Development of the Headliner Module System

Headliner module system implies that all components, including fasteners that are attached to the headliner substrate panel prior to vehicle assembly installation. The headliner substrate becomes an installation fixture which facilitates the assembly process. Since headliner module is an integration of many separate components into one more complex assembly, prior to vehicle assembly, a number of additional requirements must be considered. Many of these requirements are driven by the factors like shipping, handling and installation of a large panel with various componentry mounted for temporary installation retention or permanent retention. Substrate should be tough but, on the contrary it should be soft enough for the curtain airbag deployment. Tough substrate interferes with airbag deployment. Detachable reinforcement will enhance shipping and handling process. After installation, reinforcement can be detached from headliner module which will keep the substrate soft. The paper concludes by summarizing the physical properties achieved and shows design concept examples of pre-assembled Headliner system.