Patent Application
20140001322
The present invention generally relates to a system for attaching a trim component to a vehicle body structure, and more particularly for magnetically attaching a headliner to a non-magnetic vehicle roof.
The body structure of a vehicle roof typically includes a roof panel and several roof headers and bows, which are closed-section or channel-shaped structures secured to the vehicle body. Roof headers and bows extend along the length and across the width of the vehicle roof to provide support for the roof panel. The roof panels, headers, and bows are commonly fabricated from stamped sheet metal. A headliner is attached to the interior side of roof structure to provide an attractive appearance for the interior of the vehicle. Headliners have been attached to the roof of vehicles in a variety of manners, including using screw or snap-in fasteners, adhesives, magnets, and hook and loop type fasteners, such as VELCRO.
Recently, an interest in reducing the weight of a vehicle has led manufactures to use lighter materials, such as aluminum, for vehicle roof panels, headers, and bows. Using aluminum eliminates the ability to magnetically attach components to the roof structure because aluminum is not magnetically attachable.
One aspect of the present invention includes a vehicle headliner attachment system for mounting a headliner to a non-magnetic roof structure. The attachment system includes a headliner with an interior and an exterior surface, a magnet affixed to the exterior surface of the headliner, and a ferromagnetic clip mounted to the non-magnetic roof structure. The magnet and the ferromagnetic clip enable magnetic attachment of the headliner to the non-magnetic roof structure.
Another aspect of the present invention includes a vehicle attachment system for mounting a trim component to a non-magnetic body structure. The attachment system includes the trim component, a magnet affixed to one of the trim component and the body structure, and a ferromagnetic clip mounted to the other of the trim component and the body structure. The magnet and the magnetic clip enable magnetic attachment of the trim component to the non-magnetic body structure.
These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
In the drawings:
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “interior,” “exterior,” and derivatives thereof shall relate to the vehicle attachment system as oriented in
Referring to
The headliner 12 may be a formed and molded headliner for mounting to the interior of the roof structure 14 of the vehicle, so as to provide an aesthetically pleasing appearance for the interior thereof. The headliner 12 has an exterior surface 16 which faces the supporting roof structure 14 when installed in the vehicle, and an opposite, interior surface 18 that is upholstered to provide a decorative surface visible from the interior of the vehicle. The headliner 12 is shaped to conform to the roof structure 12 and may include a plurality of contours and apertures for mounting various overhead components, such as sunvisors, overhead consoles, grab handles, lights, and the like. The roof structure 14 includes a pair of spaced side rails 20, and at least a front header 22, a rear header, 24, and may also include additional roof bows, as is conventional. The roof structure 14 is formed of non-magnetic material, such as aluminum, or any other suitable material.
The headliner attachment system 10 further includes a magnet 26, affixed to the exterior surface 16 of the headliner 12. The magnet 26 is made of a material that has its own persistent magnetic field, even in the absence of an applied magnetic field. Examples of such types of magnetic metals include iron ore, cobalt, and nickel. In the illustrated example, a plurality of magnets 26 is spaced about the exterior surface 16 of the headliner 12. The magnets 26 can be bonded to the surface 16 by a layer of hot melt adhesive (not shown). Of course, other glues, adhesives, or means of attaching the magnets 26 to the headliner 12 are also feasible.
Referring now to
Referring to
The headliner 12, with the magnets 26 bonded to the exterior surface 16 thereof, is installed during assembly of the vehicle. The magnets 26 and clips 30 are located on the headliner 12 and roof structure 14, respectively, so that they are aligned when the headliner 12 is installed on the vehicle. When the headliner 12 is positioned in general alignment for installation, the magnets 26 will be attracted to the ferromagnetic clips 30 clipped into the non-magnetic roof structure 14, thereby enabling magnetic attachment of the headliner 12 to the non-magnetic roof structure 14. Further, the particular magnet 26 selected for use can be based on the material's magnetic magnitude, which describes how strong the magnetic attraction is. The magnets 26 must be able to attract the clips 30 with sufficient force so as to secure the headliner 12 to the non-magnetic roof structure 14 and stay secure during normal use of the vehicle.
Referring to
Additionally, the plate 60 includes several nubs 76, located on an upper surface 78 of the main body 62. The nubs 76 interface with the lower surface 72 of the roof structure 14, such that potential rattle between the plate 60 and the roof structure 14 is reduced or eliminated.
The headliner 12, with the magnets 26 bonded to the exterior surface 16 thereof, is installed in the same manner as described above with respect to the first embodiment. The magnets 26 attract the ferromagnetic plate 60 mounted to the non-magnetic roof structure 14, thereby enabling magnetic attachment of the headliner 12 to the non-magnetic roof structure 14.
It should easily be understood by one having ordinary skill in the art that the magnetic properties of the clips 30 (or plate 60) and the magnets 26 could be switched, according to another embodiment. In other words, the clips 30 and plates 60 could be made of a magnetic material, while the member that is the magnet 26 could be made of a ferromagnetic material. Additionally, as mentioned above, both the clips 30 and plate 60 could be formed of a magnetic metal as long as the polarity is reversed with respect to the magnet 26. In each of these described variations of component orientation, the headliner 12 is able to be mounted to the non-magnetic roof structure 14 by magnetic force.
With the industry-wide transition to lighter materials, which are often not magnetic, take aluminum for example, the ability to magnetically attach components to the vehicle body is lost. The vehicle attachment system 10 described herein enables magnetic attachment of a trim component, such as a headliner, to a non-magnetic body structure, such as an aluminum roof structure. Additionally, the vehicle attachment system 10 also provides an attachment means that does not have fasteners that are visible from within the vehicle's interior, which is a perceived craftsmanship improvement. Another benefit the vehicle attachment system 10 provides is the ease with which the headliner 12 can be blindly installed to the roof structure 14. Installation of the headliner 12 is considered to be a “blind” installation because the installer is not able to view the fasteners during installation.
It will be understood by one having ordinary skill in the art that construction of the described headliner attachment system and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
It is also important to note that the construction and arrangement of the elements of the headliner attachment system as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
