Process For In-Molding An Energy-Absorbing Countermeasure To A Headliner

Abstract

A process for in-molding an energy-absorbing countermeasure to a headliner 18 for use in a vehicle. The process includes the steps of ( 1 ) preparing a sheet; ( 1 A) optionally affixing to the sheet a means for adhering to form a composite sheet; ( 2 ) thermoforming the composite sheet into a composite energy-absorbing countermeasure; ( 3 ) preparing a headliner layup (including optionally a means for adhering, a headliner core, and a cover stock) before forming a bond between the headliner layup and the composite energy-absorbing countermeasure. The assembly thus includes the energy-absorbing countermeasure 22 and a means for adhering it to the headliner core 18.

1 . A process for attaching an energy-absorbing countermeasure to a headliner for use in a vehicle, comprising the steps of:
 ( 1 ) preparing a sheet from which the energy-absorbing countermeasure is made;   ( 1 A) optionally affixing to the sheet a first means for adhering that has a lower melting temperature than the sheet to form a composite sheet;   ( 2 ) thermoforming the composite sheet into a composite energy-absorbing countermeasure; and   ( 3 ) optionally affixing to the headliner layup a second means for adhering and heating a headliner layup to an optimum temperature to form a bond between the headliner layup and the composite energy-absorbing countermeasure, the headliner layup including a headliner core and a cover stock.   
     
     
         2 . The process of  claim 1 , further comprising the step of:
 ( 4 ) trimming an untrimmed energy-absorbing countermeasure headliner assembly.   
     
     
         3 . The process of  claim 1 , wherein the step of heating the composite sheet and the means for adhering comprise heating the composite sheet and the means for adhering to a temperature of about 320° F. 
     
     
         4 . The process of  claim 1 , wherein the step of forming a bond between the headliner layup and the composite energy-absorbing countermeasure comprises providing a means for adhering that includes an adhering means selected from the group consisting of a polymer film, a laminated polymer film, a co-extruded polymer film, a roll-coated polymer film, and a spray-coated polymer film. 
     
     
         5 . The process of  claim 1 , wherein step ( 3 ) comprises providing a headliner forming tool that is shaped and has a topography that defines an assembly of the energy-absorbing countermeasure and the headliner. 
     
     
         6 . The process of  claim 1 , wherein the optimum temperature in the heating step comprises heating the headliner layup to a temperature of about 375° F. 
     
     
         7 . A process for attaching an energy-absorbing countermeasure to a headliner for use in a vehicle, comprising the steps of:
 ( 1 ) preparing a sheet from which the energy-absorbing countermeasure is made;   ( 1 A) affixing to the sheet a first means for adhering that has a lower melting temperature than the sheet to form a composite sheet;   ( 2 ) thermoforming the composite sheet into a composite energy-absorbing countermeasure; and   ( 3 ) applying a second means for adhering to a headliner layup and heating the headliner layup to an optimum temperature to form a bond between the headliner layup and the composite energy-absorbing countermeasure, the headliner layup including a headliner core and a cover stock.   
     
     
         8 . The process of  claim 1  wherein optional step ( 1 A) is absent and the optional use of a means for adhering in step ( 3 ) is present. 
     
     
         9 . The process of  claim 1 , wherein optional step ( 1 A) is present and the optional use of a means for adhering in step ( 3 ) is absent. 
     
     
         10 . The process of  claim 1 , wherein the means for adhering in step ( 1 A) comprises the means for adhering in step ( 3 ). 
     
     
         11 . The process of  claim 1 , wherein the means for adhering in step ( 3 ) comprises the means for adhering in step ( 1 A). 
     
     
         12 . The process of  claim 2 , wherein the trimming step is performed by a step selected from the group consisting of a waterjet process, a laser process and combinations thereof. 
     
     
         13 . The process of  claim 1 , further comprising the step of applying a fluid pressure within an energy-absorbing unit after the headliner layup is bonded to the energy-absorbing countermeasure so that a bulge is created in the headliner layup so that its “A” surface extends convexedly outwardly in conformance with contours defined by an upper headliner form tool. 
     
     
         14 . The process of  claim 1  further comprising the step of in-molding one or more components selected from the group consisting of wiring harnesses, clips, brackets, and the like. 
     
     
         15 . A process for attaching an energy-absorbing countermeasure to a headliner for use in a vehicle, comprising the steps of:
 preparing an energy-absorbing countermeasure;   preparing a headliner layup including a headliner core and a cover stock;   applying to either or both of the countermeasure and the layup a means for adhering the countermeasure and the headliner layup; and   heating the headliner layup to an optimum temperature to form a bond between the headliner layup and the energy-absorbing countermeasure.   
     
     
         16 . A process for forming a headliner with an attached thermoformed energy-absorbing countermeasure for use in a vehicle, comprising the steps of:
 positioning an energy absorbing countermeasure adjacent an upper surface of a headliner forming core, and   heating and forming the headliner forming core and countermeasure together to form a bond therebetween and to shape the headliner forming core into a shaped headliner configuration which will allow it to be installed in a vehicle.   
     
     
         17 . The process of  claim 16 , wherein the step of heating and forming comprises:
 providing a headliner forming tool that is shaped and has a topography that defines an assembly of the energy-absorbing countermeasure and the formed headliner core.   
     
     
         18 . The process of  claim 17 , wherein the heating step comprises:
 heating the headliner forming core and countermeasure together to a temperature of about 375° F.   
     
     
         19 . The process of  claim 16 , further comprising the steps of:
 positioning one or more additional components selected from the group consisting of wiring harnesses, clips, brackets, and the like adjacent the upper surface of a headliner forming core, and   heating and thermoforming the headliner forming core, countermeasure and one or more additional components together to form a bond between them and the core, and to shape the headliner forming core into a shaped headliner configuration which will allow it to be installed in a vehicle.   
     
     
         20 . A process for forming a headliner with one or more attached components for use in a vehicle, comprising the steps of:
 positioning one or more components selected from the group consisting of wiring harnesses, clips, brackets, thermoformed energy-absorbing countermeasures and the like adjacent the upper surface of a headliner forming core, and   heating and thermoforming the headliner forming core and said one or more components together to form a bond between said one or more components and the core, and to shape the headliner forming core into a shaped headliner configuration which will allow it to be installed in a vehicle.