Method of making a sunroof sunshade

Details Method of making a sunroof sunshade Method of making a sunroof sunshade

2000-06-20

2001-10-02

Bryant, David P. (Department: 3726)

Metal working

Method of mechanical manufacture

Obtaining plural product pieces from unitary workpiece

C296S214000, C029S091100, C029S412000

Reexamination Certificate

active

06295711

ABSTRACT:

TECHNICAL FIELD
The invention relates to a method of manufacturing a sunshade for use with a vehicle having a sun roof.
BACKGROUND ART
Many vehicles are provided with a sunroof assembly that includes a frame attached to a vehicle roof, and a moveable sunroof connected to the frame. Such an assembly also typically includes a sunshade connected to the frame and disposed beneath the sunroof. The sunshade is moveable between open and closed positions so as to cover a sunroof opening formed in a headliner of a particular vehicle.
A prior method of manufacturing a sunshade includes forming a substrate to a desired size and shape, and attaching a cover layer to the substrate. Known substrates include aluminum sheets, injection molded plastic, sheet molding compound, compressed resinated-fiber mats, and sprayed urethane. Because the sunshade is formed separately from a corresponding headliner, it is difficult to obtain a good color match and/or texture match between the sunshade and the headliner. Furthermore, because the sunshade and headliner are formed separately, the combined manufacturing costs are significant.
DISCLOSURE OF INVENTION
The invention addresses the shortcomings of the prior art by providing a method of manufacturing a sunshade that includes utilizing material removed from a headlliner. The method according to the invention significantly reduces manufacturing costs as well as disposal costs. Furthermore, the sunshade produced by the method has improved color match and texture match with the corresponding headliner.
Under the invention, a method of manufacturing a sunshade for use with a vehicle having a sunroof includes cutting away material from a headliner to form a cutout and to define a sunroof opening in the headliner; and attaching edging to the cutout to form the sunshade.
Preferably, the step of attaching edging to the cutout includes attaching first and second edge pieces to first and second sides, respectively, of the cutout so that the sunshade has a lateral dimension that is at least as great as a lateral dimension of the sunroof opening in the headliner. Furthermore, the step of attaching edging to the cutout may also include attaching front and rear edge pieces to front and rear portions, respectively, of the cutout so that the sunshade has a longitudinal dimension that is at least as great as a longitudinal dimension of the sunroof opening in the headliner.
The method also preferably includes attaching a reinforcing layer to the cutout for stiffening the cutout. The reinforcing layer and the cutout may be attached together in any suitable manner such as with rollers or a press. Furthermore, the reinforcing layer may comprise any suitable material such as fiberglass, plastic and/or natural fibers.
These and other objects, features and advantages of the invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in conjunction with the accompanying drawings.


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