Abstract:
A method of assembling a roof assembly into a vehicle includes assembling the roof assembly and at least one module subassembly. The roof assembly includes a roof outer panel configured to cover a roof opening in the vehicle. The roof assembly and the module subassemblies are installed by operators working entirely outside the vehicle, resulting in increased efficiency and production cost savings.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a vehicle roof assembly and method of assembling and installing the vehicle roof assembly into a vehicle. 
     2. Background Art 
     The use of headliners to cover the interior of a vehicle roof is well known. The headliner conceals the interior structural features of the roof and presents an aesthetically pleasing appearance to the vehicle occupants. The headliner also at least partially covers a variety of components that are often assembled into the headliner itself. Such components may include sunroof assemblies, roof antennas, overhead consoles, infotainment systems, roof rail air bags, and a variety of other consoles or electronic devices. 
     Installation of headliners, which are large and relatively rigid structures, is made more difficult by the often heavy components that are installed in the headliner prior to the headliner&#39;s installation into the vehicle. The difficulty of installing a headliner is in part due to the need for an installer to work overhead from inside the vehicle. This is particularly true when the vehicle roof is attached prior to the installation of the headliner, necessitating the installation of the headliner through an open windshield or rear window. Even when an outer roof panel is installed after the headliner, overhead installation of the headliner may still be required. 
     Accordingly, it is desirable to provide a method of assembling and installing a roof assembly into a vehicle that eliminates the need for an operator to work overhead when installing the headliner or any portion of the roof assembly. 
     SUMMARY OF THE INVENTION 
     One aspect of the present invention provides a method of assembling and installing a roof assembly into a vehicle that does not require an operator to work overhead. 
     Another aspect of the invention provides a method of assembling and installing a roof assembly into a vehicle where several components of the assembly are loaded in the same station, thereby reducing the total number of assembly stations required in the general assembly facility and resulting in a labor cost savings. 
     Yet another aspect of the invention provides for increasing available space in a body shop by eliminating vehicle roof handling and welding of the vehicle roof to the vehicle in the body shop. 
     Another aspect of the invention increases vehicle assembly efficiency by moving the roof installation to the general assembly facility where vehicle components are sequenced. 
     A further aspect of the invention provides for increased flexibility by moving the roof assembly to the general assembly facility where the greater available floor space allows more installation options. 
     Accordingly, a method for assembly of a vehicle roof assembly into a vehicle is provided which comprises providing a structure defining a roof opening in the vehicle, providing a first inventory of components suitable for use inside the vehicle, and providing an inventory of panels suitable for closing the roof opening of the vehicle. At least one of the components from the first inventory of components is assembled with a panel from the inventory of panels to form a roof assembly. The roof assembly is attached to the structure defining the roof opening from outside the vehicle. 
     Another aspect of the invention provides a method for assembly of a vehicle roof assembly into a vehicle that comprises providing a structure defining a roof opening in the vehicle, providing a first inventory of components suitable for use inside the vehicle, and providing an inventory of panels suitable for closing the roof opening of the vehicle. At least one of the components from the first inventory of components is assembled with a panel from the inventory of panels and a headliner that has first and second free edges. The at least one component, the panel, and the headliner form a roof assembly. The first and second free edges of the headliner are restrained with a restraining device, and the roof assembly is installed into the vehicle by placing the headliner through the roof opening. The restraining device is then removed, and the first and second free edges of the headliner are attached to the vehicle, thereby concealing a portion of the structure defining the roof opening. 
     Yet another aspect of the invention provides a method for assembly of a vehicle roof assembly into a vehicle that comprises providing a structure defining a roof opening in the vehicle, providing a first inventory of components suitable for use inside the vehicle, and providing an inventory of panels suitable for closing the roof opening of the vehicle. At least one component is chosen from the first inventory of components, and a panel is chosen from the inventory of panels. The at least one component that is chosen from the first inventory of components is attached to the roof outer panel that is chosen from the inventory of panels to form a roof assembly. The roof assembly is then attached to the structure defining the roof opening from outside the vehicle. 
     Another aspect of the invention provides a vehicle roof assembly adapted for attachment to a structure defining a roof opening in a vehicle. The vehicle roof assembly comprises a panel having an edge for closing the roof opening of the vehicle on one side of the roof opening; the panel is selectable from an inventory of panels. Included in the vehicle roof assembly is at least one component chosen from an inventory of components. The at least one component is connected to the selected panel to form a roof subassembly. Also included is a headliner that is connectable in one manner to the roof subassembly, and in another manner to the other side of the roof opening. 
     The above object and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view illustrating a method of assembling a roof assembly into a vehicle; 
         FIG. 2  is a fragmentary perspective view of a portion of a vehicle and a roof assembly ready for installation into the vehicle; 
         FIG. 3  is a perspective view of a restraining device; 
         FIG. 4  is a perspective view illustrating the installation of side module subassemblies; 
         FIG. 5  is a perspective view illustrating the installation of headliner module subassemblies into a vehicle in accordance with an another embodiment of the invention; 
         FIG. 6  is a fragmentary perspective view illustrating the placement of a headliner module subassembly through a windshield opening in the vehicle; 
         FIG. 7  is a fragmentary perspective view illustrating the attachment of a portion of the headliner module subassembly to a side roof rail of the vehicle; and 
         FIG. 8  is a fragmentary perspective view illustrating the attachment of a roof assembly to the vehicle. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     One embodiment of the present invention is shown in  FIGS. 1-4 . A vehicle  10  has a roof opening  12  defined by headers  14  and side rails  16 . A roof assembly  18  includes a roof outer panel  20  and a plurality of components  22 . The roof outer panel  20  is chosen from an inventory of panels, and can be made from any of a variety of materials, including, but not limited to, metals, plastics, and composites. The components  22  are chosen from a first inventory of components which may include headliners, sunroof assemblies, roof antennas, infotainment systems, air ducts, switches, lights, wires and harnesses, consoles, audio components, navigation systems, display systems, compasses, thermometers, mirrors or combinations thereof. In this embodiment, the roof assembly  18  includes a plurality of electronic components  24  (electrical connectors shown in FIG.  2 ), and a headliner  26 . 
     The components  22 , including the headliner  26  and the electronic components  24 , are typically assembled prior to being shipped to the vehicle assembly plant. It is contemplated however, that all of the component assembly may occur at the vehicle assembly plant sometime prior to the roof assembly  18  being installed in the vehicle  10 . The headliner  26  is secured to the roof outer panel  20  by an adhesive that is applied in such a way so as to leave a portion of the headliner unattached to the roof outer panel  20 . The headliner  26  may be secured to the roof outer panel  20  offsite, such as at a supplier&#39;s facility, or it may be integrated into the assembly operations at the vehicle assembly plant. 
     The unattached portion of the headliner  26  includes first and second free edges  30 ,  32  which are displaceable relative to the roof outer panel  20 . The first and second free edges  30 ,  32  are located in a position corresponding to the headers  14 . The sides of the headliner  26  that correspond to the side rails  16  are configured so they do not overlap the side rails  16  when the roof assembly  18  is installed in the vehicle  10 . As explained below, separate side module subassemblies are attached after the roof assembly  18  is installed in the vehicle  10 . 
     A restraining device  34 , one example of which is shown in  FIG. 3 , is placed around the headliner  26 , including the first and second free edges  30 ,  32 , to facilitate installation of the roof assembly  18  into the vehicle  10 . The restraining device  34  can be installed around the headliner  26  before or after the headliner  26  is attached to the roof outer panel  20 . The restraining device  34  includes a hook and loop fastening device  36 , and a rigid frame  38 . The rigid frame  38  is sized to fit into the roof opening  12  without interfering with the headers  14  or the side rails  16 . The hook and loop fastening device  36  represents one of many possible configurations for the restraining device  34 . Others include using different types of fastening devices, or making the restraining device adjustable so as to obviate the need for any fastening device. 
     Installation of the roof assembly  18  into the vehicle  10  is shown in  FIGS. 1 and 2 . The roof assembly  18  is moved to the vehicle  10 , where it is shown in phantom, with a movable transport arm  40 , that helps to guide and position the roof assembly  18 . An operator controls the transport arm  40  by using guide handles  42 , which are attached to a transport frame  44 . The transport frame  44  has suction cups  46  which selectively grip and release a surface of the roof outer panel  20 . The transport frame  44  initially moves the roof assembly  18  from a storage rack  47  to an adhesive station  48 . At the adhesive station  48 , an underside  50  of the roof outer panel  20  is accessible to an operator. This allows the operator to apply an adhesive  52 , such as a pumpable urethane, to the underside  50  of the roof outer panel  20 . 
     After the roof assembly  18  is positioned over the roof opening  12 , it is then seated on the headers  14  and side rails  16  with the help of guide pin locators  54 . Once the roof assembly  18  is seated, it is secured to the vehicle  10  with the previously applied adhesive  52  and fasteners  56  that are secured to mounting holes  58 , only one of which is seen in FIG.  2 . The next step is to remove the restraining device  34 , thereby allowing the first and second free edges  30 ,  32  to spring back to their unrestrained configuration. The first and second free edges are then positioned to cover a portion of the headers  14  inside the vehicle, with further securing of the first and second free edges being performed as required. 
     As explained above, the headliner  26  is configured not to overlap the side rails  16 . One of the reasons for this is to facilitate easier installation of side roof rail air bags into the vehicle  10 .  FIG. 4  illustrates the final steps of the roof assembly installation, which includes attachment of side module subassemblies  60 . After the roof assembly  18  is secured to the vehicle  10 , which was removed from this view for clarity, the side module subassemblies  60  are attached to the vehicle.  FIG. 4  shows only a driver&#39;s side module subassembly, though its mirror image is attached on the passenger&#39;s side of the vehicle. 
     The side module subassemblies  60  include a side trim component  62 , and a side roof rail air bag assembly  64 , shown in phantom. Once the roof assembly  18  is secured to the vehicle  10 , it is a simple matter for an operator to place the side module subassemblies  60  through an open window and attach them to the vehicle. In this embodiment, rosebud clips  66  are attached to the side trim component  62 , and allow for an easy snap fit into the vehicle. In addition to the side trim component  62  and the side roof rail air bag assembly  64 , a variety of other components (not shown) can be assembled into the side module subassemblies. These components are chosen from a second inventory of components and may include assist handles, assist straps, hooks, hangers or combinations thereof. 
     Another embodiment of the present invention is shown in  FIGS. 5-8 . Unlike the previous embodiment where the headliner and some associated components were made part of the roof assembly, this embodiment includes a roof assembly  68  (see  FIG. 8 ) separate from a headliner module subassembly  70 . The roof assembly  68  includes a roof outer panel  72  and components  74  chosen from a first inventory of components. In this embodiment, the first inventory of components does not include headliners, but will typically include sunroof assemblies, roof antennas, infotainment systems, consoles or combinations thereof. It is contemplated that the heaviest vehicle interior components will be included in the roof assembly  68 . 
     The headliner module subassembly  70  is assembled from a headliner  76  and components  78 , chosen from a third inventory of components, see FIG.  5 . Typically the components  78  will include side roof rail air bags, but may also include air ducts, switches, lights, wires and harnesses, audio components, navigation systems, display systems, compasses, thermometers, mirrors or combinations thereof. The headliner module subassembly  70  will often be assembled at a supplier&#39;s facility and shipped complete to the vehicle assembly plant; however, headliner module subassemblies can be assembled at the vehicle assembly plant, prior to their installation into the vehicle. 
       FIG. 5  shows headliner module subassemblies  70  being loaded into a vehicle  80 , shown in phantom. An operator uses a transport device  82  to move the headliner module subassemblies  70  from a storage rack  84  to the vehicle  80 , where they are moved through a windshield opening  86 . In some vehicles, it will be more convenient to move the headliner module subassembly through the rear window opening.  FIG. 7  shows a portion of the headliner module subassembly  70  being attached to the side roof rail  88 . The attachment of the headliner module subassembly  70  can be effected by using a portion of a side roof rail air bag assembly  90 , shown in phantom, and fasteners  92 . Because the headliner module subassembly  70  is attached to the vehicle  80  before the roof assembly  68 , the headliner module subassembly  70  can be installed by an operator standing outside the vehicle  80 . 
       FIG. 8  illustrates the attachment of the roof assembly  68  to the vehicle  80 . A transport arm such as  40  shown in  FIGS. 1 and 2  is used to position the roof assembly  68  over the roof opening  94 , where it is guided into place and secured with adhesive such as  52  shown in FIG.  2 . Openings  96  in the headliner module subassembly  70  are configured to accommodate the components  74  in the roof assembly  68 . Flaps (not shown) may be provided on the headliner  76  around the openings  96  to surround the edges of the components  74  after installation. 
     Some of the benefits of the present invention are readily seen from the description above. Installation of the roof assembly into the vehicle occurs with all operators outside the vehicle. This eliminates the need for operators to work overhead with unwieldy headliner assemblies, which increases efficiency and lowers production costs. Further cost reductions are realized because several components of the roof assembly—e.g., headliner, electronic components, and roof outer panel—are loaded in one station. This reduces the total number of assembly stations required in the vehicle assembly plant. In addition, because the roof assembly process is moved to the general assembly plant, welding of metal roof panels does not occur in a body shop where space is limited. The limited space in body shops put constraints on the number of options vehicle manufacturers can offer in a vehicle platform. Taking advantage of the greater available space at a general assembly facility not only increases efficiency, but also allows vehicle manufacturers greater flexibility in the options they offer in a vehicle platform. 
     While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.