Vehicle panel

Abstract

A vehicle panel with a folded-over or wrapped edge is disclosed. The vehicle panel comprises a main body portion. The main body portion includes a first layer and a second layer. The first layer is formed of a substantially rigid material and has a first surface, a second surface and an edge. The second layer is coupled to the second surface of the first layer and formed of a substantially flexible material. The vehicle panel also comprises a flap integrally formed with the main body portion at the edge and comprises at least the second layer. The vehicle panel further comprises a hinge separating the flap from the main body portion, the hinge is defined by at least a portion of the first layer having a reduced thickness. The flap is folded back about the hinge towards the first surface of the first layer to substantially conceal the edge.

What is claimed is: 
     
         1 . A vehicle panel comprising:
 a main body portion including a first layer and a second layer, the first layer being formed of a substantially rigid material and having a first surface, a second surface and an edge, the second layer being coupled to the second surface of the first layer and formed of a substantially flexible material;   a flap integrally formed with the main body portion at the edge and comprising at least the second layer; and   a hinge separating the flap from the main body portion, the hinge being defined by at least a portion of the first layer having a reduced thickness,   wherein the flap is folded back about the hinge towards the first surface of the first layer to substantially conceal the edge.   
     
     
         2 . The vehicle panel of  claim 1  wherein the edge is at least one of a peripheral edge and an internal edge. 
     
     
         3 . The vehicle panel of  claim 1  wherein the vehicle panel is a headliner configured to be supported at a roof of a vehicle. 
     
     
         4 . The vehicle panel of  claim 3  wherein the edge defines an opening for a sunroof in the main body portion. 
     
     
         5 . The vehicle panel of  claim 1  wherein the flap further comprises the first layer which provides a reinforcement member at the edge when the flap is folded back towards the first surface of the first layer of the main body portion. 
     
     
         6 . The vehicle panel of  claim 1  wherein the portion of reduced thickness is formed by at least partially removing the first layer or by compressing the first layer. 
     
     
         7 . The vehicle panel of  claim 1  wherein the first layer is thinned from the second surface of the main body portion to provide the portion of the first layer having the reduced thickness and defining the hinge. 
     
     
         8 . The vehicle panel of  claim 1  wherein the first layer is thinned from the first surface of the main body portion to provide the portion of the first layer having the reduced thickness and defining the hinge. 
     
     
         9 . The vehicle panel of  claim 1  wherein a portion of the first layer is substantially removed to provide the portion of the first layer having the reduced thickness and defining the hinge. 
     
     
         10 . The vehicle panel of  claim 1  wherein the hinge is further defined by a portion of the second layer having a reduced thickness. 
     
     
         11 . The vehicle panel of  claim 10  wherein the second layer is thinned from a side opposite the first layer to provide the portion of the second layer having the reduced thickness and defining the hinge. 
     
     
         12 . A method of manufacturing a vehicle panel, the method comprising:
 forming a main body portion having a substantially rigid substrate and a substantially flexible cover material coupled to the substrate, the substrate having an edge;   providing an area of reduced thickness in the substrate, the area of reduced thickness defining a living hinge;   integrally forming a flap with the main body portion, the flap being provided on a side of the living hinge opposite the main body portion and comprising at a least the cover material; and   folding the flap about the living hinge towards the substrate of the main body portion to substantially conceal the edge.   
     
     
         13 . The method of  claim 12  further comprising forming an opening in the main body portion and wherein the edge defines the opening. 
     
     
         14 . The method of  claim 12  further comprising configuring the flap to include both the substrate and the cover material, the substrate on the flap providing a reinforcement member adjacent to the edge when the flap is folded about the living hinge. 
     
     
         15 . The method of  claim 12  wherein providing an area of reduced thickness in the substrate comprises thinning the substrate from a surface opposite the cover material.