Reinforced composite inner roof panel of the cellular core sandwich-type and method of making same

Abstract

The invention relates to reinforced composite inner roof panels of the sandwich-type having a cellular core. In a method for making a inner roof panel of the invention, a stack is formed that is made up of: an upper skin made of a reinforced thermoplastic material; a cellular core made of a thermoplastic material; and a bottom skin made of a reinforced thermoplastic material. The upper and lower skins and the cellular core are formed together and have regions of reduced thickness and regions of increased thickness that may provide head impact absorbing characteristics or form structural components of the passenger compartment. Examples of structural components that may be formed include HVAC ducts, wiring conduits, video display panel mounts or air bag receptacles.

1 - 14 . (canceled)  
   
   
       15 . A method of making an inner roof panel for a vehicle roof assembly comprising: 
 cutting an upper skin of fiber reinforced thermoplastic material, a cellular core and a bottom skin of fiber reinforced thermoplastic material;    placing the upper skin, cellular core and bottom skin in a mold, having an upper die and a lower die that define a mold cavity having a varied thickness;    heating the upper skin, cellular core and bottom skin while in the mold;    applying pressure to the upper skin, cellular core and bottom skin while in the mold to form the inner roof panel that is thicker in local areas; and    removing the inner roof panel from the mold.    
   
   
       16 . The method of  claim 15  wherein the step of applying pressure further comprises forming head impact absorption areas by the thicker areas.  
   
   
       17 . The method of  claim 15  wherein the step of applying pressure further comprises forming a structural component by the thicker areas.  
   
   
       18 . The method of  claim 17  wherein the step of forming structural components further comprises forming a video display mount.  
   
   
       19 . The method of  claim 17  wherein the step of forming structural components further comprises forming a wiring conduit.  
   
   
       20 . The method of  claim 17  wherein the step of forming structural components further comprises forming a side curtain air bag pocket.