Lear Corporation

John C Walters

Michael C Dykman

Jason Whitman

Scott A Barber

Brian H Scholfield

A vehicle headliner assembly includes a first structural member cooperating with a second structural member to form air ducts between them. A portion of the first structural member is covered by a decorative cover that presents an appearance surface to the vehicle passenger compartment. Integrally formed in the second structural member are an energy absorbing structure and an attachment structure. Thus, the headliner assembly eliminates the need for separate air ducts, separate energy absorbing material, and separate wiring harness and hose clamps. The headliner assembly is also configured to facilitate attachment of passenger compartment devices such as grab handles, without the use of separate fasteners or retainers.

Integrated headliner assembly

A method for forming a headliner assembly includes forming a main body having a periphery, and a shape corresponding to a desired shape of the headliner assembly; positioning the main body in a mold having a recess; closing the mold; and injecting foam into the recess to simultaneously form an energy absorbing member and join the energy absorbing member to the main body proximate the periphery of the main body.

Growing community of inventors

Knoxville, TN, United States of America

John C Walters