Ford Global Technolgoies, LLC

Jeffrey Todd Baxter

David R Huelke

Lara Daniv Zarewych

A vehicle includes a support structure. A headliner is disposed proximate the support structure and includes a substrate and a cover stock disposed over the substrate. The substrate defines an elongated recess. A visor assembly includes a visor coupled to the headliner via a shaft on a first side of the visor. The visor includes a coupling member on a second opposing side of the visor. The check assembly is coupled to the headliner within the elongated recess and selectively engages the coupling member of the visor. The check assembly includes an upper check member and a lower check member configured to at least partially separate from the upper check member and translate along the elongated recess in response to a predetermined force acting on the lower check member.

Vehicle visor assembly

A headliner includes a ceiling and an edge flange extending away from the ceiling. The edge flange has a backing section at a free end and a wall section connected to the ceiling. An edge fold is formed on the headliner by a method that includes heating the flange and folding the backing section over and parallel to the ceiling. The method also includes forming a reverse turned edge by folding the backing section over the wall section and compressing the backing section against the wall section.

Method for forming a headliner

A machine for forming a bonded edge fold on a headliner is disclosed. The headliner includes a ceiling and an edge flange that has a wall section and a backing section. The machine includes a lower die that receives the headliner and an upper die disposed above the lower die. The machine further includes a slide connected to the upper die and at least one actuator operable to move the slide. Movement of the slide causes the slide to engage with the backing section and fold the backing section over the wall section forming a bonded edge fold. A method of forming a headliner is also disclosed.

Machine for forming a headliner

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.

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Carleton, MI, United States of America

Jeffrey Todd Baxter