IP Library › Granted Patent US 7,309,521
Granted Patent B2
US 7,309,521 · App. 10/862,219 · Granted Dec 18, 2007

Headliner apparatus with foam imbedded NVH pad

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Quick Facts
Patent No.
US 7,309,521
App. No.
10/862,219
Granted
Dec 18, 2007
Kind
B2
Abstract

A vehicle headliner assembly ( 152 ) includes a headliner structural layer. A foam beam ( 174 ) is joined to the headliner structural layer. An NVH pad ( 156 ) is partially embedded within the foam beam ( 174 ). A method of forming a headliner structure is provided. The method includes forming a headliner main body ( 170 ). The headliner main body ( 170 ) is positioned in a mold ( 220 ) that has a recess ( 224 ). The mold ( 220 ) is closed. Foam is introduced into the recess ( 224 ) to form a foam beam ( 174 ) and to join the foam beam ( 174 ) to the headliner main body ( 170 ). A portion of an NVH pad ( 156 ) is embedded in the foam.

Claims (16)

1. A vehicle headliner assembly comprising:

at least one structural layer;

at least one foam beam joined to said at least one structural layer; and

at least one noise, vibration, and harshness (NVH) pad, said pad having at least one tab member partially embedded within said at least one foam beam.

2. An assembly as in claim 1 wherein said at least one headliner structural layer comprises:

a backing layer; and

a substrate layer coupled to said backing layer.

3. An assembly as in claim 1 wherein said at least one headliner structural layer comprises a cover layer.

4. An assembly as in claim 1 wherein said at least one headliner structural layer comprises a scrim layer.

5. An assembly as in claim 1 further comprising at least one channel in said at least one foam beam, said at least one channel, having at least one fluid line residing therein.

6. An assembly as in claim 5 wherein said at least one foam beam substantially encases said at least one fluid line.

7. A vehicle overhead system comprising:

at least one headliner structural layer;

at least one foam beam joined to said at least one headliner structural layer; and

a plurality of NVH pads, each of said pads having a tab member thereon, each of said tab members partially embedded within said at least one foam beam.

8. A system as in claim 7 further comprising at least one recess provided between two foam beams, and at least one of said tab members is embedded within said at least one recess.

Assignments (7)
RELEASE OF SECURITY INTEREST Recorded Feb 5, 2016
From: JPMORGAN CHASE BANK, N.A., AS AGENT
To: LEAR CORPORATION
Reel/Frame 037731/0918 →
RELEASE OF SECURITY INTEREST Recorded Oct 5, 2015
From: GENERAL ELECTRIC CAPITAL CORPORATION, AS COLLATERAL AGENT
To: INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH AMERICA, INC.
Reel/Frame 036777/0904 →
RELEASE OF SECURITY INTEREST Recorded Apr 21, 2014
From: JPMORGAN CHASE BANK, N.A.
To: LEAR CORPORATION
Reel/Frame 032722/0553 →
SECURITY AGREEMENT Recorded Dec 10, 2010
From: INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH AMERICA, INC.
To: GENERAL ELECTRIC CAPITAL CORPORATION, AS AGENT
Reel/Frame 025882/0019 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 27, 2007
From: LEAR CORPORATION
To: INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH AMERICA, INC.
Reel/Frame 019215/0727 →
SECURITY AGREEMENT Recorded Jun 23, 2006
From: LEAR CORPORATION
To: JPMORGAN CHASE BANK, N.A., AS GENERAL ADMINISTRATIVE AGENT
Reel/Frame 017858/0719 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 7, 2004
From: BROWN, BARI W.
To: LEAR CORPORATION
Reel/Frame 015441/0118 →