Multi-piece headliner
A modular vehicle headliner system with nested studs and connectors simplifies assembly and maintenance by allowing panels to be fitted through smaller openings, improving ease of installation and access.
Patent Information
- Authority / Receiving Office
- GB · GB
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-09-17
- Publication Date
- 2026-03-18
AI Technical Summary
Existing vehicle headliners are large single components that are time-consuming to assemble and replace due to access requirements, necessitating early assembly integration and complicating maintenance.
A modular vehicle headliner system comprising multiple panels with nested studs and connectors, allowing each panel to be smaller and easier to fit through vehicle openings, with elastically deformable clips for secure attachment.
Facilitates easier assembly and maintenance by enabling panels to be fitted through smaller openings, while maintaining structural integrity and insulation properties.
Smart Images

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Abstract
Description
TECHNICAL FIELD The present disclosure relates to a multi-piece headliner. Aspects of the invention relate to a vehicle headliner, a vehicle cabin, a vehicle and a method of fitting a vehicle headliner. BACKGROUND It is known to provide vehicle headliners on the interior of a vehicle cabin to cover structural components and to improve noise insulation and thermal insulation within the cabin. Such headliners are provided as large single components which must be assembled to the vehicle at a relatively early stage of the assembly process and are time consuming to replace due to access requirements for removing the headliner. 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 vehicle headliner, a vehicle cabin, a vehicle and a method of assembling a vehicle cabin as claimed in the appended claims. According to an aspect of the present invention, there is provided a vehicle headliner couplable to a roof portion of a vehicle structure, the vehicle headliner comprising: a first panel comprising first locating means for positioning the first panel relative to the vehicle structure and a first connector for coupling the first panel to the vehicle structure; and a second panel comprising second locating means for positioning the second panel relative to the first panel and a second connector for coupling the second panel to the vehicle structure. According to a further aspect of the present invention there is provided a vehicle headliner couplable to a roof portion of a vehicle structure, the vehicle headliner comprising: a first panel comprising a hollow first stud of the first panel for positioning the first panel relative to the vehicle structure, the hollow first stud configured to be received in a corresponding aperture within the vehicle structure, and at least one first connector for coupling the first panel to the vehicle structure; and a second panel comprising a first stud of the second panel for positioning the second panel relative to the first panel, the first stud of the second panel configured to be received in the hollow first stud of the first panel, and at least one second connector for coupling the second panel to the vehicle structure. Providing the vehicle headliner as a modular system comprising two or more panels improves ease of assembly of the vehicle cabin, by allowing each panel to be made smaller than the overall size of the vehicle headliner. Each panel may therefore be passed through the windscreen aperture or through the door gap during assembly. Providing a part-to-part assembly stack between the first and second panels may help achieve tolerance requirements and further improve ease of assembly of the vehicle headliner. By providing the first and second panels with nested studs a single datum can be provided on the vehicle structure off which both panels of the headliner can be located. The first panel may have a first end and a second end. The hollow first stud may comprise a first four-way locator at the first end of the first panel. The first panel may further comprise a first two-way locator at the second end of the first panel. Providing a separate four-way and two-way locator may allow the first panel to be fully constrained relative to the vehicle structure without over-constraining the panel. This may allow manufacturing and / or assembly tolerances to be met. A four-way locator is here defined as a locating means for constraining movement of a component in a positive and negative first direction and in a positive and negative second direction perpendicular to the first direction. A two-way locator is here defined as a locating means for constraining movement of a component in a positive and negative first direction only. The first two-way locator may comprise a second stud of the first panel configured to be received in an elongate slot within the vehicle structure. A stud configured to be received in an elongate slot may provide a convenient method of constraining movement of the first panel in a first direct whilst permitting manufacture and assembly tolerances in directions perpendicular thereto. The second panel may have a first end and a second end. The first stud of the second panel may comprise a second four-way locator at the first end of the second panel. The second panel may further comprise a second two-way locator at the second end of the second panel. Providing a separate four-way and two-way locator may allow the second panel to be fully constrained relative to the vehicle structure without over-constraining the panel. This may allow manufacturing and / or assembly tolerances to be met. The second stud of the first panel may be hollow. The second two-way locator may comprise a second stud of the second panel configured to be received within the second stud of the first panel. By providing the first and second panels with nested studs at their second ends, a second datum can be provided on the vehicle structure off which both panels of the headliner can be located. The hollow first stud of the first panel and / or the second stud of the first panel may be provided as one or more separate components removably coupled to the first panel, optionally using at least one fastener, Providing the first and / or second studs of the first panel as a separate component coupled to the panel may improve ease of manufacture. It may also allow the headliner to be made modular such that similar first panels may be fitted to vehicle structures having different datums or vice versa. The hollow first stud of the first panel and / or the second stud of the first panel may each be provided as an injection moulded component. Injection moulding may provide a convenient method of manufacturing each stud component whilst achieving manufacturing tolerances. The first stud of the second panel and / orthe second stud of the second panel may be provided as one or more separate components removably coupled to the second panel, optionally using at least one fastener. Providing the first and / or second studs of the first panel as a separate component coupled to the panel may improve ease of manufacture. It may also allow the headliner to be made modular such that similar first panels may be fitted to vehicle structures having different datums or vice versa. The first stud of the second panel and / or the second stud of the second panel may each be provided as an injection moulded component. Injection moulding may provide a convenient method of manufacturing each stud component whilst achieving manufacturing tolerances. The vehicle headliner may further comprise a third panel. The third panel may comprise a first stud of the third panel for locating the third panel relative to the first panel. The third panel may comprise a second stud of the third panel for locating the third panel relative to the second panel. The third panel may comprise at least one third connector for removably coupling the third panel to the vehicle structure, A third panel may for example be used to hide and / or strengthen the joint between the first and second panels and may allow the headliner to be made more modular. The first stud of the third panel may comprise a four-way locator. The second stud of the third panel may comprise a two-way locator. Providing the first stud of the third panel as a four-way locatorto locate the third panel relative to the first panel and the second stud of the third panel as a two-way locator to locate the third panel relative to the second panel may avoid over constraining the third panel. This may allow manufacturing and / or assembly tolerances to be met. Each of the first, second and / or third connectors may comprise one or more elastically deformable clips arranged to engage with corresponding connection points on the vehicle structure. Elastically deformable clips may provide a convenient way of coupling each panel to the vehicle structure such that that panel may be removed, for example for maintenance and / or customisation. Each panel may further comprise at least one electrical component coupled thereto. Each panel may comprise any combination of an electrical harness, a conduit for retaining an electrical harness, a sun visor mounting portion, and an air conditioning unit mounting portion. Providing each panel with an electrical component coupled thereto may improve the ease of assembling components adjacent the headliner or housed within the headliner. Another aspect of the invention provides a vehicle cabin comprising: a vehicle structure comprising a roof portion comprising a first and second cantrail, each cantrail extending along opposing sides of the vehicle structure; and the vehicle headliner of the further aspect of the invention. The first panel may be arranged to cover the first cantrail the second panel may be arranged to cover the second cantrail. A yet further aspect of the invention provides a vehicle comprising the vehicle cabin of the another aspect of the invention. A still further aspect of the invention provides a method of fitting a vehicle headliner to a roof portion of a vehicle structure, the method comprising: providing a first headliner panel and a second headliner panel as separate components, the first headliner panel comprising a hollow first stud of the first panel for positioning the first panel relative to the vehicle structure, the hollow first stud configured to be received in a corresponding aperture within the vehicle structure, and a first connector for removably coupling the first panel to the vehicle structure; the second headliner panel comprising a first stud of the second panel for positioning the second panel relative to the first panel, the first stud of the second panel configured to be received in the hollow first stud of the first panel, and a second connector for removably coupling the second panel to the vehicle structure; locating the first headliner panel relative to the vehicle structure using the hollow first stud of the first panel; coupling the first headliner panel to the vehicle structure using the first connector; locating the second headliner panel relative to the first headliner panel by inserting the first stud of the second panel into the hollow stud of the first panel; and coupling the second headliner panel to the vehicle structure using the second connector. 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 shows a perspective view of a vehicle to provide context for the invention; Figure 2 shows a vehicle cabin; Figure 3 shows a top plan view of a multi-piece headliner according to the invention; Figure 4 shows a cross sectional view of a portion of the multi-piece headliner of Figure 3; Figure 5 shows a simplified view of an example of a location strategy for a multi-piece headliner; Figure 6 shows a further simplified view of an example of a location strategy fora multi-piece headliner; Figure 7 shows a perspective view from below and to one side of multi-piece headliner according to the invention; Figure 8 shows a top plan view of a portion of the headliner of Figure 7; Figure 9 shows a simplified view of an example of a four-way locator in use; Figure 10 shows a simplified view of an example of a two-way locator in use; and Figure 11 shows a flow chart of a method according to the invention. DETAILED DESCRIPTION Figure 1 shows a vehicle 1 to provide context for the invention. The vehicle 1 comprises a vehicle cabin 10 in which passengers may sit. The vehicle cabin 10 is defined by one or more vehicle structures 12 which may collectively be referred to as a body in white or a portion of the body in white. The body in white may comprise a series of vehicle structures 12 coupled together, for example using welding. The vehicle cabin 10 is at least partially defined by a roof portion 14 of the vehicle structure 12, which may define an upper region of the vehicle cabin 10. The roof portion 14 may comprise a first and second cantrail 15, 16, each extending along opposite sides of the vehicle structure 12 in a forwards-backwards direction of the vehicle 1. Each cantrail 15, 16 may extend from substantially the front of the vehicle cabin 12 to substantially the rear of the vehicle cabin 12 and may optionally extend beyond the limits of the vehicle cabin 12 as shown in Figure 2. There is a need to cover the vehicle structure 12 within the vehicle cabin 10 so as to prevent passengers from seeing and accessing the vehicle structure 12. As such there is provided a vehicle headliner 100 (which may be referred to hereinafter as a headliner 100) to extend over or substantially cover the roof portion 14 of the vehicle structure 12. The headliner 100 may be manufactured from an insulating material such as a wet pour rubber substrate, which may provide noise reduction and thermal insulation within the vehicle cabin 10. It is preferable to provide a headliner 100 that is removably couplable to the vehicle structure 12, in particular to the roof portion 14 thereof, such that the vehicle structure 12 may be selectively accessed from within the vehicle cabin 10, for example for the purposes of repair and / or maintenance. There is therefore provided a vehicle headliner 100 comprising a plurality of panels as shown in Figure 3. As such, the headliner 100 may be referred to hereinafter as a multi-piece headliner 100. A panel is here defined as a component having a width and / or a length substantially greater than its thickness. Each panel may be non-load bearing and may alternatively be referred to as a vehicle trim. Each panel is configured to engage with one or more other panels and / or the vehicle structure 12. Providing the headliner 100 as a series of panels may improve ease of assembly of the headliner 100, by reducing the maximum size of a panel to be fitted to the vehicle structure 12 compared to (for example) a single-piece headliner configured to extend to cover the entirety of the roof portion 14 of the vehicle structure 12. There is provided a first panel 110 and a second panel 120 as shown in Figure 3. Each of the first 110 and second 120 panels may be arranged to cover a respective one of the first 15 and second 16 cantrails described earlier with reference to Figure 2. Each panel 110,120 may extend beyond its respective cantrail as shown in Figure 3 to define a closed loop extending around the roof portion 14 of the vehicle structure 12. Although shown as a loop defining an aperture through the centre of the headliner 100, it will be appreciated that in an alternative embodiment, not shown, each panel 110, 120 may extend to fill this aperture. Alternatively, there may be provided a further panel (not shown) couplable to any combination of the first panel 110, the second panel 120, and the vehicle structure 12, and arranged to fill the aperture. The first panel 110 comprises a first locating means 112 for positioning the first panel 110 relative to the roof portion 14 of the vehicle structure 12. The first locating means 112 may comprise a four-way locator shown in more detail in Figure 4, here defined as a locator for constraining movement of the panel in a positive and negative first direction, and in a positive and negative second direction perpendicular to the first direction. In the illustrated embodiment, the first locating means 112 comprises a first stud 113 of the first panel 110 configured to be received in a corresponding aperture 17 within the roof portion 14 of the vehicle structure 12. This arrangement is illustrated most clearly in Figure 5, which shows a cross section of a portion of the vehicle cabin 10 taken through the first locating means 112. The aperture 17 may be sized to closely receive the first stud 113 of the first panel 110, such that movement of the first stud 113 and hence the first panel 110 is substantially constrained in all directions perpendicular to the longitudinal axis of the first stud 113 and the aperture 17. The diameter of the aperture 17 may be nominally 2% greater than the diameter of the first stud 113 of the first panel 110. The first panel 110 further comprises at least one first connector 114 for removably coupling the panel 110 to the vehicle structure 12 as described previously. The at least one first connector 114 may comprise a plurality of fasteners as shown in Figure 3 (only some of which are labelled with reference numerals for clarity), such as for example a plurality of elastically deformable clips configured to engage with corresponding connection points on the vehicle structure 12. Each clip may be configured to be received in a connection aperture within the vehicle structure 12 and exert a biasing force to couple the first panel 110 to the vehicle structure 12. The second panel 120 is located relative to the first panel 110. This may be referred to as part-to-part location, where a single datum (i.e. the aperture 17) on the vehicle structure 12 is used to locate multiple components (i.e. the first 110 and second 120 panels). As such the second panel 120 comprises a second locating means 122 for positioning the second panel 120 relative to the first panel 110 shown in more detail in Figure 4. In the embodiment shown, the first stud 113 of the first panel 110 is hollow or more generally comprises an aperture. The second locating means 122 comprises a first stud 123 of the second panel 120 configured to be received in the hollow first stud 113 of the first panel 110 as shown in Figure 4. The first stud 113 of the first panel 110, optionally the aperture within the first stud 113 of the first panel 110, may be sized so as to closely receive the first stud 123 of the second panel 120. In this way, movement of the second panel 120 relative to the first panel 110 is substantially constrained in all directions perpendicular to the longitudinal axis of the first stud 123 of the second panel 120. The second panel 120 further comprises at least one second connector 124 for removably coupling the second panel 120 to the vehicle structure 12 as described previously. The at least one second connector 124 may comprise a plurality of fasteners as shown in Figure 3 (only some of which are labelled with reference numerals for clarity), such as for example a plurality of elastically deformable clips configured to engage with corresponding connection points on the vehicle structure 12. Each clip may be configured to be received in a connection aperture within the vehicle structure 12 and exert a biasing force to couple the second panel 120 to the vehicle structure 12. The first 110 panel may further comprise a second locating means 116 for further constraining movement of the first panel 110. It may be preferable to provide the first locating means 112 at a first end of the first panel 110, and the second locating means 116 at a second end of the first panel 110 distal the first end as shown in Figure 3. This may be preferable where the first stud 113 of the first panel 110 comprises a cylindrical stud not configured to constrain rotational movement of the first panel 110 about the longitudinal axis of the stud 113. In this case, providing the second locating means 116 at a second end of the first panel 110 distal the first may reduce the reaction force required to prevent the panel from rotating, by increasing the moment arm. In order to avoid over constraining the system, the second locating means 116 of the first panel 110 may comprise a two-way locator, here defined as a locator for constraining movement of the panel in a positive and negative single direction only. The two-way locator of the first panel 110 may be referred to hereinafter as a first two-way locator, and the direction in which movement is constrained may be referred to as a first constraint direction. The first two-way locator may comprise a second stud 117 of the first panel 110, configured to be received in an elongate slot 18 within the vehicle structure 12. The elongate slot 18 has a width configured to closely receive the second stud 117 of the first panel 110, and a length longer than the length of the second stud 117 and extending in a direction perpendicular to the first constraint direction. This arrangement is illustrated most clearly in Figure 6, which shows a cross section of a portion of the vehicle cabin 10 taken through the second locating means 116 of the first panel 110 and in a plane perpendicular to the first constraint direction. In this way, movement of the second stud 117 of the first panel 110 is permitted in a direction perpendicular to the first constraint direction only (i.e. left to right as shown in Figure 6), which may help to achieve manufacturing and / or assembly tolerances between the first panel 110 and the vehicle structure 12. The second panel 120 may also comprise a second locating means 126 for further restricting movement of the second panel 120, optionally for constraining the second panel 120 relative to the first panel 110. As described previously with respect to the first panel 110, it may be preferable to provide each of the first locating means 122 of the second panel 120 and the second locating means 126 of the second panel 120 at distal ends of the second panel 120. The second locating means 126 of the second panel 120 may comprise a two-way locator, here defined as a locator for constraining movement of the second panel 120 in a positive and negative single direction only. The two-way locator of the second panel 120 may be referred to hereinafter as a second two-way locator, and the direction in which movement is constrained may be referred to as a second constraint direction. The first constraint direction may be parallel to the second constraint direction and both directions being circumferential with respect to a centre of potential rotation of the panels about the longitudinal axes of the studs 113, 123. As shown in Figure 6, the first two-way locator (i.e. the second stud 117 of the first panel 110) may comprise a hollow elongate stud 117 received in an elongate slot 18, the elongate slot 18 having a depth greater than the length of the hollow elongate stud 117. The second locating means 126 may comprise a second stud 127 of the second panel 120 configured to be received in the hollow elongate stud 117. The hollow elongate stud 117 may have a width configured to closely receive the second stud 127 of the second panel 120, and a length longer than the length of the second stud 127 of the second panel 120 and extending in a direction perpendicular to the second constraint direction. In the embodiment illustrated in Figure 6, the first constraint direction is aligned with the second constraint direction, such that the second stud 117 of the first panel 110 may move left to right relative to the vehicle structure 12, and the second stud 127 of the second panel 120 may move left to right relative to the first panel 110. Each of the first locating means 112 of the first panel 110 and the second locating means 116 ofthe first panel 110 may be provided as one or more separate components removably coupled to the first panel 110. Similarly, each ofthe first locating means 122 ofthe second panel 120; and the second locating means 126 ofthe second panel 120 may be provided as one or more separate components removably coupled to the second panel 120. Providing each as a separate component may allow each panel to be made modular, for example a generic panel may be adapted to fit multiple different vehicle structures 12 and / or vehicles 1. One or more fasteners may be used to couple each locating means to its respective panel such that the locating means may be readily replaced, for example for maintenance. Each locating means may be manufactured from plastic, optionally using injection moulding techniques. The embodiment described with reference to Figures 3 to 6 comprise two interfaces between the first 110 and second panels 120 - a first interface at the first end of each panel 110,120 where there is provided the first locating means 112, 122 ofthe first and second panels 110,120 respectively, and a second interface at the second end of each panel where there is provided the second locating means 116,126 ofthe first and second panels 110,120 respectively. It may be preferable to provide one or more further panels to cover each of these interfaces, for example to hide the interface and prevent vehicle users from accessing the interface, or to increase the strength ofthe interface between the first 110 and second 120 panels. It will be appreciated that the following description made with reference to a third panel 130 arranged to cover the first interface between the first 110 and second 120 panels may be applied to a further panel arranged to cover the second interface as described previously. Figure 7 shows a multi-piece headliner 100 comprising a first panel 110, a second panel 120 and a third panel 130. The first 110 and second panels 120 may be identical to those described with reference to Figures 2 to 5 and as such will not be discussed again here in detail. The third panel 130 is similar to each ofthe first 110 and second panels 120 in that it has a width and / or height substantially greater than its thickness and may be manufactured from an insulating material to improve thermal and / or noise insulation within the vehicle cabin 10. The third panel 130 is configured to extend across (or cover) the interface between the first 110 and second 120 panels once the headliner 100 is assembled. The third panel 130 is located relative to the first panel 110 using a first locating means 132 of the third panel 130 as shown in Figure 8. The first locating means 132 of the third panel 130 may comprise a four-way locator as defined previously, arranged to constrain movement of the third panel 130 relative to the first panel 110. The four-way locator may comprise a first stud 133 of the third panel 130 configured to be received in a corresponding aperture 118 within the first panel 110 as shown in Figure 9. The aperture 118 may be sized to closely receive the first stud 133 of the third panel 130, such that movement of the stud 133 and hence the third panel 130 is substantially constrained in all directions perpendicular to the longitudinal axis of the first stud 133 and the aperture 118. The diameter of the aperture 118 may be nominally 2% greater than the diameter of the first stud 133 of the third panel 130. The third panel 130 is located relative to the second panel 120 using a second locating means 136 of the third panel 130. So as to not over-constrain the third panel 130, the second locating means 136 of the third panel 130 may comprise a two-way locator as defined previously, arranged to constrain movement of the third panel 130 relative to the second panel 120 in a positive and negative single direction only - this may be referred to as a third constraint direction. The two-way locator may comprise a second stud 137 of the third panel 130 configured to be received in an elongate slot 128 within the second panel 120 as shown in Figure 10. The elongate slot 128 has a width configured to closely receive the second stud 137 of the third panel 130 and is elongated in a direction perpendicular to the third constraint direction. In this way, movement of the second stud 137 of the third panel 130 is permitted in a direction perpendicular to the third constraint direction only (i.e. left to right as shown in Figure 10), which may help to achieve manufacturing and / or assembly tolerances between the third panel 130 and the second panel 120. The third panel 130 further comprises at least one third connector 134 for coupling the third panel 130 to the headliner 100 and / or the vehicle structure 12. The at least one third connector may comprise a plurality of fasteners. Each fastener may comprise an elastically deformable clip configured to be received in and engage with a connection aperture in any of the first panel 110, the second panel 120, and the vehicle structure 12. In the embodiment shown, the third panel 130 comprises a first clip configured to couple the third panel 130 to the first panel, and a plurality of further clips to couple the third panel 130 to the vehicle structure 12. It may be preferable to couple the third panel 130 to the first panel 110 ratherthan the second panel 120 since movement of the third panel 130 relative to the first panel 110 is more closely constrained than movement of the third panel 130 relative to the second panel 120. This may reduce the tolerance requirements when coupling the third panel 130 to the first panel 110. Each panel 110, 120, 130 may provide a convenient platform for supporting electrical components, such as for example an electrical harness, speakers, and air conditioning vents. As such, each panel may further comprise at least one electrical component coupled thereto. This may allow electrical components on adjacent panels to be connected, for example to assemble a complete electrical harness. Providing each panel with one or more electrical components coupled thereto may improve ease of assembly of the electrical components to the vehicle structure 12. Figure 11 illustrates a method 200 of fitting a headliner 100 to a roof portion 14 of a vehicle structure 12. At step 210 there is provided a multi-piece vehicle headliner 100 comprising a first panel 110 and a second panel 120 as described previously. It will be appreciated that the headliner 100 may comprise further panels such as the third panel 130 described previously, also provided as a separate component prior to fitting to the vehicle structure 12. At step 220 the first panel 110 is located relative to the vehicle structure 12. It will be appreciated that this may be completed manually or using an automated system. Where the first panel 110 comprises a stud 113, locating the first panel 110 relative to the vehicle structure 12 may comprise aligning the first stud 113 of the first panel 110 with and / or in a corresponding aperture 17 as described with reference to Figure 5. Locating the first panel 110 relative to the vehicle structure 12 may further comprise aligning a second stud 117 of the first panel 110 with an elongate slot 18 of the vehicle structure as described previously with reference to Figure 6. Once the first panel 110 is located relative to the vehicle structure 12, the first panel 110 is coupled to the vehicle structure 12 using the at least one first connector 114 at step 220. At step 230 the second panel 120 is located relative to the first panel 110. It will be appreciated that this may be completed manually or using an automated system. Where the first panel 110 comprises a hollow stud 113 and the second panel comprises a first stud 123, locating the second panel 120 relative to the first panel 110 may comprise aligning the first stud 123 of the second panel 120 with and / or in the hollow stud 113 of the first panel 110 as described previously with reference to Figure 5. Locating the second panel 120 relative to the first panel 110 may further comprise aligning a second stud 127 of the second panel 120 with the second stud 117 of the first panel 110. The second stud 117 of the first panel 110 may be hollow and / or define an elongate slot for receiving the second stud 127 of the second panel 120 as described previously with reference to Figure 6. Once the second panel 120 is located relative to the first panel 110, the second panel 120 is coupled to the vehicle structure 12 using the at least one second connector 124 at step 240. Where the headliner 100 comprises a third panel 130, the method may comprise further steps following step 240. These may comprise locating the third panel relative to the first 110 and second panels 120 as described with reference to Figures 7 to 9, and coupling the third panel 130 to any of the first panel 110, the second panel 120, the vehicle structure 12 or any combination thereof. 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 vehicle headliner couplable to a roof portion of a vehicle structure, the vehicle headliner comprising: a first panel comprising a hollow first stud of the first panel for positioning the first panel relative to the vehicle structure, the hollow first stud configured to be received in a corresponding aperture within the vehicle structure, and at least one first connector for coupling the first panel to the vehicle structure; anda second panel comprising a first stud of the second panel for positioning the second panel relative to the first panel, the first stud of the second panel configured to be received in the hollow first stud of the first panel, and at least one second connector for coupling the second panel to the vehicle structure.
2. A vehicle headliner according to claim 1, wherein the first panel has a first end and a second end, wherein the hollow first stud comprises a first four-way locator at the first end of the first panel, and wherein the first panel further comprises a first two-way locator at the second end of the first panel.
3. A vehicle headliner according to claim 2, wherein the first two-way locator comprises a second stud of the first panel configured to be received in an elongate slot within the vehicle structure.
4. A vehicle headliner according to any preceding claim, wherein the second panel has a first end and a second end, wherein the first stud of the second panel comprises a second four-way locator at the first end of the second panel, and wherein the second panel further comprises a second two-way locator at the second end of the second panel.
5. A vehicle headliner according to claim 4 when dependent on claim 3, wherein the second stud of the first panel is hollow, and the second two-way locator comprises a second stud of the second panel configured to be received within the second stud of the first panel.
6. A vehicle headliner according to any preceding claim, wherein the hollow first stud of the first panel and / or the second stud of the first panel are provided as one or more separate components removably coupled to the first panel, optionally using at least one fastener.
7. A vehicle headliner according to claim 6, wherein the hollow first stud of the first panel and / or the second stud of the first panel are each provided as an injection moulded component.
8. A vehicle headliner according to any preceding claim, wherein the first stud of the second panel and / or the second stud of the second panel are provided as one or more separate components removably coupled to the second panel, optionally using at least one fastener.
9. A vehicle headliner according to claim 8, wherein the first stud of the second panel and / or the second stud of the second panel are each provided as an injection moulded component.
10. A vehicle headliner according to any preceding claim, further comprising a third panel, the third panel comprising a first stud of the third panel for locating the third panel relative to the first panel and a second studof the third panel for locating the third panel relative to the second panel, and at least one third connector for removably coupling the third panel to the vehicle structure.
11. A vehicle headliner according to claim 10, wherein the first stud of the third panel comprises a fourway locator and the second stud of the third panel comprises a two-way locator.
12. A vehicle headliner according to any preceding claim, wherein each of the at least one first, second and / or third connectors comprise one or more elastically deformable clips arranged to engage with corresponding connection points on the vehicle structure.
13. A vehicle headliner according to any preceding claim, wherein each panel further comprises at least one electrical component coupled thereto.
14. A vehicle cabin comprising:a vehicle structure comprising a roof portion comprising a first and second cantrail, each cantrail extending along opposing sides of the vehicle structure; andthe vehicle headliner of any preceding claim, wherein the first panel is arranged to cover the first cantrail and the second panel is arranged to cover the second cantrail.
15. A vehicle 1 comprising the vehicle cabin 10 of claim 14.
16. A method of fitting a vehicle headlinerto a roof portion of a vehicle structure, the method comprising:providing a first headliner panel and a second headliner panel as separate components, the first headliner panel comprising a hollow first stud of the first panel for positioning the first panel relative to the vehicle structure, the hollow first stud configured to be received in a corresponding aperture within the vehicle structure, and at least one first connector for coupling the first panel to the vehicle structure; the second headliner panel comprising a first stud of the second panel for positioning the second panel relative to the first panel, the first stud of the second panel configured to be received in the hollow first stud of the first panel, and at least one second connector for coupling the second panel to the vehicle structure;locating the first headliner panel relative to the vehicle structure using the hollow first stud of the first panel;coupling the first headliner panel to the vehicle structure using the at least one first connector; locating the second headliner panel relative to the first headliner panel by inserting the first stud of the second panel into the hollow stud of the first panel; andcoupling the second headliner panel to the vehicle structure using the at least one second connector.13
Citation Information
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