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WO1997010950A9 - Garniture interieure absorbant l'energie pour vehicules - Google Patents

Garniture interieure absorbant l'energie pour vehicules

Info

Publication number
WO1997010950A9
WO1997010950A9 PCT/US1996/015044 US9615044W WO9710950A9 WO 1997010950 A9 WO1997010950 A9 WO 1997010950A9 US 9615044 W US9615044 W US 9615044W WO 9710950 A9 WO9710950 A9 WO 9710950A9
Authority
WO
WIPO (PCT)
Prior art keywords
layer
foam
headliner
body member
vehicle
Prior art date
Application number
PCT/US1996/015044
Other languages
English (en)
Other versions
WO1997010950A1 (fr
Filing date
Publication date
Application filed filed Critical
Publication of WO1997010950A1 publication Critical patent/WO1997010950A1/fr
Publication of WO1997010950A9 publication Critical patent/WO1997010950A9/fr

Links

Definitions

  • This invention relates to headliners for a vehicle and more particularly to headliners made from layers of foam and fibers.
  • trim molding used to cover most above belt line locations in a vehicle in the vicinity of a headliner therein do not respond to impact loading so as to absorb energy.
  • Future Federal Safety Regulations are expected to require that such trim moldings be configured to absorb energy on impact to offer better impact protection to the occupants of the vehicle in the event of an accident.
  • Overhead parts of a vehicle body between the front, mid and rear pillar posts of a vehicle are covered at the present time by headliners that do not have significant energy absorbent capabilities. While such arrangements have an aesthetic appeal they do not provide controlled energy absorption of kinetic energy through energy absorption.
  • the present invention involves making use of an improved process for forming a headliner having a decorative cover material and an energy management core with a preformed energy absorbing segment thereon that defines a connecting feature therein that can be fastened to a vehicle body while providing an improved energy absorbent structure to protect against head impact at overhead locations between the front, mid and rear pillar locations of a vehicle.
  • the resulting headliner requires no additional tooling than that presently used to manufacture headliners and does not require additional assembly labor to provide head impact protection features at an overhead location within the passenger compartment of a vehicle. It can also decrease the total thickness required to achieve certification under new standards since the headliner will include segments thereon that become part of the total energy management system within the passenger compartment.
  • the present invention addresses the problem of providing a connection of an energy absorbing component in a headliner assembly having a body member and a separate decorative cover member to a body member such as an overhead rail extending between the front and rear pillars of the vehicle.
  • the connection is provided by a preformed energy absorbing component that includes interposed layers of expanded, reticulated or open cell foam and reinforcing fiber that are impregnated with a reinforcing binder such that the are impregnated with a reinforcing binder such that the fibers will provide a high strength cover and the foam will provide an energy absorbing core that are molded in a single mold with the decorative cover to form a shaped configuration that can be secured in place without the need for fasteners while including an outer decorative cover.
  • the headliner includes a ratio of thickness of a resin impregnated flexible foam layer and the thickness of the resin impregnated fiber material associated with the decorative cover thereon providing a premolded headliner that has a connection feature that will be joined to the vehicle body member to provide head impact energy absorption protection and a decorative outer appearance.
  • An object of the present invention is to provide a headliner for a vehicle providing energy absorption between a vehicle body member and a trim cover by use of a precast composite structure that includes layers of composite material that can be cast in a single mold to form a shaped configuration that can be secured in place without the need for fasteners while including an outer decorative cover and while providing energy absorption head impact protection.
  • a further feature of the present invention is to provide the aforesaid headliner for a vehicle providing energy absorption between a body member and a trim cover by a preformed composite structure that includes layers of polymeric foam and layers of fiber reinforcement impregnated by a heat-accelerated binder and a cover layer that provides a decorative appearance and the precast composite structure having laterally spaced energy absorbent segments that provide head impact protection.
  • a still further feature of the invention is to provide the aforesaid headliner for a vehicle providing energy absorption between a body member and a trim cover
  • the polymeric foam material is formed from expanded, reticulated or open cell plastic material such as polyether, polyolefin, polyester, polyurethane or any combination thereof and the reinforcing fibers are glass fibers or synthetic fibers such as Kevlar® or any other suitable like reinforcing fiber and wherein the reinforcing layers and foam layers are impregnated with a heat-accelerated liquid hardening compound/binder which enters and fills the cells of the foam coating the cell walls and also impregnating interstices in the reinforcing fiber layer.
  • a still further feature of the invention is to provide the aforesaid headliner for a vehicle providing energy absorption between a body member and a trim cover wherein at least one of the foam layers has a core weight in the range of .95-2 pounds/ft 3 ; a concentration of MDI binder in the range of 400 grams to 900 grams/meter 2 and a glass fiber weight of 100-400 grams/meter 2 .
  • Yet another feature of the invention is to provide the aforesaid headliner for a vehicle providing energy absorption between a vehicle body member and a trim cover wherein the preformed material includes two layers of foam.
  • Still another feature is to provide such a headliner wherein the two layers of foam have a layer of glass fibers formed therebetween.
  • Still another feature is to provide such a headliner wherein the glass fibers are woven glass fibers.
  • Still another feature of the present invention is to provide the glass fiber thickness from air deposited laid up non-woven fibers.
  • Yet another object of the present invention is to provide such headliners that include a matrix having different densities of foam and resin impregnated fiber material at different parts of the matrix.
  • Yet another object of the present invention is to provide such headliners wherein the preformed casting includes a decorative cover bonded to a layer of resin/binder impregnated glass fibers by an adhesive layer of heat meltable material such as polyester, polyamide, polyethylene, polypropylene and other olefins which melt or forms bonds during die molding of a preformed connection feature in the headliner.
  • the preformed casting includes a decorative cover bonded to a layer of resin/binder impregnated glass fibers by an adhesive layer of heat meltable material such as polyester, polyamide, polyethylene, polypropylene and other olefins which melt or forms bonds during die molding of a preformed connection feature in the headliner.
  • Still another object of the present invention is to provide such a headliner wherein the preformed casting includes an exterior layer selected from thermoplastic materials such as polyvinyl chloride; thermoplastic polyurethanes; thermoplastic elastomers; thermoplastic olefins and blends of the aforesaid materials all of which can be premolded at the same time as the resin/binder is activated to reinforce the foam materials and fill the interstices of the reinforcing fiber layer.
  • thermoplastic materials such as polyvinyl chloride; thermoplastic polyurethanes; thermoplastic elastomers; thermoplastic olefins and blends of the aforesaid materials all of which can be premolded at the same time as the resin/binder is activated to reinforce the foam materials and fill the interstices of the reinforcing fiber layer.
  • a still further feature of the invention is to provide a method for making the aforesaid headliner for a vehicle providing energy absorption between a body member and a trim cover wherein a layer of decorative cover material is placed in a single mold tool along with a layer of reinforcing fiber and a layer of a polymeric foam material of expanded, reticulated or open cell plastic material such as polyether, polyolefin, polyester, polyurethane or any combination thereof and the reinforcing fibers are glass fibers or synthetic fibers such as Kevlar® or any other suitable like reinforcing fiber and wherein the reinforcing layers and foam layers are impregnated with a heat-accelerated hardening compound/binder which enters and fills the cells of the foam coating the cell walls and also impregnating interstices in the reinforcing fiber layer while the layered material is shaped by the mold either by compression or vacuum forming to have a desired energy absorbing thickness at preselected points therein while forming a connection feature on a result
  • FIG. 1 is a fragmentary perspective view of a motor vehicle headliner constructed in accordance with the present invention
  • Figure IA is a fragmentary side elevational view of a passenger compartment showing a impact segment of a headliner including the present invention
  • Figure 2 is a sectional view taken along the line 2-2 of Figure 1 looking in the direction of the arrows;
  • Figure 3 is an enlarged sectional view taken along the line 3-3 of Figure 2 looking in the direction of the arrows;
  • Figure 4 is an enlarged fragmentary cross- sectional view of a another embodiment of a headliner having a preformed composite energy absorbent interior of the present invention
  • Figure 5 is a fragmentary view of a passenger compartment showing a front pillar covered by another embodiment of the present invention.
  • Figure 6 is a perspective view of an energy absorbent trim assembly in the embodiment taken along line 6-6 of Figure 5.
  • Figure 1 illustrates the use of the subject invention on a headliner 10 of a vehicle. It is to be appreciated that the invention may also be practiced on other interior components, such as a cover for pillar posts, headliners, side doors, consoles or other interior trim parts that have a decorative covered member supported on a vehicle body part or accessory.
  • the headliner 10 extends between the front pillars 12 and rear pillars 14 of the vehicle.
  • the headliner 10 includes a core 16 of expanded, reticulated or open cell foam; a reinforcing layer 18 of fiber material and a decorative cover 20 all premolded together to form an integral unitary member that is impregnated with a reinforcing binder such that the fiber layer 18 will provide a high strength component and the foam core of expanded, reticulated or open cell foam will have the cell walls thereof coated by the reinforcing binder to provide an energy absorbing core.
  • the decorative cover 20, foam core 16 and fiber layer 18 are placed in a single mold and are molded by compression forming or the like and the application of binder activating heat to form a shaped energy absorbent headliner 10 that can be secured in place without the need for fasteners while including an outer decorative cover.
  • the amount of MDI material in the heat accelerated binder material is selected such that the headliner 10 can have sufficient flex to fit over the supporting pillars or other vehicle body parts for securing the headliner 10 in place at the preformed recesses 30, 32 therein.
  • the headliner 10 has a greater cross-section at the sides thereof that define laterally spaced, integral side impact segments 24, 26 located above the belt line to provide side impact head protection along the full longitudinal extent from the front of the passenger compartment to the rear of the passenger compartment.
  • Impact surfaces 27, 28 are formed on the outer decorative cover 20 along the full length of each of the impact segments 24, 26.
  • Preformed side recesses 30, 32 are formed in the headliner 10 during the vacuum or compression form shaping step of the process of the present invention.
  • the recesses have a shape suitable for fitting the headliner 10 on the adjacent pillars to completely cover such pillars with an energy absorbent headliner made up of the thickened sections within the premolded components of the headliner 10.
  • a suitable cross-section would provide a thickness of material in the region of the impact segments 24, 26 in the range of 18mm to provide an adequate amount of energy absorbing fiber and foam core material when impregnated with the binder materials outlined in the aforesaid '027 patent.
  • a preferred range of thickness at the impact segments 24, 26 is in the range of from l8-25mm.
  • the center segment 34 of the headliner 10 can have a thickness in the range of 4mm to 25mm with a preferred thickness of around 8 mm.
  • the impact segments 24, 26 can be configured to have openings 33 therein at appropriate points therealong to accommodate headliner accessories such as hand grips and the like. Also, while the impact segments 24, 26 are shown along the sides of the headliner 10 they could be provided at the front and rear of the headliner in appropriate configurations.
  • Such a single mold tool allows use of a vacform or press form process capable of molding vinyl or other thermoplastic decorative covers to be preloaded and covered by layers of foam and reinforcing fibers in a single mold.
  • cloth, woven and nonwoven, nylon, polypropylene in the case of headliners and vinyl or vinyl blend decorative covers or decorative covers of other materials such as TPO, TPU and TPE can be used in the single mold process of the aforesaid '675 patent for other applications, including headliners.
  • the binder material is impregnated into the foam and fiber layers the part can be processed to result in the illustrated premolded integral energy absorbent headliner 10 of the present invention.
  • the polymeric foam material is formed from expanded, reticulated or open cell plastic material such as polyether, polyolefin, polyester, polyurethane or any combination thereof and the reinforcing fibers are glass fibers or synthetic fibers such as Kevlar® or any other suitable like reinforcing fiber and wherein the reinforcing layers and foam layers are impregnated with a heat- activated liquid hardening compound/binder which enters and fills the cells of the foam coating the cell walls and also impregnating interstices in the reinforcing fiber layer.
  • expanded, reticulated or open cell plastic material such as polyether, polyolefin, polyester, polyurethane or any combination thereof
  • the reinforcing fibers are glass fibers or synthetic fibers such as Kevlar® or any other suitable like reinforcing fiber and wherein the reinforcing layers and foam layers are impregnated with a heat- activated liquid hardening compound/binder which enters and fills the cells of the foam coating the cell walls and
  • Figure 5 illustrates a passenger compartment of an automotive vehicle 34 in which a frame 36 of the vehicle is shown extending about an adjacent window 38 and including an energy absorbent trim assembly 40 constructed according to the present invention.
  • the trim assembly 40 is associated with the upright front or A pillar 42 of the vehicle with it being understood that the invention is suitable for side rail components of the interior trim of a vehicle including but not limited to the window frame components and the upright back or B pillar portion .
  • the trim assembly 40 has the same general shape and configuration as the front A pillar 42 on which it is mounted and in the illustrated embodiment the headliner 40 includes a decorative trim cover 44 that is associated with an energy absorbent center 46 that is preformed by casting in a single mold.
  • the preformed center 46 includes a foam core 48 covered by a layer of fiber 50 both impregnated with binder as in the case of the embodiment shown in Figures 1 and 2.
  • the preformed center 46 and cover 44 have a preformed groove 35 therein that receives a flange 37 on the pillar 42.
  • the groove 35 and flange 37 are merely representative of a premolded interconnection feature that can be secured to a vehicle body part.
  • the feature can have a cross-section that will vary from a channel shape as shown to a curved hole; a V-shaped hole or other interconnection that can be either molded integrally of or adhesively connected to the inner surface 56 of the cover 44.
  • the energy absorbent trim assembly 40 includes a premolded composite center that has layers of polymeric foam and layers of fiber reinforcement connected by adhesive layers.
  • the energy absorbent material making up either the headliner or the pillar post cover includes a foam core 48 of expanded, reticulated or open cell foam; and a reinforcing fiber layer 50 of fiber material to form an integral unitary member that is impregnated with a reinforcing binder such that the fiber layer 50 will provide a high strength component and the foam core of expanded, reticulated or open cell foam will have the cell walls thereof coated by the reinforcing binder to provide an energy absorbing center comprised of the material types previously set-forth in the embodiment of Figures 1 and 2.
  • the cover 44 is adhered to the fiber layer 50 by a layer 52 of adhesive.
  • the adhesive layer can be a layer of heat meltable thermoplastic material such as polyester, polyamide, polyethylene, polypropylene and other olefins which melt or forms a bond during die molding of a preformed connection feature in the headliner.
  • a center 65 is formed by a plurality of foam layers 64, 66 of different thicknesses are formed on either side of a layer of fiber 68 all of which are impregnated with a binder of the type previously described.
  • a base support layer shown as a layer of SCRIM 70 is provided over a second layer 72 of reinforcing fiber and connected thereto by a layer of adhesive 74.
  • the fiber layers 68, 72 can be formed from of either woven or chopped fibers of a suitable material such as glass fibers, or a high strength fiber material such as carbon with the compressive characteristics of the foam in layers 64, 66 to provide a desired deformation and energy absorption protection over the pillar post configuration.
  • the materials used in the cover and center will depend upon a particular application. However, in many cases the cover can be formed of a suitably formed thermoplastic material such as thermoplastic urethane or thermoplastic polyvinyl chloride or alloys of same backed by the foam layer 64.
  • thermoplastic materials such as ABS or polycarbonates can be used for a base layer 70 for the foam material and for defining the connection groove on the core foam 10.
  • a preferred working embodiment includes a foam core have a weight in the range of .95-2 pounds/ft 3 ; a concentration of MDI binder in the range of 400grams to 900 grams/meter 2 and a glass fiber weight of 100-400 grams/meter 2 .
  • the foam layer can be polyurethane foam or urea foam having a specific gravity in the range of .05- .2 and an initial load deflection, ILD, of 20-80 psi.

Abstract

L'invention porte sur un doublage de toit absorbant l'énergie (10) pour véhicule comportant une couche d'un matériau plastique expansé réticulé ou à cellules ouvertes et une couche de couverture de fibres de renfort imprégnées et/ou saturées d'un composé/liant durcisseur liquide thermoactivable moulé de manière à constituer des segments intégraux (24, 26) absorbant l'énergie et protégeant les passagers contre les chocs latéraux.
PCT/US1996/015044 1995-09-20 1996-09-19 Garniture interieure absorbant l'energie pour vehicules WO1997010950A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US401795P 1995-09-20 1995-09-20
US60/004,017 1995-09-20

Publications (2)

Publication Number Publication Date
WO1997010950A1 WO1997010950A1 (fr) 1997-03-27
WO1997010950A9 true WO1997010950A9 (fr) 1997-07-03

Family

ID=21708723

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1996/015044 WO1997010950A1 (fr) 1995-09-20 1996-09-19 Garniture interieure absorbant l'energie pour vehicules

Country Status (1)

Country Link
WO (1) WO1997010950A1 (fr)

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19700091A1 (de) * 1997-01-03 1998-07-16 Fehrer Gummihaar Energieabsorbierendes Verkleidungsteil
DE19813592A1 (de) 1998-03-27 1999-09-30 Audi Ag Flächiger Verbundkörper, insbesondere Kraftfahrzeug-Karosserieelement
SE515808C2 (sv) 1998-11-30 2001-10-15 Volvo Personvagnar Ab Arrangemang för skydd av åkande i fordon
GB2353502A (en) * 1999-08-27 2001-02-28 Lear Corp Vehicle trim products
US6832810B2 (en) 2002-07-05 2004-12-21 Lear Corporation Flexible headliner for automotive vehicle
CN101198462B (zh) * 2005-06-13 2012-03-28 奎德兰特塑料合成股份公司 挠曲刚性复合片材
FR2891190B1 (fr) * 2005-09-29 2007-11-09 Chomarat Composites Soc Par Ac Complexe de renforcement mecanique destine a etre incorpore dans une piece composite
US7726728B2 (en) 2007-12-19 2010-06-01 Toyota Motor Engineering & Manufacturing North America, Inc. Headliner having a sunroof opening
GB2464540B (en) 2008-10-20 2013-03-13 Acell Group Ltd Patterned composite product
US9404231B2 (en) 2014-08-26 2016-08-02 The Texas A&M University System Module for use in a crash barrier and crash barrier

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5089328A (en) * 1988-02-26 1992-02-18 Van Dresser Corporation Panel and method of making the same
US5082716A (en) * 1989-10-16 1992-01-21 Process Bonding, Inc. Headliner

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