Composite Headliner Frame for Panoramic Roof Rigidity
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Solution Overview
Problem
Existing lightweight headliners for motor vehicles with sliding or panoramic roofs lack sufficient rigidity to provide a stable frame for the windows, necessitating additional stabilization measures.
Innovation Solution
A headliner with a stiffening frame made of a fiber-reinforced composite material, comprising a fiber mat and a textile lattice material, which is impregnated together to enhance energy absorption capacity without significantly increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a lightweight headliner is used, then the weight is reduced, but the rigidity is insufficient to provide a stable frame for sliding or panoramic windows
Solution Approach 1:
The stiffening frame is constructed from a composite material consisting of a fiber mat and a textile lattice material. The fiber mat provides baseline structural properties while the textile lattice material, applied flat to and impregnated together with the fiber mat surface, significantly enhances rigidity and energy absorption capacity. This composite structure enables the frame to provide sufficient structural support for sliding or panoramic windows while maintaining the lightweight characteristic of the headliner.
2Strength
If a stiffening frame is added to stabilize the headliner, then the rigidity is improved, but the weight increases
Solution Approach 1:
The stiffening frame utilizes a composite material system comprising a fiber mat and a textile lattice material that work synergistically. The fiber mat serves as the base structure, while the textile lattice material, when impregnated together with the fiber mat, provides enhanced rigidity with minimal additional weight. This composite approach allows the stiffening frame to achieve necessary structural support while keeping the overall headliner weight low.
3Strength
If the textile lattice material is added to the fiber mat, then the energy absorption capacity is increased, but the manufacturing complexity increases
Solution Approach 1:
The manufacturing process merges the impregnation of the textile lattice material with the fiber mat into a single integrated step. The textile lattice material is applied flat to the fiber mat surface, and both materials are impregnated together simultaneously, eliminating the need for separate impregnation processes. This combined approach increases energy absorption capacity while avoiding significant additional manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite material achieves an energy absorption capacity that meets the requirements for head impact safety standards, such as FMVSS201, while maintaining a lightweight design.
Implementation Method 1
The bond can be a mechanical, thermal and/or chemical bond, for example by needling, spunlace or thermobonding.
Implementation Method 2
The bond can be a mechanical, thermal and/or chemical bond, for example by needling, spunlace or thermobonding.
Implementation Method 3
The bond can be a mechanical, thermal and/or chemical bond, for example by needling, spunlace or thermobonding.
Implementation Method 4
the textile lattice material being applied flat to and impregnated together with a surface of the fiber mat
Data Source
AI summary
The disclosure provides an interior trim part for a motor vehicle having a sliding or panoramic roof comprising a headliner and a stiffening frame attached to the headliner and enclosing and stabilizing an opening in the headliner enclosing the sliding or panoramic window, the stiffening frame being made of a fiber-reinforced composite material comprising a fiber mat and a textile lattice material, the textile lattice material being applied over a surface of the fiber mat and impregnated together therewith.