Modular automotive roof installation method

A method for assembly of a vehicle roof assembly into a vehicle, comprising the steps of:

• a) providing a structure defining a roof opening in a vehicle;
• b) providing a multi-layer laminate headliner having a first configuration that is larger in dimension than said roof opening and a free peripheral edge;
• c) installing a plurality of components into said headliner;
• d) securing said headliner to a roof panel at a central portion of said headliner for forming a roof assembly;
• e) elastically deforming said headliner to a second configuration for displacing said free peripheral edge;
• f) applying an adhesive to said roof panel;
• g) providing a restraining device for maintaining said headliner in said elastically deformed second configuration;
• h) maintaining said headliner in said second elastically deformed configuration with said restraining device;
• i) installing said roof assembly onto said vehicle by placement of said headliner through said roof opening so that said adhesive on said roof panel joins said roof panel to said structure defining said roof opening;
• j) removing said restraining device and permitting said headliner to return toward said first configuration substantially free of plastic deformation from said maintaining step (h);
• and
• k) attaching said free peripheral edge to said vehicle for concealing said structure defining said root opening.

A method for assembly of a vehicle roof assembly into a vehicle, comprising the steps of:

• a) providing a structure defining a roof opening in a vehicle;
• b) providing a headliner having a first configuration that is larger in dimension than said roof opening and a free peripheral edge;
• c) installing a plurality of components into said headliner;
• d) securing said headliner to a roof panel at a central portion of said headliner for forming a roof assembly;
• e) deforming said headliner to a second configuration for displacing said free peripheral edge;
• f) providing a restraining device for maintaining said headliner in said second configuration;
• g) maintaining said headliner in said second configuration with said restraining device;
• h) placing said headliner and restraining device into a storage rack for receiving a plurality of headliners;
• i) removing said headliner from said storage rack;
• j) securing said headliner to a roof panel at a central portion of said headliner for forming a roof assembly;
• k) installing said roof assembly onto said vehicle by placement of said headliner through said roof opening;
• and
• l) removing said restraining device and permitting said headliner to return toward said first configuration.