Browse Topic: Headlining

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Unique Hybrid Panoramic Headliner Clip with High Tolerance to Replace Dual Lock Fasteners2026-26-02991/16/2026
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. [2] 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. [5]
D, Gowtham, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti
Headliner Design Considerations to Meet Safety and Regulations2025-01-82454/1/2025
Headliners are one of the largest components inside an automobile, stretching from the front windshield to the rear windshield. Besides its aesthetic purpose, it contributes to multiple other purposes like housing different components, helps in NVH, defines the interior roominess, and plays a crucial role in defining the deployment of curtain airbag. The headliner also plays a role in meeting regulatory requirements like upward visibility and headroom requirements of the occupants. During the deployment of curtain airbag, it is important that the headliner-pillar interface aids in the easy opening of airbag, with the least hindrance. This is defined by multiple factors like the location of headliner-pillar interface, its distance from the airbag ramp bracket, the position of the inflator, the mountings of the headliner and pillar trims, to name a few. Also, during the deployment of the airbag, it is important that parts such as grabhandle, speaker grilles, etc which are fitted on the headliner does not get detached or break off, which in turn can be dangerous to the occupants. The design of pillar trims and the ramp bracket also plays a critical role in ensuring that the pillar trim edges are secure during the airbag deployment, and aid in the easy release of airbag into the cabin. Incorrect design of headliner or pillar trim, can result in different problems such as improper airbag deployment, airbag getting struck between pillar trim to body, fly-off of headliner child parts, etc. This would also result in several iterations of design which is a waste of time and resources. In this paper, we cover various design aspects of headliner assembly to meet the safety and regulations and have an improved deployment of curtain airbag. By considering the design aspects upfront, we were able to save at least two iterations of air bag deployment and quicken the development time by four months.
Sabesan, Arvind Kochi, D., Anantha, Kakani, Phani Kumar
2024 Lincoln Nautilus: The brand's first global SUV24AUTD05_115/1/2024
While there is a tendency for new vehicles to have a focus on ride, handling, performance and other dynamic elements, the model year 2024 Lincoln Nautilus team added another element to how the driver will experience the midsize SUV. Not that the ride, handling, etc. were ignored, but the global design and engineering team wanted to do something different with this two-row SUV. Recognize that this is a vehicle with a sumptuous interior that includes not only first-class seating (24-way adjustable front seats) and materials (Alpine Venetian leather available on the seats; cashmere for the headliner) but also an available high-end Revel Ultima 3D audio system with 28 speakers. What's more, there's “Lincoln Digital Scent,” small electronically activated pods containing various aromas (e.g., Mystic Forest, Ozonic Azure, Violet Cashmere). Across the top of the instrument panel there is a 48-inch backlit LCD screen and a 11.1-inch touchscreen in the center stack.
Vasilash, Gary
A Study on Optimizing Headlining Open-Structure for Face-to-Face Roof-Airbag Deployment2024-01-23944/9/2024
In this study, an optimized structure for opening the headlining considering the deployment of the face-to-face roof airbag was studied. It was confirmed that the deployment performance differs depending on the skin of the headlining, and a standardized structure with mass production was proposed. Non-woven fabric and Tricot skin, which are economical and high-end specifications, satisfy the performance of PVC fusion application specifications after cutting 80% of the skin. The structure that satisfies the entire body including the knit specifications is a type that separates the roof airbag area piece, the corresponding soft piece is separated, and the deployment performance is satisfied with safety. Therefore, the structure is proposed as a standardized structure. This structure is expected to be applicable to roof DAB (Driver Airbag), PAB (Passenger Airbag), and Sunroof Airbag, which will be necessary technologies to secure indoor space. Regardless of which area the airbag will be applied to, and which area the headlining skin specifications will be selected by the customer, it can be applied only if the mounting bracket conditions are satisfied. A patent will be applied for the structure to secure intellectual property rights.
Park, Jiseob
Foam and FRP Sheets Packaging for Headliner Stiffness at Curtain Airbag Area2024-26-00081/16/2024
As we all know, automotive headliners are an essential component of any car’s interior as they cover all the internal components and provide a clean and finished look. Headliners not only increase the aesthetic appeal of a car’s interior, but also acts as an insulation and sound absorption source. As per the latest Government norms, Curtain Airbag (henceforth called as CAB) has been made mandatory and this change calls for the corresponding changes in the Headliner packaging of all passenger vehicles. In general, curtain air-bag deployment calls for a twist open of Headliner at lateral sides (a portion below Hinge-line) during the deployment. This enables the inflated airbag to flow inside the passenger cabin to protect the passenger from any injury. Conventionally no components are packaged below the hinge-line area of headliner to avoid obstruction for CAB deployment and any part fly-off concerns. For this reason, no foams/components are kept below the hinge-line region of the headliner. In this paper we are discussing the pros of introducing the Polyurethane (henceforth called as PU) foams below the hinge-line without hampering the CAB deployment criteria. This paper also dwells upon the characteristic and type of the foams that need to be used to serve the purpose. These foams have been specifically designed to increase the stiffness and solidity of Headliner at all joinery/interface areas without any compromise on the CAB deployment requirements mandated by ARAI*. Height and the width of the foams are optimized to act as a guide for deployment rather than obstructing it.
D, Gowtham, L, Dharshan, Bornare, Harshad, Ritesh, Kakade, Deoli, Manish, Vadla, Vilas, Kakani, Phani Kumar
Headliner Composition Optimization without Compromising the Safety and Performance2024-26-01901/16/2024
Reducing material wherever there is a possibility in automobile industry is inevitable for weight and cost saving. This paper explains about the possibilities of optimizing the material composition of automotive Headliners (also called as Roof liners) without affecting the performance and safety criteria. In this paper, we are targeting at optimizing the individual constituents of a composite Headliner. A conventional Headliner comprises of many sandwich layers of which PU foam shares the major percentage of the composition contributing to 80% of the Headliner thickness. In this paper, we are discussing about the optimization done in Headliner sandwich constituents without affecting the core performance parameters of headliner such as curtain airbag deployment, ergonomic regulations, drop test etc. By incorporating this change, without significant changes in other layers, overall weight reduction of ~24% and overall cost reduction of ~24% is achieved.
D, Gowtham, Vadla, Vilas, Bhaskararao, Pathivada, Sai, Konduru, Bornare, Harshad, Ritesh, Kakade, Deoli, Manish, Kakani, Phani Kumar
SUPPLIER EYE23AUTP12_0612/1/2023
Regular readers of Supplier Eye will note that this author tries to outline the positives and the negatives of supplier strategies. It's a moving target. A recent deluge of negative headlines with respect to EVs has OEMs, suppliers and other participants re-evaluating their strategies. Slower consumer acceptance and stalled sales of some EVs - in combination with the recent eye-popping labor agreements with the UAW and Unifor unions - underscore that return on capital and labor-cost challenges will be core considerations going forward. At no point was this transition going to be smooth - “lumpy” is a better description. While there are several positives with the ICE-to-EV transition (emissions, efficiency, reduction of carbon-fuel dependence and running costs), there are hurdles that cannot be dismissed. Of late, several of these concerns have become more prominent. One surrounds the ability for government and industry to effectively bridge the higher costs (due to scale economies) of EVs in an environment of higher average-vehicle cost.
Time of Flight vs. FMCW LiDAR SystemsTBMG-453263/1/2022
Recent papers1, 2, 3, 4, 5 have presented a number of marketing claims about the benefits of Frequency Modulated Continuous Wave (FMCW) LiDAR systems. As might be expected, there is more to the story than the headlines claim. This article will examine these claims and offer a technical comparison of Time of Flight (ToF) vs. FMCW LiDAR for each of them.
Green Method for Producing Hydrogen PeroxideTBMG-394287/1/2021
Hydrogen peroxide has made headlines as researchers and medical centers around the country have been testing its viability in decontaminating N95 masks to deal with shortages amid the COVID-19 pandemic. While results so far are promising, some researchers worry that the chemical’s poor shelf life could make such decontamination efforts costly.
Headliner Trim Design Methodology Development with Finite Element Simulation and Optimization Considering Multi Domain Performance2020-01-10994/14/2020
Passenger cars in the top segment have seen fast growth over the last few decades with an increasing focus on luxury, convenience, safety and the quality of driver experience. The headliner is a decorative and functional trim system covering the underside of the roof panel. It enhances the aesthetics and elegance of the car interiors. In premium vehicles, the headliner system has to suffice interior quietness and integrity apart from the performance and regulatory requirements. The Design Validation Plan requirements cover its contribution to the vehicle interior noise control, occupant safety, and perception of build quality. Contributions can be very significant and primarily be determined by design and material parameters. Also, headliner interactions with an adjacent body in white structure are crucial from performance point of view. Various foam options are available with different functions such as structural, acoustic, and energy-absorption. Part thicknesses vary depending on the class of vehicle and respective demands. Foam locations and types greatly influence the proportional performance. Selection of each parameter in an efficient way is a critical task, as cost factor also plays an important role in decision making. Finite Element Method and optimization tools are used to setup the process for deriving design which meets performance characteristics by sequential process. The scope of this paper is to propose a suitable process for conceptual design for the headliner trim. Applicable load cases from NVH, durability, and IHI domain are considered during the development. To accelerate the process, linear problem definition is considered using equivalent static loading conditions. Different variables including part thickness, part material properties, foam properties, and foam locations have been considered. Proposed headliner design optimization process helped to find the efficient design with reduction in the development cycle time.
Sathaye, Ashish, Vishnu, S., Patil, Suhas, Banbare, Prashant
Combating Infrared Threats on the BattlefieldTBMG-329019/1/2018
There have been several news headlines lately about offenders pointing commercial lasers at helicopters or police personnel, temporarily blinding and distracting them. An increasing number of “laser assault” incidents have led to tougher penalties with fines and jail time in various countries. The lasers typically used in these attacks operate in the visible light spectrum; therefore, these lasers can be blocked by special absorbing optical dyes contained in special laser defense eyewear.
Q&A17AUTP02_162/1/2017
IQM's Dan Lawrence talks flexible hybrid wiring.
Brooke, Lindsay
Enhanced Acoustic Performance using Key Design Parameters of Headliners2015-01-23396/15/2015
Sound absorption materials can be key elements for mass-efficient vehicle noise control. They are utilized at multiple locations in the interior and one of the most important areas is the roof. At this location, the acoustic treatment typically comprises a headliner and an air gap up to the body sheet metal. The acoustic performance requirement for such a vehicle subsystem is normally a sound absorption curve. Based on headliner geometry and construction, the sound absorption curve shape can be adjusted to increase absorption in certain frequency ranges. In this paper an overall acoustic metric is developed to relate design parameters to an absorption curve shape which results in improved in-vehicle performance. This metric is based on sound absorption coefficient and articulation index. Johnson-Champoux-Allard equivalent fluid model and diffuse field equations are used. The results are validated using impedance tube measurements. It is shown the specific airflow resistance of the headliner is a primary governing factor to improve in-vehicle acoustic performance. The relationship between airflow resistance, air gap and headliner thickness is also explored.
Calçada, Márcio, Parrett, Alan
Development Process of the Prototype and Evaluation on the Biodegradability of Jute Fiber/PLA Fiber Composites for Automotive Headlining2011-28-000710/6/2011
Biodegradable headlinings were developed using jute fiber, PLA (polylactic acid) fiber. More specifically, the main felt which consists of jute fibers and PLA fibers was produced by carding process, and then laminating PLA Films or light PLA felts as reinforcement. After lamination, cotton nonwovens were used as skin layers. Evaluation on the biodegradation of headlinings was tested under conditions (KS M 3100-1 and ISO-14855-1) of aerobic biodegradation. The test results of biodegradable headlinings showed a reduction of weight by 48 % and a decrease of mechanical strength by 90% for the biodegradation period. This feature would be attributed to the decomposition of the bio-materials during its biodegradation.
Jeoung, Sun Kyoung, Lee, Pyoung-Chan, Yoo, Seung Eul, Lee, Ki Dong, Lee, Su Nam, Han, Joo Kwon
Jute Fibre Based Composite for Automotive Headlining2011-01-02244/12/2011
With increased awareness about environmental issues, the trend of automobile industry is to use ‘Recycled’ or ‘Biodegradable’ or ‘Energy Recoverable’ material. As a part of this programme, to make the vehicle ‘Green’ in nature, many automobile OEMs have taken the initiative to make use of natural fibre composite in their vehicles. Natural fibre based composite has been successfully proven for less critical as well as for semi-structural applications in an automobile. These typical applications are insulations, headlining, carpets, door pad etc. There is a demanding task for automotive OEMs to meet 85% Recyclability and 95% Recoverability targets by year 2015. To meet the RRR (Reuse, Recycle & Recover) and the ELV (End of Life) regulatory requirements, increased use of natural fibre based composite/ biopolymers is unavoidable. Natural fibre can offer potential advantages such as weight saving and improve overall green rating of the vehicle. Use of renewable resources can also encourage thermal recycling. This paper describes the application of jute based composite for ‘Headlining’, where the properties of jute based composites are compared with those of conventional polyurethane foam + glass fibres based headlining. To address the limitation of lower strength of jute fibre, the basic substrate design of jute composite was optimized so that it offers properties equivalent / comparable to those of conventional polyurethane foam + glass fibre based material. In the proposed jute based composite, jute fibres are mixed with Polypropylene fibres to get stiffness for the substrate. The GSM (Grams per Square Meter) of jute based composite was selected in such a way that it addresses all the end product requirements such as flexural strength, adhesion, flammability, environmental resistance, thermal conductivity etc.
Sathaye, Asmita
Managing a Network of Self-Encrypting Hard DrivesTBMG-79045/1/2010
With high-profile data breaches making headlines regularly, organizations are carefully evaluating their options for protecting mobile data. For years, software full disk encryption, (FDE), has been the preferred means of addressing this threat. But widespread adoption has been hampered by the complexity and cost surrounding these software-based FDE deployments.
Random Incidence Sound Absorption Measurement of Automotive Seats in Small Size Reverberation Rooms2007-01-21945/15/2007
Random incidence sound absorption measurements of automotive components such as floor carpets, seats, headliners and hoodliners are important during the design and development of noise control treatments in a vehicle. Small volume reverberation rooms [1]1 have been widely used in practice to determine the absorption properties of those components. The SAE Acoustical Materials Committee has organized a task force to develop a standard procedure for measuring random incidence sound absorption properties of flat samples, as well as automotive components in small reverberation rooms. Statistical analysis and correlation study between large reverberation rooms and small reverberation rooms of flat samples using data acquired from a recent round robin study were reported in SAE Paper 2005-01-2284 [2, 3]. Based on data acquired in the same round robin tests, this paper investigates the measurement precision of random incidence sound absorption measurements of automotive seats using small reverberation rooms.
Pan, Jian, Saha, Pranab, Veen, Jerry R.
Globalization is in the driver's seatAUTOMAY07_055/1/2007
Johnson Controls is positioned to supply everything from single components to complete interiors wherever in the world it is needed. The automotive industry's sales are increasingly distributed to markets all over the world, and at the same time, the engineering talent needed to design components for those cars is also globally distributed, remarked Charles Baker, Group Vice President for Engineering in Johnson Controls' Automotive Experience division. That scenario means that suppliers such as JCI are also increasingly spread over the globe, supporting customers as they move into new markets, tapping local talent to develop products for those markets, and enjoying the flexibility to let engineering resources in one region support others when they are overloaded.
Carney, Dan
Feasibility of a Standardized Test Procedure for Random Incidence Sound Absorption Tests Using a Small Size Reverberation Room2003-01-15725/5/2003
In the automotive industry, random incidence sound absorption tests are conducted on flat material samples as well as on finished components such as headliners, seats, and floor carpet systems. This paper discusses a feasibility study that is being pursued by an SAE task force, under the direction of the Acoustical Materials Committee, to develop a small volume reverberation room test method for conducting random incidence sound absorption tests. This method has the potential to be suitable for flat material and component testing. A round-robin test program is being conducted to determine variability due to test procedures, room size differences and laboratory differences. The paper discusses the selection of test samples and provides an update on the findings of the round-robin test study.
Veen, Jerry R., Saha, Pranab
Waterjet Cutting and Routing for the Automotive and Aerospace2002-01-339211/19/2002
The automotive and the aerospace industries are constantly looking at optimizing their production with cost effective and versatile material separation processes suitable for machining three-dimensional parts (3D) in all kind of materials. Automation with robots has become quite common for manufacturing large serials of parts with constant quality and accuracy, avoiding risks for the operator. This paper will deal with robotised waterjet cutting used to cut automotive floor carpets and other interior trim parts such as headliners, instrument panels, door panels, trunk liners, acoustical insulation, parcel shelves and some fiberglass reinforced components. Furthermore we will talk about robotised routing, a suitable alternative for machining some of the above mentioned components. We will also describe abrasive waterjet, ideal for cutting 3D components made of metals, alloys and thick composites.
Girard, Dominique, Lobo, Rejane
Foresight Vehicle: Specification and Acceptability Criteria for Copper-Clad Dielectric Materials Used in Large Automotive Flexible Printed Circuits2002-01-11293/4/2002
Flexible Printed Circuits (FPCs) have been used extensively in instrument clusters and more recently in headliners of some vehicles. Interest in large area FPCs as a replacement for traditional wiring harnesses has been propelled by the potential benefits, which include weight and space savings, ease of assembly into the vehicle, intelligence through direct mounting of electronic components, and creative design opportunities. This paper describes the development of a specification for flexible copper-clad dielectric materials to be used in the construction of a large FPC intended to replace an instrument panel wiring harness.
Jaggernauth, W. A., Webb, D. P., Cottrill, M. C. W., Palmer, P. J., Conway, P. P., West, A. A.
A Method to Determine the Power Input Associated with Rain Excitation for SEA Models2001-01-16254/30/2001
Statistical Energy Analysis is used to predict the sound pressure level (SPL) in the interior of the vehicle. This is accomplished by knowing the energy sources (tire, engine, wind, etc) affecting the interior as well as the acoustic performance (absorption and transmission loss) of the interior trim components (headliner, door panels, instrument panel, etc). One of the noise sources that has not been seriously examined to-date is panel excitation by precipitation. The excitation of the roof due to raindrops can be a major noise source. Knowing how to properly model this power input would help analyze different headliners or roof treatments to minimize the SPL in the interior cavity. This will involve computational determination of mass, speed, and energy of standard water droplets for one of rain condition. A power spectrum is presented for one rain intensity condition on a test fixture.
Mealman, Marv, Unglenieks, Rob, Naghshineh, Koorosh
Development of Low Density Glass Mat Thermoplastic Composites for Headliner Applications2000-01-11293/6/2000
Glass-mat-thermoplastic (GMT) composites are frequently used in structural applications in the automotive industry. Typically, these materials are flow molded in a compression press and weigh 4000 - 4900 g / m2. In this paper, we present the development of low-density (700 -2000 g / m2), long-fiber GMT composites for applications in headliner and other interior components. The new thermoplastic headliner materials offer several advantages over existing headliner materials, including low weight and cost; high rigidity at elevated temperatures and high humidity; faster cycle time; recyclability; design flexibility; a more environmentally friendly production method; and reduction of raw material inventory compared to existing processes. In this paper, we will discuss the mechanical and acoustical properties of this new headliner material and compare it with current headliner material substrates. The design flexibility and improved processability of GMT headliners for modular / structural configurations vs. current headliner materials will be discussed. Finally, commercial applications of this new materials technology on2000 MY vehicles will be reviewed.
Haque, Enamul, Ickes, Steve
The Next Generation in Fabrics1999-01-02483/1/1999
MIRATEC® -- a new fabric that cannot be described as a woven, knit, or a nonwoven. This patented new technology places MIRATEC® in a category all of its own. Learn about how this new technology is truly revolutionary. It provides an unlimited design capability on strong, extremely uniform substrates with performance equal to or better than many traditional textiles. Unique fabrics can be designed from fiber to finished fabric. Unlimited fiber choice, weights up to 350 grams per square meter, and designs and images limited only by your imagination are all combined with proprietary finishing technology. Three dimensional automotive fabrics, including headliners, visors, door panels, ABC pillars, and other trim components, can be designed to meet specific end-use requirements.
Walton, John H.
High Efficiency Energy Absorption Olefinic Foam1999-01-02963/1/1999
The passing of the federal regulation for head impact protection for upper interior components (FMVSS 201U) has led to the use of a variety of foam materials in interior trim pillar and headliner reinforcement applications. Polyurethane foams and expanded bead foams are some of the commonly used foams in these applications. However, the low energy absorption efficiency (35% - 55%) of the current foams requires the use of 20 mm - 40 mm of packaging space to integrate the countermeasures that make it possible to meet the regulations. A newly developed high efficiency olefin based foam is able to meet the performance requirements at a reduced packaging space. A combination of physical structure and superior mechanical properties provides the much needed higher efficiency (80% - 90%) of the olefinic foam. This paper discusses the foam architecture and performance benefits for many interior applications, such as energy absorbing countermeasures in pillar trim, headliners, and door panels. Performance comparisons with current competitive foams for head impact applications are also presented.
Gandhe, Gajanan V., Tusim, Martin H.
New Headliner Composites with Improved Acoustical Performance9809462/23/1998
The substrate selection for headliner composites is driven by acoustics, systems integration, weight and cost considerations. However, the acoustical contribution of headliners plays a primary role in their design. This paper highlights the acoustical contribution of the various headliner composites. Various current headliner composites based on glass-fiber mat, polyurethane foam, resinated reclaimed fiber composites are considered. New composite structures are developed that exhibit good acoustical performance. The random incident acoustic evaluation is performed in an alpha-cabin which serves as a small reverberation room.
Aggarwal, Anuj, Khan, Hameed, Crepeau, Howard
Modular Headliner Systems: Opportunities and Challenges for Today and Tomorrow9809412/23/1998
The processes used to design and assemble the modern passenger car/truck are undergoing major evolutionary changes which reflect the competitive pressures to become more and more efficient. Efficiencies in this context translates to: Fast to Market (Concept to Product) Reduced Assembly Time/Resources (OEM Plants) Flexibility in the Product Mix (OEM Plants) Reduced OEM Structural Costs (Engineering) One of the prime tactics to support these strategies is to design and source certain groups of related components to be installed as a complete subsystem called a module. One such system is the Overhead Systems Module or more commonly a Modular Headliner System. This paper will discuss the various aspects of Modular Headliners from the perspective of an OEM. We will define specifically what we mean by “Modularity” for Overhead Systems and why they are significant in our current and future planning. We will describe our expectations of the supplier community to supply a much more complex and sophisticated product than heretofore. We will also discuss what we perceive to be special requirements which need to be addressed for these systems such as: Better Retention Systems Greatly Improved Substrate Toughness Improved Structure Better Planning and Program Management Along with these module requirements we will suggest some internal constraints that we (OEM's) must address and will solicit further inputs.
Shedlowsky, James P., Lambert, George F.
Comparison of New Headliner Materials9809452/23/1998
Many competitive headliner substrate materials were tested to determine the strengths and weaknesses of each material including new headliner materials such as those on the 97 Ford Expedition, 96 Chevrolet Cavalier, 97 GM G Van, 96 Ford Contour, and 96 Chrysler Cirrus, all of which are urethane/foam/glass layered substrates and the 96 Nissan Altima, a corrugated cardboard base substrate. In general, today's headliners are based upon three substrate types glass, foam, or cellulose (paper or cotton). Glass headliners are requested less frequently due to the lack of recycleability and the skin irritation caused to assembly plant workers. Of those substrate candidate materials screened, the best performing headliner substrate materials were 1997 Ford Expedition and 1997 GM G Van. Both materials meet all requirements of the screening specification, however, the Expedition substrate is lighter weight and has better acoustical absorption properties than the G Van, while the G Van carries a slightly higher transverse load. Both the G Van and Expedition substrates have demonstrated the ability to mold in ducting. The following report depicts graphical comparisons of physical properties, as well as an explanation of the results.
Marshall, Mary K., Salisbury, Wayne C., Souders, Steve
Utilization of Isocyanate-based Binders in Recycling of Automotive Composite Headliners9809492/23/1998
Recycling of automotive headliners has been carried out by grinding them and forming composites with isocyanate-based binders. Rear-seat-to-back-window trim panels have been prepared. Composites with 80-90 wt.% of scrap manufactured in plant runs exhibited mechanical properties comparable to the existing products. The rear-seat-to-back-window trim panel composites were produced by compression molding ground scrap-binder pre-preg sheets for 30 seconds at moderate temperatures, with no postcuring. This is the best indication that the utilization of the scrap headliners is both technically and economically sound. The plant runs have confirmed the feasibility of production of large parts with relatively complex shapes such as headliners. The adhesion of decorative materials to the composite substrates was excellent. More importantly, the decorative materials can be applied to the substrate during compression molding without any additional adhesive.
Gebreselassie, Girma M., Wolf, Harold, Sendijarevic, Vahid, Anjum, Qavi, Klempner, Daniel, Frisch, K. C.
Current and Past Technologies for Headliners Including Acoustics, Recycling and Safety9809512/23/1998
Headliner technology will be presented in this paper. Older established technologies such as cut & score, fiberglass, hardboard and resinated cotton are still used because of their proven reliability and low cost. But newer processes including polyester, natural fiber, Tramivex™ and urethane offer reliability, structure, acoustic performance and some recyclability. Fiberglass has always been a leader in acoustical performance but has breakage and handability issues in the assembly plants. This paper will be divided in four sections. The first section discusses manufacturing processes for headliners covering current and past. It also covers the materials used and types of facing. This section will state why headliner technology used in the USA is different than Europe or emerging markets. Second section describes acoustics. It will explain performance as related to material types. Porosity, cell type, fiber length and diameter is explained as it relates to the absorption of sound. The relationship between acoustics and construction will be discussed. Testing methods such as impedance tube, reverberation room and vehicle testing are explained and applied. Section three discusses the need for recycling and preferred materials. The future policy of auto companies may include shipping headliners to the supplier upon disposal/dismantling of automobiles. This will force manufactures to think recycling or they will have to pay for headliners to be sent to landfill. The final section will discuss the new head impact requirement in the USA. This section will discuss the need to minimize HIC (head injury criteria) with the use of foam or other energy absorbing materials.
Davies, Bryn A.
Assessing Headliner and Roof Assembly Acoustics9719265/20/1997
Although automotive headliners are primarily designed for their aesthetic qualities, technical experts realize that they play a significant role in affecting the acoustics in the cab of the vehicle. This paper suggests that the roof sheet metal and headliner perform as an assembly system, and explores how the acoustical attributes of that system, including the sound absorption, sound transmission loss and damping, can be assessed in the acoustics laboratory. New test methodologies and devices are introduced, and a wide variety of headliner and roof assembly designs are tested.
Wentzel, Richard E., Green, Edward R.
Recycling of Multicomponent Parts95220810/1/1995
The future in which the auto makers will be forced to implement the after use recycling in cars is already tangible. The total numbers of parts to be recycled must be minimised and also the number of materials presented in each recycling item. The tendency is to have one material or same family materials on each part. This paper deals with the main families of materials present in each of the car multicomponent parts, stressing large parts such as instrument panels, bumpers, door panels, headliners and other interior and exterior components. Examples of the current materials in use and some trends are discussed together with the weaknesses and strengths of the recycling systems implemented to date.
Filho, Wilson Franco
Sound Absorption Composites and Their Use in Automotive Interior Sound Control9512445/1/1995
Optimization of component/system sound absorption can account for improvements in interior automotive sound quality. Components such as headliners, seats, etc., account for a large portion of a vehicle's available interior surface area and can provide significant sound absorption and thus improve sound quality if their sound absorption potentials are considered. In this paper, the authors attempt to convey a proper understanding of component absorption and its place in a vehicle interior system. The relation between sound absorption and component airflow resistance is discussed., and it is also shown that the processings for absorption materials have to be carefully designed. In order to evaluate the overall effectiveness of the absorption treatments, a reliable method for determining interior automotive reverberation times is reviewed.
Qian, Yang, Vanbuskirk, Jeff A.
Low Odor Binder for Molded Fiberglass9405063/1/1994
Molded automotive headliners are composed of a matrix of glass fibers and an organic thermosetting binder. Conventional fiberglass binders for applications such as automotive headliners contain nitrogen based formaldehyde scavenging compounds to reduce the release of highly irritating formaldehyde fumes in the product forming and molding steps. The scavenging compounds employed can result in the formation and deposition of objectionable amine compounds, specifically trimethylamine, in the finished products. Since the release of highly odorous compounds in a vehicle interior is very undesirable, a new fiberglass binder has been developed for molded products that eliminates the root cause of objectionable odors.
Miele, Philip F.
Intrinsically Foamed SMA in Interior Trim Applications9407083/1/1994
Co-Polymers of styrene and maleic anhydride have been around since the '40's. The addition of maleic anhydride to the polymer backbone has a two fold effect; firstly, it increases chain stiffness and secondly chain-chain interactions are increased. Both of these effects increase the glass transition temperature of the co-polymer. A production technology has been developed which enables to generate co-polymers containing a relatively high maleic anhydride content (typically up to 35 wt %) resulting in materials with glass transition temperatures up to 170 °C. A technology has been discovered and patented whereby these high maleic anhydride containing co-polymers can, under the influence of the right chemistry and temperatures (between 230 - 260 °C), release carbon dioxide which is then used as the blowing agent to generate low density (intrinsically blown) foams. In general these foams are produced on tandem foaming lines and typically have the following property profile: The advantages of SMA-foam produced by the intrinsic foaming technology are obvious: High temperature resistance. Environmental friendly (no CFC or hydrocarbon emission). Low cost. Based on this intrinsically blown SMA foam, a new generation of headliners has been developed. The thermomechanical properties of these headliners are comparable to those of structures based on thermosetting polyurethane. The SMA used in the headliners can be recycled using a “solvent recycling” process. Due to the large segmental repulsion between the polar/a-polar monomer units SMA forms miscible or compatible blends with a large range of polymers or co-polymers, which effectively reduces this internal repulsion. Examples of polymers which are compatible with SMA are PMMA, SAN, PVC, PCL, ABS, PA and PET. This broad miscibility/compatibility range enhances options for recycling.
Gill, J. S., Härtel, V., Schoot, H. G.
Balancing Customer Driven Requirements for High Value Headliner Systems9405083/1/1994
This paper outlines a process for a vehicle manufacturer to identify and prioritize requirements for headliners which provide CUSTOMER VALUE. The process includes those requirements placed on headliners to satisfy the vehicle purchasing customer, as well as the in-process customers involved in the design, development and manufacturing of the vehicle and the headlining assembly. Means of quantifying performance for each requirement are proposed. CUSTOMER VALUE can be compared for various headliner alternatives using the definition; A VALUE SELECTION WORKSHEET is presented as the framework for a vehicle manufacturer to select the highest value headliner design and materials for a specific vehicle application.
Shedlowsky, James P., Wentworth, Thomas F.
Headliner Trimming Using Robotic Waterjet Cutting Systems9303063/1/1993
Accurate, high-quality trimming is critical in the manufacture of automotive headliners. And as a wide variety of headliners are trimmed with various patterns, flexibility is essential. The method of cutting headliners with a high-velocity, ultrahigh-pressure stream of water attached to a robot offers not only flexibility, but also competitive process times, clean, non-compressed cuts and no harmful fumes. In the life of a headliner, it is not uncommon to have hundreds of engineering changes. Before water jet cutting, these changes were handled by retooling cutting dies, which requires weeks of work and costs thousands of dollars. Robotic waterjet cutting can accommodate these changes in a matter of hours by simply reprogramming the robot. When robotic waterjet cutting was introduced, it was typical for a system to cost as much as $350,000 to $500,000. With the recent innovation of more sophisticated robots, supporting software and lower-cost waterjet components, this cost has dropped to the $160,000 to $300,000 range. Ultrahigh-pressure waterjet systems have become more reliable and affordable, offering an effective reduction in the upfront capital cost and lower operating costs throughout the life of the equipment.
Mabie, Scott W.
Combining Materials and Functions for Low Cost Manufacturing of Headliners9303093/1/1993
Headliners are large parts that must be lightweight, sound absorbent and sturdy enough to carry a complement of other interior components as well. And as the dashboard becomes loaded with more and more technologies, there is a drive to spread some of that complexity over the rest of the interior of the car. Automotive headliners offer an opportunity for slashing vehicle production costs by integrating components and functions in a one-step operation. The headliner is the ideal candidate not only to accept sun visors, lighting systems and hand grips, but also garage door openers, cellular telephones and audio speakers. This paper will discuss the use of low pressure injection molding as a way to reduce headliner production costs while expanding functionality. It will also examine the equipment requirements and the implications of this process for designers and manufacturers of vehicle headliners.
Hettinga, Siebolt
Study on Test and Product Variations of Noise Reduction Capabilities of Headliners9110925/1/1991
This paper discusses the importance of studying different variabilities (test and product variations) that may affect the noise reduction capabilities of automotive headliners, constructed from different materials. For this purpose, interior noise measurements were made at a position approximating the operator ear level, with different headliner materials under various operating conditions. For better understanding of the effect of different variabilities on acoustical performance, various single number values were computed from the measured data reduced in 1/3 octave band frequencies. Statistical data analyses show that the acoustical performance evaluation of headliners is affected by the product variation from one headliner to another, as well as experimental variation due to vehicle performance and test variation.
Saha, Pranab, Patel, Tushar
Design and Application of Thermoplastic Adhesive Films for Headliner Composites9107812/1/1991
The construction of most automotive interior headliners requires an adhesive material to bond polyurethane foam-backed fabric to a molded headliner shell. More than ten years ago, The Dow Chemical Company qualified and began supplying a thermoplastic adhesive polymer film for headliner applications which replaced wet adhesive systems at several fabricators. DAF 899 adhesive film has gained acceptance in the industry due to excellent performance, convenience, and cost effectiveness without additional waste handling or volatile organic emission concerns. Recent advancements in headliner design such as additional recessed areas with more demanding contours, new substrate materials and the desire for more efficient operations created an opportunity to design improved adhesive films to meet the emerging industry demands. A development program was initiated to determine the key film properties to maximize adhesion at reduced molding cycles with deep contoured parts while maintaining the desired performance properties at elevated temperatures. The research program resulted in the development of a multilayer, multicomponent thermoplastic adhesive film which exhibited excellent deep draw characteristics and significantly reduced molding cycle times. Both adhesive films may be pre-applied to foam-backed fabric to further improve fabrication efficiency. The paper will discuss the design procedures used to develop a new adhesive film system, headliner adhesive requirements, and review pertinent results from fabrication trials. Adhesive film performance on various headliner substrates and processes and recommended process parameters will also be reviewed.
Brandon, Richard H., Kocsis, Michael J., Stewart, Mark T., Pikula, Daniel G.
Thermoplastic Polyurethane Headliners: Properties, Processing, and European Market9107872/1/1991
Prefabricated headliners are now completely accepted in Europe and have almost fully substituted conventional suspension headliners. This success in the European marked did however take some time. The headliner versions developed in the USA and Japan provided guidelines for the European development. The initial reason for using prefabricated headliners came from the assembly line. It was necessary to make it easier for workers to fit the headliner into the car. But there was a second important argument which still applies: cost reduction. The cost reduction argument became the pet of all who had developed a prefabricated headliner. This is ultimately the reason why in the early days of the changeover to the new system only very cheap solutions were ever discussed. This demand has since remained the most important challenge for all innovative steps.
Wagner, Werner
Application of Formable and Self-Skinning Polyurethane Foams in Headliners9008252/1/1990
The initial function of headliners in automobiles was to conceal the rough appearance of the exposed roof construction. As the roof construction evolved towards solid metal, the requirements for headliners grew to include acoustic and styling properties. Today, fiberglass-based headliners have the major share of the North American market in high and mid-line vehicles. However, there is a recent trend to find substitutes for fiberglass headliners because of their skin irritation effects on assembly workers. Headliners based on formable and self-skinning polyurethane foam have gained wide acceptance in Europe as an alternative to fiberglass. This paper discusses the different PUR processes involved and the characteristics of the finished headliners produced with these PUR foams.
Gronemeier, Uwe, Paul, Reiner, Koshute, Mark A.
Headliners and Other Interior Trim Parts Made of Thermoformable Urethane Foam Core Sandwiches9008272/1/1990
The following paper discusses Elastoflex® TF foam, it's use in headliners and other non-load bearing automotive interior trim. Elastoflex® TF foam's history and present use in Europe are reviewed. Raw materials, such as the thermoformable foam, reinforcements, and adhesives for this sandwich construction, are also discussed, along with processing parameters such as the foam manufacturing, sandwich lamination and thermoforming. The key physical properties and acoustics are shown on the included charts and tables. The total process and weight saving advantages are given.
Stoll, J. R., Schlotterbeck, Dietrich G.
Structural Headliners-Their Development, Acoustical and Physical Performance, Modular Capabilities and Economics9008262/1/1990
This paper covers the development of different species of structural headliners, such as fiberglass, styrene, polyester fiber, thermoformable polyurethane foam and foam composites. The recent development emphasis of the structural headliner is focused on the acoustical performance being equal to the in-vehicle test results of non-structural headliners being utilized in conjunction with roof bows in North America. The critical criteria in the development of the structural headliner is the physical performance with regard to both roof deflection and the ability to function as a modular headliner.
Doerer, Richard P., Scott, Tracy E., Souders, Steven
Techniques and Equipment for Processing Headliner Materials9008282/1/1990
A process known as High Caloric Transfer Medium (HCTM*) has been developed and patented by Astechnologies that involves the use of superheated vapor introduced to a perforated tool or three (3) dimensional mold for forming and/or laminating. This process offers very unique possiblilites for cost reductions in the manufacture of most soft interior trim parts including headliners. This process utilizes the super-heated vapor combined with vacuum to cure thermosets, heat thermoplastics, shape fabrics and cool a variety of materials. This provides for reduced cycle times and in some cases eliminates processing steps in the manufacture of headliners. Comparisons are made between conventional and HCTM* forming and laminating methods in order to fully describe the advantages of the latter process.
Simmons, Art, Elliott, George, Elliott, Chris
Engineering, Optimization, and Tuning of vehicle interior Sound Absorption and Other mechanisms for Sound Reduction8902342/1/1989
This paper treats the engineering, optimization and tuning of vehicle sound absorption with emphasis on headliners. It covers the methodology of measuring sound. The mechanisms for sound reduction damping are discussed. The report compares the acoustical performance of worldwide headliner constructions at different frequencies and leaves it up to the reader to make his/her own evaluation. The Authors discuss means to enhance and optimize and tune headliners to increase the acoustic functionality of the parts. The paper also shows the relative acoustic performance of interior trim parts. Future trends and methodology are explored along with the European trend to eliminate roof bows and the headliner being robotically adhered to the roof to improve acoustics, structural effectiveness and lower cost.
Souders, Steven L., Doerer, Richard P., Scott, Tracy E.
Sound Absorbing Properties of Molded Fiberglass Panels for Use in Vehicle Noise Control8709874/28/1987
Molded fiberglass headliners and headliners are widely used in vehicles for controlling sound. These parts frequently must be molded to fit structural contours thus resulting in variations in part thickness, bulk density and spacing of the part from underlying sheet metal surfaces. This paper reviews the results of a study which was conducted to determine the effects of these variables on the sound absorption characteristics of the material. Random incidence sound absorption coefficients over the frequency range of 80 to 6300 Hz. were measured using fiberglass panels in thicknesses ranging from 1/4 to 2 inches and bulk densities from 1 to 8 pounds per cubic foot with air spaces from 0 to 1 inch.
Haines, James C.
A History of Automotive Headliners and Characteristics of Tramivex™, an Engineered Composite material8703812/1/1987
Tramivex™ is a trademark of Van Dresser Corporation for an engineered composite material which is currently being used extensively throughout Europe. It is being released in the United States as a headliner material and for other applications. This patented material is a multi-layer composite material of which the heart is a resin impregnated polyether foam. An in-line heated mold carries out the polymerization of the composite structure. Due to the flexibility of the process the thickness, of the foam, stiffness or flexibility, the type of impregnation, the density of the fiberglass and the types of scrim cover material may all be varied. This variability allows this engineered composite material to meet a rather broad range of specifications and to be engineered for diverse applications.
Doerer, Richard P., Sandoe, Michael D.
Headliners Designed to Dampen Roof Vibration8703802/1/1987
Traditionally, headliners for improved acoustics have concentrated on absorbing sound generated within the vehicle. In-car testing has shown that the most effective constructions combine interior noise absorption with dampening of roof vibration. Technology has been developed which provides better dampening of roof vibration than the combination of a traditional headliner and dampening pad. Benefits of eliminating a separate dampening pad include guaranteed roof contact for long term roof dampening and the elimination of a separate labor intensive operation. In-car acoustic excitation and structural excitation tests demonstrated the benefit of this technology. Road testing in a Mercury Topaz showed that, while the full benefit of this technology may not be fully realized in all vehicles, the good acoustical performance of fiberglass headliners can be matched or exceeded with FSL headliner designs which offer more styling flexibility and toughness during installation. This technology can be used to tailor headliners for the cost performance required for various car sizes and models. This paper discusses the details of 1) comparative noise levels recorded during acoustic and structural excitation tests, and 2) comparative noise levels recorded during Topaz road tests.
Kostelnik, Robert J., Brant, Angela L., Battle, Keith J.
Fibre Cor - The Next Generation in Headliners8703792/1/1987
A new material called Fibre Cor has been developed that is the next “generation” in headliner materials. Fibre Cor consists of one or two layers of Dylark ® foam laminated between a poylester nonwoven material. The result is a light weight, strong, highly moldable substrate for use in headlinings. Acoustically it is equivalent to currently available headliner materials. Fibre Cor is not only an effective sound absorber, but it is also an effective sound dampener and sound barrier. All current materials require additional dampening pads which add steps, material, complexity and costs to the total system. Fibre Cor also has much more structural integrity than currently available material. Fibre Cor is a significant breakthrough and does represents the next generation of headliners.
Landry, Chris, Rozek, Harry
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