Modular headliner assembly and method of making same

Abstract

A modular headliner assembly includes a headliner having an appearance surface and a back surface. At least one component is disposed adjacent the back surface of the headliner. Furthermore, an integration sheet is attached to the back surface for securing the at least one component to the headliner. A method of manufacturing the headliner assembly is also disclosed.

1 . A headliner assembly for use with a motor vehicle having a passenger compartment, the headliner assembly comprising: 
 a headliner having an appearance surface and a back surface, the appearance surface being viewable from the passenger compartment when the headliner assembly is installed in the vehicle, and the back surface being adapted to face away from the passenger compartment;    a component disposed adjacent the back surface; and    an integration sheet attached to the back surface for securing the component to the headliner, wherein the component is sandwiched between the integration sheet and the headliner.    
     
     
         2 . The headliner assembly of  claim 1  wherein the integration sheet has a thickness of less than two millimeters.  
     
     
         3 . The headliner assembly of  claim 1  wherein the integration sheet has a thickness of less than one millimeter.  
     
     
         4 . The headliner assembly of  claim 1  wherein the integration sheet covers substantially the entire back surface.  
     
     
         5 . The headliner assembly of  claim 1  wherein the back surface of the headliner has a locating feature that receives the component.  
     
     
         6 . The headliner assembly of  claim 1  wherein the back surface of the headliner has a recess, and the component is disposed in the recess.  
     
     
         7 . The headliner assembly of  claim 1  wherein the back surface includes a plurality of projections, and the component is snap fit between the projections.  
     
     
         8 . The headliner assembly of  claim 7  wherein the component is a wire harness.  
     
     
         9 . The headliner assembly of  claim 1  wherein the component is an air bag module.  
     
     
         10 . The headliner assembly of  claim 1  wherein the integration sheet includes a locating feature for receiving the component.  
     
     
         11 . The headliner assembly of  claim 10  wherein the locating feature forms an interference fit with the component.  
     
     
         12 . The headliner assembly of  claim 1  wherein the integration sheet includes an integrally formed reinforcement rib.  
     
     
         13 . The headliner assembly of  claim 1  wherein the reinforcement rib is hollow.  
     
     
         14 . The headliner assembly of  claim 1  wherein the integration sheet includes an integrally formed energy absorbing member.  
     
     
         15 . The headliner assembly of  claim 14  wherein the energy absorbing member has a honeycomb configuration.  
     
     
         16 . The headliner assembly of  claim 14  wherein the energy absorbing member is collapsible.  
     
     
         17 . The headliner assembly of  claim 1  wherein the integration sheet has a plurality of integrally formed reinforcement ribs, a plurality of integrally formed energy absorbing members, a groove, a recess, a channel, and a thickness of less than two millimeters, wherein the component is a wire harness disposed in the groove, and wherein the headliner assembly further includes an acoustic mat disposed in the recess, and an air bag module disposed in the channel.  
     
     
         18 . The headliner assembly of  claim 1  wherein the integration sheet includes multiple laterally extending, integrally formed reinforcement ribs.  
     
     
         19 . The headliner assembly of  claim 1  wherein the component is an acoustic member.  
     
     
         20 . The headliner assembly of  claim 19  wherein the acoustic member is an acoustic mat.  
     
     
         21 - 38 . (Canceled)  
     
     
         39 . The headliner assembly of  claim 1  wherein the integration sheet includes a groove, and the component is snap fit in the groove.  
     
     
         40 . The headliner assembly of  claim 1  wherein the integration sheet comprises a flexible film.  
     
     
         41 . The headliner assembly of  claim 40  wherein the integration sheet has a thickness of less than two millimeters, and the integration sheet is heat shrunk around the component.