UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS

Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense. In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. The new design achieves precise tolerance control, ensuring reliable headliner installation under varying Body-in-White (BIW) conditions, while significantly improving performance metrics such as push-in and pull-out forces. Notwithstanding, the hybrid clip seamlessly fits within the existing packaging space, preserving the headliner’s aesthetics, interior headroom, and vehicle design integrity. Beyond technical improvements, this hybrid clip offers a substantial cost advantage — delivering approximately ~80% savings compared to traditional DLFs — while simplifying the assembly process and enhancing production line efficiency. Key words: Hybrid clip, DLFs- Dual lock Fasteners, BIW- Body-in-white, Headroom, Tolerance management, Mounting feasibility