Roof lining system and installation method thereof

Abstract

A headliner for use in a vehicle having a roof, the headliner comprising a sheet and a plurality of first snap portions adapted to couple with a corresponding plurality of second snap portions secured to the roof, so that the sheet is mounted to the inner side of the roof through interaction of the plurality of first snap portions and the corresponding second snap portions. A method for mounting a headliner on a roof structure, comprising: providing a headliner, wherein the headliner comprises a sheet and a plurality of first snap portions secured to the sheet, the sheet having an upper surface and a lower surface; and combining the plurality of first snap portions to a plurality of second snap portions, wherein the plurality of second snap portions are secured to the roof structure, the plurality of second snap portions adapted to couple with the plurality of first snap portions to mount the sheet to the inner side of the roof structure.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Utility Application Serial No. 16 / 862,654, filed on April 30, 2020, which in turn claims priority to U.S. Provisional Application Serial No. 62 / 856,188, filed on June 3, 2019, the contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates generally to headliners and headliner systems for attachment to a roof structure of a vehicle, and particularly to headliners and headliner systems that utilize mechanical snap fasteners to secure the headliner to the roof structure of the vehicle. Background Art

[0004] As is known in the art, it is desirable to provide an aesthetically pleasing and durable interior headliner for covering the underside of a vehicle roof. The headliner separates the passenger compartment of the vehicle from the roof structure. The headliner provides a decorative panel that makes the roof structure more aesthetically pleasing when viewed from within the passenger compartment and absorbs sound from within the passenger compartment as well as sound originating from outside the passenger compartment. Of course, it is important that such a headliner be of low cost and relatively simple to manufacture and install.

[0005] The headliner is usually composed of a suitable soft fiber, woven, knitted or supported vinyl fabric so that the fabric can be tensioned to follow the general contour of the roof and fixed to the upper edge of the roof structure. The headliner can also be composed of a relatively rigid molded or formed structure that conforms to the general contour of the roof.

[0006] In some cases, the headliner is secured to the roof structure using adhesives or push pins to bond the headliner directly to the underside of the roof structure, or corresponding halves of hook and loop fasteners are secured to the headliner and the roof structure, which are then attached to the roof structure using hook and loop fasteners. A trim panel may be used to further secure the headliner to the roof structure and hide the edges of the headliner. Over time, these adhesives may degrade and fail, causing a reduction in the tension applied to the headliner, resulting in sagging or falling off of the headliner.

[0007] Additional problems are associated with headliners for vehicles having removable roof assemblies, such as sport utility vehicles (SUVs) and convertibles. Such vehicles allow a user to remove the roof from the vehicle's body when desired for an open-air driving experience, and to attach the roof to the vehicle's body when a standard enclosed, weather-protected driving experience is needed or desired. In such vehicles, a trim panel for concealing the edges of the headliner is not easily employed given the removable nature of the roof, the motion associated with removal and attachment of the roof structure to the body applies atypical forces to the headliner, thereby shortening the life of the headliner and associated attachment adhesives, and the headliner is more susceptible to damage, such as tearing and soiling, given the frequent manipulations associated with removal and attachment of the roof structure to the body.

[0008] Therefore, there is a need for a headliner that is removably attached to the roof structure of a vehicle and is robust and less susceptible to damage, accidental detachment and sagging than current headliner systems. Additionally, there is a need for a headliner system that provides easier replacement than all current headliner systems while being less expensive and easier to manufacture and install. Summary of the invention

[0009] The present invention provides a roof lining for use in a vehicle having a roof. The roof lining includes a sheet having an upper surface and a lower surface. The sheet is suitable for being installed to be located below the roof. The roof lining also includes a plurality of first buckle portions fixed to the sheet.

[0010] The present invention also provides a roof lining system, the roof lining system comprising: a roof lining, the roof lining having a sheet and a plurality of first buckle parts fixed to the sheet, the sheet having an upper surface and a lower surface; and a roof structure, the roof structure having an outer side and an inner side; and a plurality of second buckle parts fixed to the roof structure, the plurality of second buckle parts being suitable for being coupled with the plurality of first buckle parts. The roof lining sheet is suitable for being installed to the inner side of the roof structure through the interaction of the plurality of first buckle parts and the corresponding second buckle parts.

[0011] In addition, the present invention provides a method for installing a roof lining on a roof structure, the method comprising: providing a roof lining, wherein the roof lining comprises a sheet and a plurality of first snap-in portions fixed to the sheet, the sheet having an upper surface and a lower surface; and combining the plurality of first snap-in portions to a plurality of second snap-in portions, wherein the plurality of second snap-in portions are fixed to the roof structure, and the plurality of second snap-in portions are suitable for connecting with the plurality of first snap-in portions to install the sheet to the inner side of the roof structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The present invention is described in further detail with respect to the following drawings, which are intended to illustrate certain aspects of the present invention but should not be construed as limitations on the implementation of the present invention.

[0013] Figure 1 is an exploded perspective view of a roof lining system according to an embodiment of the present invention;

[0014] Figure 2 is a perspective view of a lower surface of a headliner according to an embodiment of the present invention;

[0015] Figure 3 is an exploded view of a pressure fastener according to an embodiment of the present invention;

[0016] Figure 4A is a cross-sectional view of a second buckle portion fixed to a roof structure according to an embodiment of the present invention;

[0017] Figure 4B is a cross-sectional view of a first buckle portion of a sheet material fixed to a headliner according to an embodiment of the present invention;

[0018] Figure 4C is with Figure 4B The first buckle portion is engaged with Figure 4A A cross-sectional view of a second buckle portion;

[0019] Figure 5A is a cross-sectional view of a second buckle portion fixed to a roof structure according to an embodiment of the present invention;

[0020] Figure 5B is a cross-sectional view of a first buckle portion of a sheet material fixed to a headliner according to an embodiment of the present invention;

[0021] Fig. 6A is a front view of a flat mounting bracket according to an embodiment of the present invention;

[0022] Figure 6B yes Fig. 6A A cross-sectional view of a mounting bracket;

[0023] Fig. 7A is a front view of a flat mounting bracket according to an embodiment of the present invention;

[0024] Figure 7B yes Fig. 7A A cross-sectional view of a mounting bracket;

[0025] Fig. 8A is a front view of a tilted top hat mounting bracket according to an embodiment of the present invention;

[0026] Figure 8B yes Fig. 8A A cross-sectional view of a mounting bracket;

[0027] Fig. 9A is a front view of a rectangular top hat mounting rod according to an embodiment of the present invention;

[0028] Fig. 9B yes Fig. 9A A cross-sectional view of a mounting rod;

[0029] Fig. 10A is a front view of a beveled top hat mounting rod according to an embodiment of the present invention;

[0030] Fig. 10B yes Fig. 10A A cross-sectional view of a mounting rod;

[0031] Fig.11 is an exploded perspective view of a roof lining according to an embodiment of the present invention;

[0032] Fig.12 is a bottom perspective view of a roof structure according to an embodiment of the present invention;

[0033] Fig.13A is a bottom perspective view of a portion of a roof structure according to an embodiment of the present invention;

[0034] Fig. 13B According to an embodiment of the present invention Fig. 13B A bottom perspective view of a roof structure portion of a vehicle with the roof lining portion of the present invention mounted on the roof structure portion;

[0035] Fig.14 is an exploded view of a pressure fastener according to an embodiment of the present invention; and

[0036] Fig.15 is an exploded view of a pressure fastener according to an embodiment of the present invention. DETAILED DESCRIPTION

[0037] The present invention is applicable to a headliner attached to a roof structure of a vehicle and a headliner system that secures the headliner to the roof structure of the vehicle using mechanical snap fasteners. The headliner is removably attached to the roof structure of the vehicle and is stable and less prone to damage, accidental detachment and sagging than current headliner systems. In addition, the headliner system and method for installing the headliner provides easier replacement than all current headliner systems while being less costly and easier to manufacture and easier to install.

[0038] The present invention will now be described with reference to the following examples. As will be apparent from these descriptions, the present invention can be implemented in different forms and should not be construed as being limited to the embodiments set forth herein. On the contrary, these embodiments are provided to make this disclosure thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. For example, features described in conjunction with one embodiment can be incorporated into other embodiments, and features described for a particular embodiment can be deleted from the embodiment. In addition, according to this disclosure, it will be clear to those skilled in the art that many changes and additions to the embodiments proposed herein do not depart from the present invention. Therefore, the following description is intended to illustrate some specific embodiments of the present invention, rather than to describe in detail all its permutations, combinations and variations.

[0039] It should be understood that where a range of values ​​is provided, the range is intended to include not only the endpoints of the range, but also the intermediate values ​​of the range expressly included in the range and varying by the last significant digit of the range. For example, the exemplary range from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4 and 1-4.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the invention belongs. Here, the purpose of the terms used in the present specification is only to describe specific embodiments and is not intended to limit the present invention.

[0041] Unless indicated otherwise, explicitly or by context, the following terms are used herein as described below.

[0042] As used in the description of the invention and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0043] Also as used herein, "and / or" refers to and encompasses any and all possible combinations of one or more of the associated listed items, as well as the lack of a combination when interpreted in the alternative ("or").

[0044] like Figure 1 As shown, the headliner system 10 of the present invention includes the headliner 20 of the present invention and a roof structure 40 having an outer surface 42 and an inner surface 44. The headliner 20 of the present invention is configured to be removably attached and mounted to the inner surface 44 of the roof 40 using a plurality of compression fasteners 30, also known as snaps.

[0045] According to an embodiment, each of the plurality of pressure fasteners 30 includes a first buckle portion 32 and a second buckle portion 34. Figure 3 , Fig.14 and Fig.15As shown, the first buckle portion 32 of each of the plurality of pressure fasteners 30 includes a cover 35 and a socket 36, and the cover 35 and the socket 36 are configured to be fixed together by a piece of material between the cover 35 and the socket 36. Figure 3 As shown in , the second buckle portion 34 of each of the plurality of pressure fasteners 30 includes a stud 37 and a column 38, and the stud 37 and the column 38 are configured to be fixed together by a piece of material between the stud 37 and the column 38. Alternatively, as Fig.14 and 15 As shown, the second buckle portion 34 is formed by a single second buckle component including a stud portion 37 and through portions 39, 39'. Fig.14 As shown, the through-portion 39 is a threaded fastener, such as a screw. Fig.15 As shown, the through-portion 39' is an extrusion rivet configured to expand when compressed. According to an embodiment including a single-body second snap portion 34 having the through-portions 39, 39', the second snap portion 34 is fastened to the roof structure 40 on the inner surface 44, thereby avoiding the need for a pre-formed through hole for mounting the second snap portion 34 to the roof structure. The first snap portion 32 and the second snap portion 34 correspond to each other and are configured to be connected together to form a releasable attachment. According to an embodiment, a plurality of pressure fasteners 30 are formed of a thermoplastic, a thermosetting polymer or a metal. According to a specific embodiment of the present invention, the cover 35 of each of the pressure fasteners 30 may be stamped or embossed with a design such as a logo.

[0046] Reference again Figure 1 The headliner 20 includes a sheet 21 adapted to be installed below the vehicle roof 40, the sheet 21 of the headliner 20 having an upper surface 22 and an oppositely opposed lower surface 24. According to an embodiment, the sheet 21 of the headliner 20 is an unsupported fabric layer such as a soft fiber fabric. According to another embodiment, the sheet 21 of the headliner 20 is a supported fabric layer. That is, the sheet 21 is a layer of fabric such as a soft fiber fabric, whose supporting backing is a foam, a thermoplastic, a sheet molding compound, or some other material suitable for imparting hardness and rigidity to the fabric layer so that the headliner is self-supporting and maintains its desired shape without folding, bending or buckling. According to several embodiments of the present invention, the sheet 21 of the headliner 20 is formed of cloth, compression molded fiber, molded sheet molding compound (SMC), thermoplastic, or a combination thereof. According to an embodiment, the sheet 21 is contoured to have a non-planar shape corresponding to the shape of the inside of the roof structure, so that the sheet 21 conforms to the contour of the inner surface 44 of the roof 40. Figure 1 and Figure 2As shown, the sheet 21, when formed from a supporting layer of fabric, SMC or thermoplastic, can be preformed to have a three-dimensional structure whose contour corresponds to the contour of the inner surface 44 of the roof 40. In addition, the inventive headliner is sufficiently hard and rigid that, for example, when one end is held in an orientation generally parallel to the ground, the headliner is self-supporting and maintains its desired shape and contour without folding, bending or buckling.

[0047] Multiple halves of multiple pressure fasteners 30 are attached to the sheet 21 of the headliner 20. Figure 1 As shown, a plurality of first buckle portions 32 are fixed to the sheet 21. Therefore, a corresponding plurality of second buckle portions 34 are provided on the inner side 44 of the roof 40, and Figure 1 Those skilled in the art will appreciate that a plurality of second snap portions 34 may be provided on the sheet 21 and a plurality of first snap portions 32 may be provided on the roof 40. An important feature of the compression fastener 30 is that the first snap portions 32 and the second snap portions correspond to each other in shape, size and position and are adapted to be coupled together to mount the sheet 21 to the roof 40.

[0048] like Figure 4A and Figure 4B As shown, in an embodiment in which a plurality of first snap-in portions 32 are fixed to the sheet 21, the sheet 21 is positioned between the socket 36 of each first snap-in portion 32 and the cover 35, and the cover 35 and the socket 36 are fixed together with the sheet 21 positioned therebetween. According to an embodiment, the cover 35 and the socket 36 are fixed together by riveting. A corresponding plurality of second snap-in portions 34 are fixed to the roof structure 40, wherein a portion of the roof structure 40 is positioned between the stud 37 and the column 38 of each second snap-in portion 34, and the stud 37 and the column 38 are fixed together with the roof structure 40 positioned therebetween. According to an embodiment, the stud 37 and the column 38 are fixed together by riveting. Figure 4A and Figure 4B As shown, the cover 35 is positioned on the lower surface of the sheet 21 , the socket 36 is positioned on the upper surface of the sheet 21 , the stud 37 is positioned on the inner side 44 of the roof structure 40 , and the post 38 is positioned on the outer side 42 of the roof structure 40 .

[0049] like Figure 5A As shown, according to an embodiment of the present invention, a plurality of second snap-fit ​​portions 34 are provided on the single-layer roof structure 40 by being attached to a plurality of mounting brackets 52, which are attached to the inner side 44 of the roof structure 40. Each of the plurality of mounting brackets 52 is adhesively attached to the inner side 44 of the roof structure 40 by a strong epoxy adhesive 50. Figure 5AAs shown, the column 38 and the stud 37 of the second clip portion 34 are aligned at the through hole 54 and are joined together through the through hole 54. That is, the column 38 is positioned on one side of the mounting bracket 52 between the inner side 44 of the roof structure 40 and the mounting bracket 52, while the stud 37 is positioned on the opposite side of the mounting bracket. As described above, the column 38 and the stud 37 are riveted together. In such an embodiment, a high gloss "Class A" surface finish is provided on the outer side 42 of the roof structure, thereby further reducing the weight of the roof structure 40 because there is no need for a finishing panel to cover the clip portion that would otherwise be visible on the outer side 42 of the roof structure 40. As shown in FIG. Figure 5A As shown, the mounting bracket 52 is a flat circular mounting bracket 52 defining a through hole 54. Figure 6A-10B As shown, according to the embodiment, the shapes of the mounting brackets 52, 52', 52", 52'", 52"" are variable. Figure 6A-6B As shown, the mounting bracket 52 is flat and has a cylindrical through hole 54. Figure 7A-7B As shown, the mounting bracket 52' is flat and has a tapered through hole 54'. Figures 8A-8B As shown, the mounting bracket 52" is a top cap formed with a cylindrical through hole 54". Figures 9A-9B As shown in FIGS. 10A-10B , the mounting brackets 52 ″′, 52 ″″ are mounting rods that define a plurality of through holes 49 ″′, 49 ″″. Figures 9A-9B As shown, the mounting rod 52"' has a rectangular top hat shape, and Figures 10A-10B The mounting rod 52"" has a beveled top hat shape. According to an embodiment, the mounting brackets 52, 52', 52", 52'", 52"" are formed of metal or plastic.

[0050] According to an embodiment, such as Figure 4A As shown in , a finishing panel 46 is applied to the outer surface 42 of the roof structure 40 to cover and hide the plurality of pillars 38 positioned thereon so that the pillars 38 are not visible on the exterior of the vehicle. According to an embodiment, the finishing panel 46 is a high gloss surface sheet formed from sheet molding compound (SMC), thermoplastics, dicyclopentadiene (DCPD), overmolded polyurethane (PU), or a combination thereof. According to an embodiment, the high gloss surface sheet includes a filler material to strengthen and / or to reduce the weight of the high gloss surface sheet. The filler material is any one of glass fiber, carbon fiber, natural fiber, hollow or solid glass microspheres, or a combination thereof. The fibers may be oriented or non-oriented. In some embodiments of the present invention in which the SMC forms a high gloss surface, a high gloss surface sheet manufactured by Continental Structural Plastics, Inc. under the trade name is used herein. and ULTRA-LITE TMResin encapsulation for sale. Exemplary formulations thereof are detailed in patent documents US7700670, patent documents WO2017 / 184761 and US 7524547B2. It should be understood that high gloss sheets generally include additives for maintaining dimensions. These additives generally include glass fibers; carbon fibers; inorganic particulate fillers such as calcium carbonate, talc and carbon black; glass microspheres; carbon nanotubes; graphene; low profile additives; dewatering agents; and combinations thereof. Without considering the edge, the typical thickness of the high gloss surface sheet of the present invention is in the range of 0.5 to 3.5 millimeters (mm). As used herein, the term "high gloss surface" refers to a surface with minimal perceptible surface defects when the surface defects are visually inspected at + / -90 degrees perpendicular to the surface of the part for about 3 seconds from an observer about 24-28 inches away and in a well-lit area. That is, the term "high gloss surface" refers to a surface that can be painted and identified as a "Class A" body part. This is typically measured by ASTM D523. In the automotive industry, Class A surfaces are surfaces that consumers can see without operating the vehicle (e.g., with the hood or trunk lid open), while Class A surface finish generally refers to the exterior panels of the paint, and specifically refers to the distinctness of image (DOI) and gloss level on the part. It should be understood that the surface layer may be sanded, trimmed, and primed before obtaining a coating of paint that imparts a high gloss, but the dimensionality and bonding uniformity of the primer and paint must be maintained to achieve a high gloss finish.

[0051] like Figure 4CAs shown, when the first snap portion 32 and the corresponding second snap portion 34 are combined together to attach the sheet 21 of the headliner 20 to the roof structure, a gap G is maintained between the inner surface 44 of the roof structure 40 and the upper surface 22 of the sheet 21. In contrast, existing headliner systems that use adhesives to attach the headliner to the roof structure do not have such a gap. Therefore, the cost of the stability of the headliner system of the present invention is the cost of the empty roof head space in the passenger compartment of the vehicle, as well as the changes and new challenges to the requirements of the acoustics and sound attenuation system of the vehicle. For example, the gap G of the headliner system of the present invention may cause the sheet 21 to vibrate during the operation of the vehicle, especially on rough or uneven driving terrain that may cause uncomfortable vibration acoustics in the passenger compartment of the vehicle, thereby requiring the addition of a sound attenuation system or an additional layer within the gap G to stabilize the headliner. In existing headliner systems, since such a gap does not exist, such a problem has never been faced. While the robustness of the headliner system of the present invention comes at the expense of cost and is sacrificed by other vehicle systems, it has been surprisingly discovered that the gap G created by the buckle 30 of the present invention provides an unexpected benefit of dead space between the vehicle roof and the headliner that helps regulate the temperature within the vehicle passenger compartment. That is, the gap G unexpectedly provides an insulating pocket that insulates the vehicle passenger compartment from the extreme temperatures outside the roof 40.

[0052] Fig.11 An exploded perspective view of an inventive headliner 20 according to an embodiment of the present invention is shown. As shown, a sheet 21 having a plurality of first snap-fit ​​portions 32 fixed thereto, as described above, is one of the multiple layers that together constitute an embodiment of the headliner 20 of the present invention. According to an embodiment, the headliner 20 includes a support sheet 26 adhered or otherwise attached to the upper surface 22 of the sheet 21. The support sheet 26 provides strength and rigidity to the sheet 21. According to an embodiment, the sheet 21 is sufficiently rigid and self-supporting, in which case the support sheet 26 is not required. According to an embodiment, the support sheet 26 defines a plurality of through holes 27, the shape and position of which correspond to the plurality of first snap-fit ​​portions 32 fixed to the sheet 21. Therefore, when the upper surface 22 of the sheet 21 is covered by the support surface, the first snap-fit ​​portions 32 are still accessible. According to an embodiment, the support sheet 26 is planar or has a three-dimensional structure corresponding to the contour of the inner surface 44 of the roof structure 40.

[0053] According to an embodiment, the headliner 20 includes a functional material 25 disposed on the upper surface 24 of the sheet 21. According to an embodiment, the sheet 21 and / or the roof structure 40 includes a cavity 48 configured to accommodate the volume of the functional material 25 and the headliner 20 (see Fig.12). According to an embodiment, the functional material 25 is a phase change material, an odor absorbing material, a flame retardant or fire resistant material, or a combination thereof. Phase change materials that can be used in this article include wax or an inorganic salt hydrate. Considering that the roof structure of the vehicle, especially those that can be removed from the body, encounters extreme weather conditions such as sunlight, rain, ice or snow, this feature can help regulate the temperature inside the vehicle. When the roof structure 40 is attached to the vehicle, the phase change material helps regulate the temperature inside the vehicle. As described above, according to an embodiment of the headliner 20, the functional material 25 is a fire resistant material and / or a flame retardant material. A fire resistant material is a material designed to resist combustion and withstand heat and provide insulation to the substrate, while a flame retardant material is designed to burn slowly and reduce the rate at which the flame spreads. The working principle of the intumescent refractory material is to expand its volume from 15 times to 30 times and produce an ash-like char layer that corrodes with continued exposure to fire. Then the expansion occurs again, and the number of times the process repeats itself depends on the thickness of the coating. The fire-resistant or flame-retardant materials useful herein include any of the following: silicone resins, casein or vinyl resins, aluminum trihydrate or antimony oxide, phosphates such as ammonium polyphosphate, pentaerythritol, melamine derivatives, halogens, phosphorus, nitrogen, minerals, oxides, intumescents and nanofillers, boric acid (H 3 BO 3 ) and borax (Na 2 B 4 O 7 10H 2 O), disodium octaborate tetrahydrate (Na 2 B 8 O 13 ·4H 2 O), dicyandiamide-formaldehyde-phosphoric acid or melamine-dicyandiamide-formaldehyde-phosphoric acid, poly(n-vinyl pyrrolidone) or colloidal silica, silicon, phosphorus and nitrogen mixtures, magnesium hydroxide (MDH), monoammonium phosphate (MAP), aluminum hydroxide (ATH) and boric acid, carbonates and bicarbonates, potassium carbonate, inorganic salts, Na 2 WO 4 、Na 2 SnO 3 、Na 2 MoO 4 , ammonium polyphosphate, pentaerythritol, melamine and expandable graphite and nano-composite coatings.

[0054] According to an embodiment, the sheet 21 includes an electrical component 23 embedded in the sheet 21. According to an embodiment, the electrical component 23 includes any one of a light, a speaker, a wire, a screen, or a combination thereof. According to an embodiment, the electrical component and any associated power supply lines are provided on the upper surface 22 of the sheet 21, but parts of the electrical component are visible on the lower surface 24 of the sheet 21 through openings provided in the sheet 21. In such an embodiment, the headliner 20 includes an electrical connector that is connected to a corresponding connector provided on the roof structure that is ultimately connected to a power source of the vehicle.

[0055] According to an embodiment, a decorative sheet 28 is adhered or otherwise attached to the lower surface 24 of the sheet 21. The decorative sheet 28 is configured to cover the sheet 21 and conceal the sheet 21 when viewed from inside the vehicle passenger compartment. According to an embodiment, the decorative sheet 28 is an aesthetically pleasing fabric layer. According to an embodiment, the decorative sheet 28 covers the cover 35 of the first snap portion 32, which would otherwise be visible on the lower surface 24 of the sheet 21. According to an embodiment, the decorative sheet 28 defines at least one through hole 29 therein, through which portions of the sheet 21 or various components embedded in the sheet 21 are visible. For example, as Fig.11 As shown, the decorative sheet 28 includes three openings 29 , the shapes and positions of which correspond to the three light emitting elements 23 embedded in the sheet 21 .

[0056] Fig.12 FIG. 4 shows a roof structure 40 according to an embodiment of the present invention. Fig.12 As shown, the roof structure 40 forms a profile. Such a profile can be used to accommodate other vehicle components, other components of the headliner 20, and / or structural beams and / or safety features used to form the roof 40 of the vehicle. Fig.12 As shown, the embodiment of the roof structure 40 includes a cavity 48 for receiving a portion of the headliner 20, such as the functional material 25 or the electrical component 23 provided in the embodiment of the headliner 20 of the present invention. Fig.12 As shown, an embodiment of the roof structure 40 includes through holes 49 defined in the structure of the roof 40 at various predetermined locations. Such through holes 49 provide attachment points for the plurality of second snap portions 34 of the plurality of pressure fasteners 30. That is, each post 38 in the plurality of second snap portions 34 is disposed on the outer surface 42 of the roof structure 40 at each through hole 49, each of the plurality of studs 37 in the plurality of second snap portions 34 is disposed on the inner side 44 of the roof structure 40 at each through hole 49, and the studs 37 are then riveted to the posts 38 through the through holes 49 defined in the roof structure 40. In some inventive embodiments, additional holes 47 are provided, which are provided for other vehicle components, such as a drain pipe, or for mounting a plurality of roof fixing rods 56, such as Fig.13A and Fig. 13B shown. Fig.13A A portion of the roof structure 40 is shown that is removable from the rest of the roof structure. As shown, a plurality of rotatable rods 56 are provided on the inner surface 44 of the roof structure 40 for locking the removable portion of the roof 40 to the rest of the roof structure. In addition, Fig.13A A plurality of second snap-in portions 34 are shown installed in the roof structure 40 within the headliner 20 receiving cavity 48 of the roof structure 40 . Fig. 13B Shown with Fig.13A Same removable roof as in 40, but in Fig. 13B In the embodiment shown in FIG. 4 , a portion of the headliner 20 is mounted within a cavity 48 of the roof structure 40 .

[0057] According to an embodiment, the roof structure 40 is formed of metal, reinforced sheet molding compound (SMC), epoxy resin, acrylonitrile butadiene styrene (ABS), polycarbonate or randomly oriented fiber reinforced thermoplastic resin (FRTP). Sheet molding compound (SMC) or sheet molding composite is an easily moldable fiber reinforced polyester material mainly used for compression molding. SMC is a reinforced composite material made by dispersing long strands (>1") of chopped glass fibers in a polyester resin bath. Thermoplastic materials mentioned herein include, but are not limited to, poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide, polylactide, polybenzimidazole, polycarbonate, polyethersulfone, polyethylene, polypropylene, polystyrene, polyvinyl chloride and block copolymers of any of the foregoing. Reinforcing fibers and fillers that can be used herein exemplarily include carbon fibers, glass fibers, aramid fibers, cellulose fibers or combinations thereof. In some inventive embodiments, the chopped fibers are glass fibers alone or in combination with other types of fibers or reinforcing fillers. According to an embodiment, the roof structure 40 is formed of glass fiber reinforced SMC.

[0058] Based on the above disclosure, one of ordinary skill in the art will recognize the benefits provided by embodiments of the roof liner 20 and roof liner system of the present invention. Without limitation, the benefits provided by embodiments of the roof liner 20 and roof liner system of the present invention include a roof liner system that does not require adhesives to be installed to the roof structure. As described above, such adhesives deteriorate and fail, resulting in a reduction in the tension applied to the roof liner, thereby causing sagging or falling off of the roof liner, which is unattractive and obstructive to the driver's field of vision. Considering the sturdy nature of the pressure fasteners employed in embodiments of the present invention and the absence of adhesives, the present invention provides the advantage that the roof liner is less likely to sag or be undesirably attached from the roof structure. In addition, considering the removable nature of the pressure fasteners employed, the roof liner of the roof liner system can be easily installed, removed and replaced. This provides the ability to easily replace a dirty roof liner, such as to clean a car before the vehicle is resold. In addition, the removability and replaceability of the roof lining allows customization and personalization of the vehicle, such as providing the roof lining with a variety of decorative prints (e.g. stripes, leopard, plaid, gingham, houndstooth, paisley, Battenberg lace) and various electrical components (e.g. optional screens, lighting functions, speaker systems, etc.), as well as various functional fabrics (e.g. winter linings made of wool, polar fleece or flannel, etc.).

[0059] The patent documents and publications mentioned in the specification are indicative of the level of technical personnel in the field to which the invention pertains. These documents and publications are incorporated herein by reference to the same extent as if each individual document or publication was specifically and individually incorporated herein by reference.

[0060] The above description is an illustration of specific embodiments of the present invention, but is not meant to limit the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the present invention.

Claims

1. A removable and replaceable headliner for use in a vehicle having a roof, the headliner comprising: a sheet adapted to be removably mounted below the vehicle roof, the sheet having an upper surface and a lower surface; a plurality of first snap-in portions secured to the sheet, each of the first snap-in portions comprising a cap and a socket, the cap being a male half of a compression fastener and the socket being a female half of a compression fastener, the cap and the socket being secured together in a manner such that the sheet is located between the cap and the socket, the plurality of first snap-in portions being adapted to be releasably directly coupled to a corresponding plurality of second snap-in portions to mount the sheet to the vehicle roof; as well as A plurality of mounting brackets are attached to the inner side of the roof, each of the plurality of second snap-in parts comprises a stud and a column, the stud is fixed to the column when one of the plurality of mounting brackets is located between the stud and the column, and each of the plurality of mounting brackets and each of the plurality of second snap-in parts are directly attached to the inner side of the roof.

2. The headliner according to claim 1, wherein: The plurality of first hook portions are fixed to the sheet material by riveting, respectively.

3. The headliner according to claim 1, wherein: The sheet is rigid.

4. The headliner according to claim 1, wherein: The sheet is formed from molded sheet molding compound (SMC) or thermoplastic.

5. The headliner according to claim 1, wherein: The sheet conforms to the contour of the roof.

6. The headliner of claim 1 further comprising a phase change material disposed on the upper surface of the sheet.

7. The headliner of claim 1 further comprising electrical components embedded in said sheet.

8. The headliner of claim 1, further comprising a decorative layer disposed on a lower surface of the sheet.

9. A removable and replaceable roof lining system, comprising: A roof structure having an outer side and an inner side; a headliner comprising a sheet adapted to be mounted to said interior side of said roof structure, said sheet having an upper surface and a lower surface; a plurality of first snap-fit ​​portions, the plurality of first snap-fit ​​portions being fixed to the sheet, each of the first snap-fit ​​portions comprising a cover and a socket, the cover being a male half of a pressure fastener and the socket being a female half of a pressure fastener, the cover and the socket being fixed together in such a way that the sheet is located between the cover and the socket; a plurality of second snap-in portions fixed to the roof structure, the plurality of second snap-in portions being adapted to be directly and releasably coupled to the plurality of first snap-in portions to mount the sheet material to the inner side of the roof structure; as well as A plurality of mounting brackets are attached to the inner side of the roof, each of the plurality of second snap-in portions comprises a stud and a column, the stud is fixed to the column when one of the plurality of mounting brackets is located between the stud and the column, and each of the plurality of mounting brackets and each of the plurality of second snap-in portions are directly attached to the inner side of the roof.

10. The headliner system according to claim 9, wherein: The roof structure is removable from the vehicle.

11. The headliner system of claim 9, wherein: The roof structure is formed from a reinforced sheet molding compound (SMC).

12. The headliner system of claim 9, wherein: The sheet is rigid.

13. The headliner system of claim 9, wherein: The sheet is contoured to have a non-planar shape corresponding to the shape of the inner side of the roof structure.

14. A method for removably mounting a headliner on a roof structure, the method comprising: providing a headliner, the headliner comprising a sheet having an upper surface and a lower surface; providing a plurality of first snap-fit ​​parts, each of which comprises a cover and a socket, the cover being the male half of the pressure fastener and the socket being the female half of the pressure fastener, the cover and the socket being fixed together in such a way that the sheet is located between the cover and the socket; The plurality of first snap-in parts are directly coupled to the plurality of second snap-in parts, each of the plurality of second snap-in parts comprising a stud and a column, the stud and the column being fixed together when one of the plurality of mounting brackets is located between the stud and the column, each of the plurality of mounting brackets and each of the plurality of second snap-in parts being directly attached to the inner side of the roof.

15. The method of claim 14, further comprising first removing an existing headliner from the roof structure to expose the plurality of second clip portions secured to the roof structure.

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