Machine and method for forming a headliner

Patent metadata

Field	Value
Publication number	US-2016185031-A1
Application number	US-201615062851-A
Country	US
Kind code	A1
Filing date	Mar 7, 2016
Priority date	Feb 17, 2014
Publication date	Jun 30, 2016
Grant date	—

Abstract

A headliner includes a ceiling and an edge flange extending away from the ceiling. The edge flange has a backing section at a free end and a wall section connected to the ceiling. An edge fold is formed on the headliner by a method that includes heating the flange and folding the backing section over and parallel to the ceiling. The method also includes forming a reverse turned edge by folding the backing section over the wall section and compressing the backing section against the wall section.

First claim

What is claimed is:

1 . A method of forming a headliner that includes a ceiling and an edge flange extending away from the ceiling, the edge flange having a backing section at a free end and a wall section connected to the ceiling, comprising:
heating the flange; folding the backing section over and parallel to the ceiling; forming a reverse turned edge by folding the backing section over the wall section; and compressing the backing section against the wall section.

2 . The method of claim 1 further comprising:
positioning the headliner on a nest that includes a base for supporting the ceiling and a forming wall that supports the edge flange.

3 . The method of claim 2 further comprising:
clamping the wall section against the forming wall with a heating element.

4 . The method of claim 1 further comprising:
cutting a notch in the edge flange at a boundary between the backing section and the wall section.

5 . A method of forming a bonded edge fold on a headliner that includes a ceiling and an edge flange extending away for the ceiling, the edge flange having a backing section at a free end and a wall section connected to the ceiling, the method comprising:
positioning the headliner on a nest that includes a base that supports the ceiling and a forming wall that supports the edge flange; clamping the wall section against the forming wall with a heating element; heating the edge flange with the heating element to activate an adhesive layer within the edge flange; advancing a slide in a first direction to fold the backing section over the heating element to be disposed substantially parallel to the ceiling; moving the slide perpendicular to the first direction toward the nest to fold the backing section over the wall section; retracting the slide in a second direction opposite the first direction; and compressing the backing section against the wall section, wherein the adhesive layer bonds the backing section to the wall section to form the bonded edge fold.

6 . The method of claim 5 further comprising:
cutting a notch in the edge flange where the backing section and the wall section meet.

7 . The method of claim 5 further comprising:
retracting the heating element before moving the slide toward the nest.

8 . The method of claim 5 wherein the step of compressing the backing section against the wall section forces the adhesive layer to seep through a backing layer of the headliner and bond the backing layers on the wall section and the backing section to each other.

9 . A method of forming a headliner, using a machine including an upper die and a slide connected thereto, comprising:
clamping the headliner to a lower die with a heating element; pushing a folding face of the slide into the headliner to form a folded-over portion; and pulling a clamping face of the slide against the folded-over portion to compress the headliner between the slide and the lower die forming an edge fold.

10 . The method of claim 9 further comprising lowering the slide to place the folded-over portion in an overlapping relationship with a wall section of the headliner.

11 . The method of claim 9 wherein the folding face and the clamping face are on opposite sides of the slide.

12 . The method of claim 9 further comprising heating a portion of the headliner with the heating element to activate an adhesive layer within the headliner.

13 . The method of claim 9 further comprising positioning the headliner on the lower die such that a base of the lower die supports a ceiling of the headliner and a forming wall of the lower die supports an edge flange of the headliner.

14 . The method of claim 13 wherein the clamping face further includes a curved portion, and wherein the forming wall further includes an arcuate portion that cooperates with the curved portion when the slide is pulled to compress the edge flange between the slide and the lower die.

15 . The method of claim 9 wherein the folded-over portion is formed by folding the headliner over the heating element.

16 . The method of claim 9 further comprising cutting a notch in the headliner at a base of the folded-over portion.

17 . The method of claim 9 further comprising retracting the heating element before pulling the clamping face of the slide against the folded-over portion.

Assignees

• Ford Global Tech Llc

Inventors

• Huelke David
• Baxter Jeffrey Todd

Classifications

• B29K2075/00

  Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material · CPC title

• B60R13/0218

  supported by adhesion with the roof panel · CPC title

• B29C53/066 Primary

  and joining the sides of the folding line, e.g. "Abkantschweissen" · CPC title

• B32B2605/08

  Cars · CPC title

• B32B27/40

  comprising polyurethanes · CPC title