Abstract: An interior trim assembly including vehicle roof structure that supports a headliner-mounted component and a headliner, a separating means proximate a mounting location perimeter of the headliner-mounted component for maintaining a mounting integrity of the headliner-mounted component upon deployment of an inflatable restraint.

Abstract: A headliner assembly (10) includes a layer of core material (16), a binding agent (26) adjacent to the core material (16), a first layer of chopped fiberglass (14) adjacent to the binding agent (26), a scrim (20) adjacent to the first layer of chopped fiberglass (14), a catalyst (38) adjacent to the scrim (20), a cover stock (22) adjacent to the catalyst (38). The catalyst (38) and the binding agent (26) are mixed together and impregnate the core material when pressure is applied to the headliner assembly (10), thereby resulting in a rigid headliner assembly. A method of forming the headliner assembly (10) is also disclosed.

Abstract: A headliner (10) for use with a motor vehicle including a combination of a chopped fiber roving (22) bonded between a non-woven film layer and a urethane core (14) to eliminate warpage in the headliner (10) after the molding and forming process is complete. The combination of stiffness and mechanical bond provides this effect. The combination may also include a polypropylene non-woven material (18) combined with a polyethylene film (20) to form a laminate top (12) and bottom layer (16). The chopped fiber roving (22) is randomly disposed between the laminate (21) and a urethane matrix (44) used to form a core (14) of the headliner (10) to provide the shape stability to the headliner (1).

Abstract: A headliner assembly comprising a core layer having upper and lower surfaces and formed of loosely intertangled polyester fibers. An upper bi-component layer of densely intertangled polyester fibers is attached to the upper surface of the core layer by a web adhesive and a lower bi-component layer of densely intertangled polyester fibers is attached to the lower surface of the core layer by a web adhesive. An outer covering layer is attached to the upper bi-component layer for providing an aesthetically pleasing outer appearance to the headliner assembly. Alternatively, the bi-component layers may be attached to the core layer by intertangling fibers of the bi-component layer with fibers of the core layer adjacent each of the upper and lower surfaces.