Abstract: A headliner reinforcement for ensuring the proper placement of a wire harness at a location above a headliner in a motor vehicle is provided. The headliner reinforcement includes a member having a top side and a bottom side, the bottom side being adjacent to the headliner and the top side being adjacent to a roof of the motor vehicle. The top side includes at least one clip attachment operable to accept at least one clip. In some instances, the top side can include at least two spaced apart clip attachments separated by a predetermined distance and operable to accept at least two spaced apart clips separated by the same predetermined distance on the wire harness. The predetermined distance between the spaced apart clip attachments and the spaced apart clips can be unique among other clip attachments on the motor vehicle and thereby prevent the installment of an undesirable wire harness above the headliner of the motor vehicle.

Abstract: A headliner assembly covers an inner surface of a motor vehicle roof having a sunroof opening. The headliner assembly includes a dimensionally stable substrate having a first edge extending along the sunroof opening. The substrate has an upper surface facing the inner surface of the motor vehicle roof. The substrate further has a bottom surface opposite the upper surface. A molded reinforcement is fixedly secured to the upper surface of the substrate. The reinforcement has a second edge extending along the sunroof opening. The second edge of the reinforcement has a contoured portion that extends further inwardly toward a center of the sunroof opening relative to the first edge of the substrate. A trim cover has a third edge extending along the sunroof opening.

Abstract: A headliner assembly covers an inner surface of a motor vehicle roof having a sunroof opening. The headliner assembly includes a dimensionally stable substrate having an upper surface facing the inner surface of the motor vehicle roof and an opposite bottom surface. The headliner assembly also includes a molded reinforcement disposed along the upper surface of the substrate. The molded reinforcement has a main wall and a box-shaped attachment structure supporting a fastener for attaching the headliner assembly to the inner surface of the motor vehicle roof. The attachment structure has spaced apart pair of side walls extending between the main wall and the inner surface of the motor vehicle roof. The attachment structure has a top wall extending between tie side walls of the attachment structure. The attachment structure also includes a reinforcing wall extending between the top wall and the side walls.

Abstract: A headliner assembly covers an inner surface of a motor vehicle roof having a sunroof opening. The headliner assembly includes a dimensionally stable substrate having a first edge extending along the sunroof opening. The substrate has an upper surface facing the inner surface of the motor vehicle roof. The substrate further has a bottom surface opposite the upper surface. A molded reinforcement is fixedly secured to the upper surface of the substrate. The reinforcement has a second edge extending along the sunroof opening. The second edge of the reinforcement has a contoured portion that extends further inwardly toward a center of the sunroof opening relative to the first edge of the substrate. A trim cover has a third edge extending along the sunroof opening.

Abstract: A headliner reinforcement for ensuring the proper placement of a wire harness at a location above a headliner in a motor vehicle is provided. The headliner reinforcement includes a member having a top side and a bottom side, the bottom side being adjacent to the headliner and the top side being adjacent to a roof of the motor vehicle. The top side includes at least one clip attachment operable to accept at least one clip. In some instances, the top side can include at least two spaced apart clip attachments separated by a predetermined distance and operable to accept at least two spaced apart clips separated by the same predetermined distance on the wire harness. The predetermined distance between the spaced apart clip attachments and the spaced apart clips can be unique among other clip attachments on the motor vehicle and thereby prevent the installment of an undesirable wire harness above the headliner of the motor vehicle.

Abstract: A headliner assembly covers an inner surface of a motor vehicle roof having a sunroof opening. The headliner assembly includes a dimensionally stable substrate having an upper surface facing the inner surface of the motor vehicle roof and an opposite bottom surface. The headliner assembly also includes a molded reinforcement disposed along the upper surface of the substrate. The molded reinforcement has a main wall and a box-shaped attachment structure supporting a fastener for attaching the headliner assembly to the inner surface of the motor vehicle roof. The attachment structure has spaced apart pair of side walls extending between the main wall and the inner surface of the motor vehicle roof. The attachment structure has a top wall extending between tie side walls of the attachment structure. The attachment structure also includes a reinforcing wall extending between the top wall and the side walls.

Abstract: A method of forming a headliner includes overlaying a cover material onto a multi-layer substrate and at least partially separating the cover material from the substrate during the overlaying. The cover material is clamped separately from the substrate. The overlayed cover material and substrate are then transported into a mold. The substrate is unclamped while the cover material remains clamped, and the cover material and substrate are molded together to form the headliner.

Abstract: A method of forming a headliner includes overlaying a cover material onto a multi-layer substrate and at least partially separating the cover material from the substrate during the overlaying. The cover material is clamped separately from the substrate. The overlayed cover material and substrate are then transported into a mold. The substrate is unclamped while the cover material remains clamped, and the cover material and substrate are molded together to form the headliner.