Granted Patent B1

US 6,836,950 · App. 10/604,238 · Granted Jan 4, 2005

Abstract

Claims (34)

1. A method for making a punched headliner adapted to be installed in a motor vehicle, the method comprising:

placing a flange element within a punch tool, said punch tool comprising a punching component and a mating component, said flange element placed abutting said mating component;

placing a headliner blank within said punch tool, said headliner blank positioned between said punching component and said flange element;

moving a punching edge towards said mating component, said punching edge positioned on said punching component;

compressing said headliner blank between said punching edge and said flange element; and

pressing said punching edge into contact with said flange element such that a shearing edge is formed on said headliner blank and a waste component is separated from said headliner blank.

2. A method for making a punched headliner adapted to be installed in a motor vehicle as described in claim 1 , further comprising:

bonding said flange element to an underside surface of said headliner blank.

3. A method for making a punched headliner adapted to be installed in a motor vehicle as described in claim 1 , wherein said flange element comprises: an arched transition portion connecting a vertical extension to a horizontal mounting section, said horizontal mounting section pressed into communication with said headliner blank by said punching component.

4. A method for making a punched headliner adapted to be installed in a motor vehicle as described in claim 1 , wherein said punching edge comprises a first angled edge, a rounded leading surface, and a second edge; said first angled edge generating shearing against said headliner blank such that said first angled edge shears said headliner blank and subsequently contacts said flange element.

5. A method for making a punched headliner adapted to be installed in a motor vehicle as described in claim 1 , further comprising:

pressing said punching edge into contact with said flange element such that said shearing edge is formed with a shearing edge radius of curvature.

6. A method for making a punched headliner adapted to be installed in a motor vehicle as described in claim 5 , further comprising:

forming said shearing edge radius of curvature to tangentially mate with an arched transition portion of said flange element.

7. A method for making a punched headliner adapted to be installed in a motor vehicle as described in claim 1 , wherein said mating component includes a mating edge comprising an upper horizontal mating surface, a vertical mating engagement surface, and a rounding mating transition edge; said flange element shaped to conform to said mating edge.

8. A method for making a punched headliner adapted to be installed in a motor vehicle as described in claim 7 , wherein said flange element includes a vertical extension section, said vertical extension section shorter than said vertical mating engagement surface.

9. A method for making a punched product assembly, the method comprising:

placing a flange element within a punch tool, said punch tool comprising a punching component and a mating component, said flange element placed abutting said mating component, and said mating component including a mating edge comprising an upper horizontal mating surface, a vertical mating engagement surface, and a rounded mating transition edge;

placing a material blank within said punch tool, said material blank positioned between said punching component and said flange element;

moving a punching edge towards said mating component, said punching edge positioned on said punching component and including a first angled edge and a rounded leading surface;

compressing said material blank between said first angled edge and said flange element in the location of said rounded mating transition edge; and

pressing said punching edge into contact with said flange element such that a shearing edge is formed on said material blank and a waste component is separated from said material blank.

10. A method for making a punched product assembly as described in claim 9 , further comprising:

applying a bonding material between said flange element and an underside surface of said material blank prior to said compressing of said material blank.

11. A method for making a punched product assembly as described in claim 9 , wherein said flange element comprises:

an arched transition portion connecting a vertical extension to a horizontal mounting section, said horizontal mounting section pressed into communication with said material blank by said punching component.

12. A method for making a punched product assembly as described in claim 9 , further comprising:

pressing said punching edge into contact with said flange element such that said shearing edge is formed with a shearing edge radius of curvature.

13. A method for making a punched product assembly as described in claim 12 , further comprising:

forming said shearing edge radius of curvature to tangentially mate with an arched transition portion of said flange element.

14. A method for making a punched product assembly as described in claim 9 , wherein said flange element is pre-formed to conform to said mating edge.

15. A method for making a punched product assembly as described in claim 9 , wherein said flange element includes a vertical extension section, said vertical extension section shorter than said vertical mating engagement surface.

16. A method for making a punched product assembly as described in claim 9 , further comprising:

placing a secondary flange element within said punch tool prior to said compressing said material blank, said secondary flange element positioned remote from said shearing edge.

Assignments (10)