vehicle interior followed by the outer panels. The side panels are then attached to the intermediate panel to form a headliner assembly. The headliner assembly is then attached to the roof of the vehicle. This is the approach of the embodiment shown in  FIG. 2 . As an alternative, and as shown in the embodiments of  FIGS. 3 through 5 , the intermediate panel is brought into the vehicle interior and is then installed on the roof of the vehicle. The outer panels are then brought into the vehicle interior and are installed. Both of these approaches rely on the headliner being provided as separate pieces. As an alternative to the multi-piece headliner, a single-piece headliner may be used as illustrated in  FIGS. 6 through 8 . 
     With reference to  FIG. 6 , a single-piece headliner, generally illustrated as  220 , is shown. The single-piece headliner  220  has a leading edge  222  which faces vehicle forward when installed and a trailing edge  224 . The single-piece headliner  220  further includes an intermediate portion  226 , a first side portion  228  and a second side portion  230 . The first side portion  228  is attached to the intermediate portion  226  along a longitudinal, flexible joint  232 . The second side portion  230  is attached to the intermediate portion  226  along a longitudinal, flexible joint  234 . 
     The single-piece headliner  220  is preferably multi-layered and is composed of the same or similar materials as disclosed above with respect to the embodiments shown and discussed in relation to  FIGS. 2 and 3 . The single-piece headliner  220  may be composed of an inner layer and an outer layer or may be composed of more layers. Proposed layering of the single-piece headliner  220  is disclosed in  FIGS. 7 and 8 , of which  FIG. 7  is a sectional view taken along lines  7 - 7  of  FIG. 6 . As illustrated, the single-piece headliner  220  is shown in its unfolded configuration as would be the case if it was installed in the vehicle interior. 
     The single-piece headliner  220  has an inner cover layer  240  which runs the entire width (and length) of the headliner  220  as shown. The inner cover layer  240  is a single piece of material. The single-piece headliner  220  also includes an inner layer  242  which may be a combination of an acoustic layer  244  which backs the intermediate portion  226  and an inner impact absorbing layer  246  which backs the side portions  228  and  230  as illustrated or the inner layer  242  may be composed of a single material. In either event, the inner layers which back the side portions  228  and  230  are integral with the intermediate portion  226  and are flexibly joined therewith along the longitudinal, flexible joints  232  and  234  respectively. The longitudinal, flexible joints  232  and  234  are formed along and between the intermediate portion  226  and the side portions  228  and  230  by molding or by post-mold forming through cutting or routing. 
     As shown in  FIG. 7 , the width of the single-piece headliner  220  is considerable and would not be passable through the rear of the vehicle as defined by the rear door or lift-gate opening of a van or a sport utility vehicle, respectively. Such an opening is illustrated as the outline  250  of the lift-gate opening shown in  FIG. 8 . To enable insertion of the single-piece headliner  220  into the vehicle&#39;s interior without removing the windshield, the side portions  228  and  230  are folded along the longitudinal, flexible joints  232  and  234  as illustrated in  FIG. 8 . The folding of the side portions  228  and  230  reduces the overall width of the single-piece headliner  220  to allow for insertion through the rear door or lift-gate opening. Once the single-piece headliner  220  has been placed into the vehicle&#39;s interior, the side portions  228  and  230  are generally unfolded to be returned to the configuration illustrated in  FIG. 7 . The single-piece headliner  220  is then attached to the roof of the vehicle by fasteners or adhesives. 
     The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.