Headliner substrate

Abstract

A headliner substrate (206) for a cantrail (102) of a vehicle (100), the headliner substrate comprising at least one aperture (402) configured to receive a cantrail feature (202) of the vehicle; a first region (404) of headliner substrate extending at least partly around a perimeter of the at least one aperture, the first region of headliner substrate having a first thickness; a second region (406) of headliner substrate arranged outside and adjacent to the first region of headliner substrate, the second region of headliner substrate (206) having a second thickness, wherein the second thickness is smaller than the first thickness. Aspects of the invention are also related to a system incorporating a cantrail of a vehicle, a headliner substrate and a cantrail feature, and a vehicle incorporating the system.

Description

TECHNICAL FIELD The present disclosure relates to a headliner substrate. Aspects of the invention relate to headliner substrate fora cantrail of a vehicle, to a system comprising the headliner substrate, and to a vehicle. BACKGROUND Consoles or cantrail features may be coupled to a cantrail of a vehicle, positioned such that they are received by an opening in a headliner substrate. Cantrail features may provide a number of services to a passenger, such as grab-handles to ease ingress and egress, speakers, air conditioning controls and air conditioning vents. Passenger side airbags may be collocated with the cantrail feature, between the cantrail of the vehicle and the headliner substrate. When the passenger airbag is triggered, the headliner substrate is pushed away from the cantrail, allowing the airbag to emerge. However, with the inclusion of a large number of services, cantrail features require a larger space. This may cause the headliner substrate to not separate from the cantrail feature cleanly when the passenger side airbag is triggered, putting excessive force on the cantrail feature. It is necessary to ensure that when an airbag is triggered, excessive force is not applied to the cantrail feature which may cause damage. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a headliner substrate for a cantrail of a vehicle, a system comprising the cantrail of the vehicle and the headliner substrate, and a vehicle as claimed in the appended claims. The disclosure provides a headliner substrate for a cantrail of a vehicle, the headliner substrate comprising a first region having a first thickness, and a second region arranged outside and adjacent to the first region of headliner substrate, the second region of headliner substrate having a second thickness, wherein the second thickness is smaller than the first thickness. According to another aspect of the invention, there is provided a headliner substrate fora cantrail of a vehicle, the headliner substrate comprising: at least one aperture configured to receive a cantrail feature of the vehicle; a first region of headliner substrate extending at least partly around a perimeter of the at least one aperture, the first region of headliner substrate having a first thickness; a second region of headliner substrate arranged outside and adjacent to the first region of headliner substrate, the second region of headliner substrate having a second thickness, wherein the second thickness is smaller than the first thickness. As such, a thinner region of headliner substrate is arranged around the aperture so as to provide a live hinge point that reduces the load required to peel the headliner substrate from around the cantrail feature in the event of airbag deployment. In doing so, if and when an air bag in the region of the cantrail feature is deployed, the thinner region of headliner substrate causes the headliner substrate to pivot at a predetermined point as it is pulled away from the cantrail, such that the headliner peels away without putting excessive load onto the cantrail feature in the process. This may reduce or prevent damage occurring to the cantrail feature. Due to its thinner construction, the second region of headliner substrate requires a lower force to pivot or bend compared to the first region of headliner substrate. As such, when a force is applied to the headliner substrate, the headliner substrate pivots or bends at the second region. The first region of headliner substrate may be 8-9mm thick. Alternatively, the first region may be 7-1 Omm, 6-11mm or any other suitable headliner substrate thickness. The second region of headliner substrate may be 2-2.5mm thick. A cantrail of a vehicle may be the longitudinal structure of the vehicle body above the side windows or doors of the vehicle. Optionally, the headliner substrate may comprise a third region of headliner substrate arranged outside and adjacent to the second region of headliner substrate, the third region of headliner substrate having a third thickness, the third thickness being substantially the same as the first thickness. Providing a third region of headliner substrate of substantially the same thickness as the first region ensures that the headliner substrate provides a clearly defined flexible joint or hinge. This ensures that the headliner substrate pivots at the second region of the headliner substrate when a force is applied to pull the headliner substrate away from the cantrail, for example, due to the deployment of an airbag. The third region of the headliner substrate may be the same thickness as the first region of headliner substrate, or within 0-2mm of the thickness of the first region of the headliner substrate Optionally, the headliner substrate may comprise a plurality of slits through the headliner substrate, wherein the slits are located such that they pass from the at least one aperture and at least partially into the second region of the headliner substrate. Providing slits through the headliner substrate further ensures that the headliner substrate cleanly detaches from the cantrail feature. Optionally, each of the plurality of slits is located in a corner region of the aperture. The corners of the cantrail feature may typically provide a more difficult geometry for the headliner substrate to separate from. Providing the slits in the corner regions of the aperture ensures that the headliner substrate cleanly detaches from the cantrail feature. Optionally, the headliner substrate is a composite PUR sandwich. Optionally, the composite PUR sandwich comprises a first layer of glass fiber matting, a second layer of glass fiber matting and a layer of polyurethane foam between the first layer and the second layer. According to another aspect of the invention, there is provided a system, the system comprising: a cantrail of a vehicle; the headliner substrate, wherein at least a portion of the headliner substrate is arranged over a surface of the cantrail of the vehicle; and a cantrail feature coupled to the cantrail of the vehicle, the cantrail feature being received by the at least one aperture of the headliner substrate. Optionally, an airbag is arranged between the cantrail of the vehicle and the headliner substrate. Optionally, the airbag is positioned in proximity to the at least one aperture of the headliner substrate, such that a deployment of the airbag causes the headliner substrate to pivot at the second region as the headliner substrate is pulled from the surface of the cantrail. As such, the airbag is located such that, when it is deployed, the force of the airbag inflation causes the thinner region of the headliner substrate to bend away from the cantrail feature, thus reducing the load on the cantrail feature as the headliner substrate is pulled away from the cantrail. For example, the airbag may be positioned adjacent to the cantrail feature and the at least one aperture of the headliner substrate. More specifically, the airbag may be positioned below the cantrail feature and the at least one aperture of the headliner substrate. Optionally, the cantrail feature comprises at least one of a grab handle; one or more electrical components. Larger cantrail features allow further services to be provided to passengers of a vehicle. The one or more electrical components of the cantrail feature may comprise speakers, switches, air-conditioning supplies or vents and air conditioning controls. Optionally, at least a portion of the first region of the headliner substrate is arranged between the cantrail of the vehicle and the cantrail feature. According to yet another aspect of the invention, there is provided a vehicle comprising the headliner substrate or the system. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in anyway and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a representation of a vehicle in accordance with an embodiment of the invention; Figure 2 is a representation of the internal components of a roof structure of the vehicle in Figure 1; Figure 3 shows a perspective view through the typical roof structure of a vehicle; Figure 4 shows a headliner substrate in accordance with an embodiment of the invention; Figure 5 shows an alternative view of the headliner substrate of Figure 4; Figure 6 shows a perspective view through the roof structure of the vehicle, including the headliner substrate of Figure 4; Figure 7A shows a view of the materials of the headliner substrate in accordance with an embodiment of the invention; Figure 7B shows a view of the compression of the materials of the headliner substrate of Figure 7A; and Figure 8 shows a view of the location of a cantrail feature, cantrail and headliner substrate in accordance with an embodiment of the invention. DETAILED DESCRIPTION Figure 1 shows a vehicle 100. The vehicle 100 comprises a cantrail 102. The cantrail 102 is the longitudinal structure of the vehicle 100 body located above the side windows 104 and / or doors 106 of the vehicle 100. The cantrail 102 forms part of the roof structure of the vehicle 100. Figure 2 shows a cutaway view of the roof structure 200 of the vehicle 100. The roof structure 200 shown in Figure 2 does not include the outer body layer or body in white of the vehicle 100, allowing the components which are ordinarily coupled to the outer body layer to be seen. For example, the cantrail 102 itself forms part of the outer body layer and is therefore not shown in Figure 2. The roof structure 200 includes one or more cantrail features 202, at least one airbag 204 and a headliner substrate 206. Whilst two airbags 204 are shown on each side of the roof structure 204 that run along the length of the headliner substrate 206, it will be appreciated that multiple airbags may be provided on each side of the roof structure 200. For example, a first set of airbags may be provided at the front of the roof structure 200 (e.g., adjacent to the driver’s seat and front passenger’s seat), and a second set of airbags may be provided at the rearofthe roof structure (e.g., adjacent to the rear passenger’s seats). Cantrail features 202 are coupled to an internal side of the cantrail 102 and configured to provide a number of services to a passenger. The vehicle 100 may include one or more cantrail features 202. For example, there may be a cantrail feature 202 located above each window 104 of the vehicle 100, allowing the occupants of the vehicle 100 to reach upwards and control the services provided by the cantrail feature 202. Cantrail features 202 may comprise grab-handles, easing ingress and egress forthe occupants of the vehicle 100. Each cantrail feature 202 may also or alternatively comprise one or more electronic components, such as speakers, switches, air-conditioning supplies, or vents and air conditioning controls. Including a large number of services in the cantrail feature 202 increases the size of the cantrail feature 202. Whilst some traditional cantrail features 202 may comprise only a grab-handle, cantrail features including other services and controls may be significantly larger. For example, some cantrail features may have a length of up to 60cm or more. A headliner substrate 206 is positioned over the internal surface of the roof structure 200. The one or more cantrail features 202 are then positioned in an aperture 402 of the headliner substrate 206, as shown further in Figure 4, which is described further below. The apertures 402 in the headliner substrate 206 allow each cantrail feature 202 to be seen and controlled by an occupant of the vehicle 100. The vehicle 100 may comprise one or more airbags or side airbags 204 (also referred to as “curtain” airbags). The airbag 204 is positioned in proximity to the at least one aperture 402 of the headliner substrate (for example, below the lower edge of the apertures 402), along the cantrail 102 of the vehicle 100. On triggering the side airbag 204 the side airbag 204 inflates, pulling the headliner substrate 206 out and away from the cantrail 102 of the vehicle 100. This creates space for the airbag 204 to emerge from the roof structure 200 and inflate along a side area of the vehicle 100. As the headliner substrate 206 moves or peels away from the roof structure 200, it is also peeled away from and around the cantrail feature 202. The use of larger cantrail features 202 which provide a wider range of services to a passenger results in an increased force being required to peel the headliner substrate 206 away from the cantrail feature 202. This may result in damage occurring to the cantrail feature 202 when the headliner substrate 206 moves during airbag deployment. As such, it is desirable to reduce the load or force required to peel the headliner substrate 206 away from the cantrail feature 202. Figure 3 shows a planar view through a typical roof structure known in the art. In the arrangement shown in Figure 3, the headliner substrate 306 around the cantrail feature 302 is substantially one thickness, with no clearly defined regions of differing thickness. The force required to bend or pivot the headliner substrate 306 may cause damage to the cantrail feature 302. In embodiments of the invention, instead of including a headliner substrate 306 of one thickness, the thickness of the headliner substrate 306 is modified to provide regions of different thicknesses as described in more detail below. Figure 4 shows a portion of the headliner substrate 206 according to an embodiment of the invention in more detail. The headliner substrate 206 comprises a modified region surrounding the aperture 402 for the cantrail feature 202 which reduces the force required to peel the headliner substrate 206 away from and around the cantrail feature 202. The headliner substrate 206 comprises the aperture 402 configured to receive the cantrail feature 202 of the vehicle 100. The aperture 402 may be any shape suitable for receiving the cantrail feature 202. For example, the aperture 402 may be substantially the same shape as the cantrail feature 202, such as a rectangular or oval aperture. The aperture 402 may be formed by stamping out or cutting away a section of the headliner substrate 206 during manufacture. A first region 404 of the headliner substrate 206 extends at least partially around a perimeter of the aperture 402. Extending at least partially around a perimeter of the aperture may comprise extending along at least part of one or more edges of the aperture 402. For example, the first region 404 may surround the aperture 402 on all sides. The first region 404 may be formed as a concentric shape around the aperture 402, such that the first region 404 and the aperture 402 have the same centre point. A second region 406 of headliner substrate 206 is arranged outside and adjacent to the first region 404 of headliner substrate 206. Outside the first region 404 may mean that the second region 406 is at a greater distance from the centre or edge of the aperture 402 compared to the first region 404. The second region 406 of headliner substrate may extend along one or more edges of the first region 404. For example, the second region 406 may surround the first region 404 on all sides. As another example, the second region 406 may not extend around the whole of the first region 404, but may instead be positioned such that it extends along a first edge of the first region 404. The first edge of the first region 404 may be selected as the area where it is desirable for the headliner substrate 206 to bend or pivot when subject to a force created by the airbag 204. For example, the first edge of the first region 404 may be an edge of the first region 404 that is in closest proximity to the airbag 204. Positioning the headliner substrate 206 such that it does not surround the first region 404 in this manner results in the headliner substrate 206 bending or pivoting adjacent to the first edge of the first region 404 in preference to the other edges of the first region 404. This allows the direction of movement of the headliner substrate 206 when subject to force to be controlled. As another example, the second region 406 may extend along a first edge of the first region 404 (e.g., the edge closest to the airbag 204) and at least partially along the two edges adjacent to the first edge (i.e., on either side) such that the headliner substrate 206 preferentially bends or pivots in this region when subject to a force created by the airbag 204. The first region 404 of headliner substrate 206 has a first thickness and the second region 406 of the headliner substrate 206 has a second thickness. By setting the first thickness to be greater than the second thickness, the headliner substrate 206 will bend or flex at the second region 406 of headliner substrate 206 in preference to bending or flexing at the first region 404. The thinner material of the second region 406 requires a smaller force to bend compared to the first region 404. When an air bag, such as the airbag 204, in the region of the cantrail feature 202 is deployed, the thinner second region 406 of headliner substrate causes the headliner substrate 206 to pivot at a predetermined point as it is pulled away from the cantrail 102, such that the headliner substrate 206 peels away without putting excessive load onto the cantrail feature 202 in the process. This reduces the possible damage that may occur to the cantrail feature 202 as the airbag 204 is deployed. Figure 5 shows an alternative schematic view of the headliner substrate 206 of Figure 4, taken as a sectional view through the headliner substrate 206. The headliner substrate 206 may optionally comprise a third region 408 of headliner substrate arranged outside and adjacent to the second region 406 of headliner substrate 206. Outside the second region 406 may mean that the third region 408 is a greater distance from the centre or an edge of the aperture 402 compared to the second region 406. The third region 408 of headliner substrate may extend along one or more edges of the second region 406. The third region 408 may surround the second region 406 on all sides. The third region 408 of headliner substrate 206 has a third thickness. The third thickness may be substantially the same as the first thickness. By including a third region 408 of headliner substrate with a greater thickness than the second region 406, the headliner substrate 206 has a clearly delineated second region 406 which requires less force to bend or pivot than either of the first region 404 or the third region 408. This helps to ensure that the headliner substrate 206 pivots at the desired location within the second region 406, thereby reducing the load exerted on the cantrail feature 202 as the headliner substrate 206 is pulled away from the cantrail 120 under the force of the airbag 204. The location of the second region 406 may therefore be positioned in an area of the headliner substrate 206 where the bending or pivoting of the headliner substrate 206 is desired. Whilst Figure 5 shows the second region 406 having a substantially square cross-sectional shape, it will be appreciated that this is purely illustrative and that the edge between the first region 404 and second region 406, and between the second region 406 and the third region 408, may be curved so as to provide a gradual slope into the first and third regions 404, 408, as is shown in Figure 6. Figure 6 is a perspective view through the roof structure 200 of Figure 2, showing in greater detail the three regions of different thicknesses 404-408 surrounding the cantrail feature 202 or the aperture 402 for the cantrail feature 202. The airbag 204 is positioned in proximity to the cantrail feature 202 and the headliner substrate 206. As discussed above, the cantrail feature 202 may comprise a grab handle (shown partially at 602), which may be arranged such that it faces into the cabin of the vehicle 100 when the headliner substrate 206 is affixed to the cantrail 102. Similarly, the cantrail feature 202 may additionally or alternatively comprise one or more electrical components (shown generally at 604), such as speakers, switches, air-conditioning supplies, or vents and air conditioning controls. When compared to Figure 3, it is clear that Figure 3 shows that the headliner substrate 206 around the cantrail feature 202 is substantially one thickness, with no clearly defined regions of differing thickness. The headliner substrate 206 may, throughout the majority of its construction, be 8-9mm thick. This thickness aids in dampening noise and provides a plusher appearance to the headliner substrate 206. As such, the thickness of the first region 404 and the third region 408 may be 8-9mm thick. Alternatively, the first region and the third region may be 7-10mm, 6-11mm or any other suitable headliner substrate thickness. The second region 406 may be significantly thinner than the first region 404 and the third region 408. The thickness of the second region 406 may be chosen in dependence on the material type used for the headliner substrate, with the second thickness chosen such that the headliner substrate 206 pivots or acts as a hinge when subjected to force. For example, the second region 406 may be 1-3mm thick, or more specifically, 2-2.5mm thick. In addition to including the second region 406 of reduced thickness headliner substrate 206, the headliner substrate 206 may also comprise a plurality of slits 410 which pass through the headliner substrate 206. These slits 410 are shown in Figure 4. The slits 410 pass from the aperture 402, through the first region 404 of headliner substrate 206 and at least partially into the second region 406 of headliner substrate 406. In some examples, the one or more slits 410 may pass all the way through the second region 406 of the substrate 406. One or more slits 410 may be included in the headliner substrate 206. For example, four slits 410 may be positioned at four comers of the headliner substrate 206. By positioning the slits 410 such that they pass from the aperture 402 to the second region 410, the slits allow the headliner substrate 206 to fold away from the aperture 402 and cantrail feature 202 in multiple directions. This divides the headliner substrate 206 into a number of regions which may fold or pivot at the second region 406 in different directions when subject to force. This reduces the force required to pull the headliner substrate 206 away from the cantrail feature 202. The headliner substrate 206 may be a composite material, such as a composite PUR sandwich. Figure 7A shows an area 700 of headliner substrate 206 as typically known in the art, comprising a first layer 702 of glass fiber matting, a second layer 706 of glass fiber matting and a layer 704 of polyurethane foam between the first layer 702 and the second layer 704. To form the second region 406 of reduced thickness, the second region 406 may be subjected to greater compression compared to the first region 404 and the third region 408. Figure 7B shows an area of the headliner substrate 206 including the first 404, second 406 and third regions 408. The compression applied to the second region 406 may cause the layer 704 of polyurethane foam in the second region 406 to be compressed and pushed into the surrounding first region 404 and third region 408, such that the layer of polyurethan foam 704 in the second region 406 is thinner than the layer of polyurethane foam in the first region 404 and third region 408. Whilst Figure 3 shows a single aperture 402 positioned within the first region 404 of headliner substrate 206 that is configured to receive a cantrail feature 202, the aperture 402 may comprise a plurality of apertures, with separate portions of one or more cantrail features 202 configured to pass through respective apertures. Figure 8 shows a different view of part of the vehicle 100 including the cantrail 102, the cantrail feature 202 and the headliner substrate 206. The cantrail feature 202 is coupled to the cantrail 102 using a coupling means 802, which may be any suitable coupling means 802 such as a bolt or screw. The headliner substrate 206 is arranged such that at least a portion of the first region 404 of the headliner substrate 206 is arranged over a surface of the cantrail 102 of the vehicle, such that it sits between the cantrail 102 and a portion of the cantrail feature 202. This ensures that the headliner substrate 206 does not have a visible edge, whilst allowing the second region 406 to not be positioned between the cantrail 102 and the cantrail feature 202. This allows the second region 406 to pivot or bend when subject to force imposed by a deploying airbag . If an airbag is deployed, force is applied to the headliner substrate 206. The headliner substrate 206 is pulled away from the surface of the cantrail 102, and the airbag begins to emerge between the cantrail 102 and the headliner substrate 206. As the airbag continues to deploy, the second region 406 will bend and pivot, thereby allowing the headliner substrate 206 to move away from the cantrail feature 202. As the second region 406 bends and pivots, the first region 404 is pulled out and detached from the space between the cantrail 102 and the cantrail feature 202. Where a plurality of slits 410 are provided in the headliner substrate 202, passing from the aperture 402 to the second region 406, the first region 204 may fold, bend or pivot away from the cantrail feature 202 in multiple directions. This further reduces the force applied to the cantrail feature 202. This ensures that the movement of the headliner substrate 206 away from the cantrail 102 does not exert an excessive load on the cantrail feature 202. The combination of the first region 404, second region 406, and optional third region 408 of the headliner substrate 206 thus allow the headliner substrate 206 to move away from the cantrail feature 202 if an airbag is deployed. The airbag which may cause the headliner substrate to move is shown in Figure 6. The airbag 204 is positioned adjacent to the cantrail feature 202 and headliner substrate 206. The airbag 204 is positioned in proximity to the at least one aperture 402 which receives the cantrail feature 202, such that a deployment of the airbag 204 causes the headliner substrate 206 to pivot at the second region 406 of the headliner substrate 206 as the headliner substrate 206 is pulled from the surface of the cantrail 102. It will therefore be appreciated that the second region 406, that is, the region having a narrowed thickness, will be provided at least along the side of the aperture 402 that is closest to the airbag 204. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims

1. A headliner substrate for a cantrail of a vehicle, the headliner substrate comprising:at least one aperture configured to receive a cantrail feature of the vehicle;a first region of headliner substrate extending at least partly around a perimeter of the at least one aperture, the first region of headliner substrate having a first thickness;a second region of headliner substrate arranged outside and adjacent to the first region of headliner substrate, the second region of headliner substrate having a second thickness,wherein the second thickness is smaller than the first thickness.

2. The headliner substrate according to claim 1, further comprising:a third region of headliner substrate arranged outside and adjacent to the second region of headliner substrate, the third region of headliner substrate having a third thickness, the third thickness being substantially the same as the first thickness.

3. The headliner substrate according to any preceding claim, further comprising:a plurality of slits through the headliner substrate, wherein the slits are located such that they pass from the at least one aperture and at least partially into the second region of the headliner substrate.

4. The headline substrate according to claim 3, wherein each of the plurality of slits is located ina corner region of the aperture.

5. The headliner substrate according to any preceding claim, wherein the headliner substrate isa composite PUR sandwich.

6. The headliner substrate according to claim 5, wherein the composite PUR sandwichcomprises a first layer of glass fibre matting, a second layer of glass fibre matting and a layer of polyurethane foam between the first layer and the second layer.

7. A system, the system comprising:a cantrail of a vehicle;the headliner substrate of any preceding claim, wherein at least a portion of the headliner substrate is arranged over a surface of the cantrail of the vehicle; anda cantrail feature coupled to the cantrail of the vehicle, the cantrail feature being received by the at least one aperture of the headliner substrate.

8. The system according to claim 7, further comprising:an airbag arranged between the cantrail of the vehicle and the headliner substrate.

9. The system according to claim 8, wherein the airbag is positioned in proximity to the at leastone aperture of the headliner substrate, such that a deployment of the airbag causes the headliner substrate to pivot at the second region as the headliner substrate is pulled from the surface of the cantrail.5 10. one of: The system according to any of claims 7-9, wherein the cantrail feature comprises at least a grab handle; one or more electrical components. 10 11. The system according to and of claims 7-10, wherein at least a portion of the first region ofthe headliner substrate is arranged between the cantrail of the vehicle and the cantrail feature.

12. A vehicle comprising: the headliner substrate of any of claims 1-6; or 15 the system of any of claims 7-11.

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