FORM 2
THE PATENTS ACT 1970
[39 OF 1970]
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10; rule 13] TITLE: “A SUPPORT BLOCK FOR A HEADLINER ASSEMBLY OF A VEHICLE”
NAME AND ADDRESS OF THE APPLICANT:
TATA MOTORS PASSENGER VEHICLES LIMITED of Floor 3, 4, Plot-18, Nanavati Mahalaya, Mudhana Shetty Marg, BSE, Fort, Mumbai, Mumbai City, Maharashtra, 400001 India
Nationality: Indian
The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
Present disclosure relates in general to a field of automobiles. Particularly, but not exclusively, the present disclosure relates to a headliner assembly of a vehicle. Further, embodiments of the present disclosure discloses a support block of the headliner assembly.
BACKGROUND OF THE DISCLOSURE
Generally, vehicles are provided with a headliner to cover an interior part of a roof of the vehicle. The headliners serve as a decorative panel that makes the vehicle roof structure more attractive when viewed from within a cabin and also act as sound deadening means which absorbs sounds from outside and within the cabin. Further, the headliner is also adapted to absorb heat originating outside the cabin. The headliners are typically constructed of suitable fiber material or may be made of a rigid material which conform with the general contour of the roof. Typically, the headliner is fixed to the roof by way of brackets, rivets, securing pins and other suitable fasteners. However, even after fixing the headliner to the roof, there exists gaps between the headliner and the roof which may arise due to various factors such as poor assembly, environmental factors such as heat, cold and due to poor adhesive properties.
In order to rigidly secure the headliner with the roof of the vehicle, foam blocks are provided in the gaps that are formed between the headliner and the roof. The foam blocks help in rigidly fixing the headliner without causing damage to the headliner due to external forces as well as prevent sagging of the headliner. Conventionally, the foam blocks are disposed between the headliner and the roof by fixing the foam blocks to the headliner by way of adhesive bonding. That is, an adhesive material may be applied to a surface of the foam block and then the foam block with the adhesive material is stuck onto the headliner. However, such mere application of adhesive material onto the foam block may not be sufficient to rigidly fix the foam block onto the headliner, as over a period of time such adhesion between the foam block and the adhesive material can weaken and the foam block gets separated from the headliner. This causes the headliner to sag or deform, which is undesired.
Present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the known arts.

The drawbacks/difficulties/disadvantages/limitations of the conventional techniques explained in the background section are just for exemplary purpose and the disclosure would never limit its scope only to such limitations. A person skilled in the art would understand that this disclosure and below mentioned description may also solve other problems or overcome the other drawbacks/disadvantages of the conventional arts which are not explicitly captured above.
SUMMARY OF THE DISCLOSURE
One or more shortcomings of the prior art are overcome by a support block as claimed and additional advantages are provided through the support block as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
In one non-limiting embodiment, a support block for a headliner assembly of a vehicle is disclosed. The support block includes a first surface which is defined on one side of the support block, where the first surface is configured to be adhesively bonded to a headliner. Further, the support block includes a plurality of provisions which are defined on the first surface of the support block. The first surface and the plurality of provisions are configured to receive adhesive material to form a single adhesive layer to adhere to the headliner of the vehicle. Additionally, the support block includes a second surface which is defined opposite to the first surface, and adapted to engage with a roof of the vehicle. This configuration of the support block which facilitates formation of the single adhesive layer with the first surface and the plurality of provisions, provide interlocking of the adhesive layer with the support block thereby retaining adhesion between the adhesive material and the support block to prevent separation of the support block and the headliner.
In an embodiment, the plurality of provisions are defined with a channel extending into the support block, to channelize the adhesive material from the first surface.
In an embodiment, the plurality of provisions are defined with a chamber extending from an end of the channel away from the first surface, to receive the adhesive material.

In an embodiment, the first surface of the support block is shaped to define a profile corresponding to the profile of a portion of the headliner.
In an embodiment, the single adhesive layer received on the first surface of the support block is defined with a profile extending from one end of the first surface to another end of the first surface through the plurality of provisions.
In an embodiment, the single adhesive layer formed through the channel and the chamber of the plurality of provisions provides interlocking of the adhesive material with the support block.
In another non-limiting embodiment, a headliner assembly for a roof of a vehicle is disclosed. The headliner assembly includes a headliner and a plurality of locking members defined on the headliner, which are configured to lock the headliner with the roof. Further, the assembly includes at least one support block that is fixed to the headliner and adapted to engage with the roof. The at least one support block includes a first surface that is defined on one side of the support block, where the first surface is configured to be adhesively bonded to the headliner. Additionally, a plurality of provisions are defined on the first surface of the support block, where the first surface and the plurality of provisions are configured to receive adhesive material to form a single adhesive layer to adhere to the headliner of the vehicle. Furthermore, the support block includes a second surface defined opposite to the first surface and adapted to engage with the roof of the vehicle.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiments when read in conjunction with the accompanying figures. One or more embodiments

are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
Fig. 1 illustrates a side cross-sectional view of a headliner assembly for a vehicle, according to an embodiment of the present disclosure.
Fig. 2 illustrates a bottom perspective view of a support block of the headliner assembly, according to an embodiment of the present disclosure.
Fig. 3 illustrates a side cross-sectional view of the support block, according to an embodiment of the present disclosure.
Fig. 4 illustrates a side cross-sectional view of the headliner assembly with adhesive material between the support block and the headliner, according to an embodiment of the present disclosure.
The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the system and method illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which forms the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that, the conception and specific embodiments disclosed may be readily utilized as a basis for modifying other devices, assemblies, system, methods and processes for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that, such equivalent construction do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, to its construction and features, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be

expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusions, such that a device or a system or a method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such device, assembly, system or method. In other words, one or more elements in a device or an assembly or a system or a method proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the device or system or method.
Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals have been used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to Figs. 1-4.
Fig. 1, illustrates a side cross-sectional view of a headliner assembly (100) for a roof [not shown in Figs] of a vehicle. In an embodiment, the vehicle [not shown in Figs] may be including but not limited to cars, sport utility vehicle (SUV), a multi utility vehicle (MUV), a light commercial vehicle (LCV), a heavy commercial vehicle (HCV) and the like which have a passenger cabin. The vehicle may include a body which may be defined with the roof and the headliner assembly (100) may be fixed to the roof. The roof may be defined with receiving portions [not shown in Figs] to receive the headliner assembly (100). In an embodiment, the vehicle may include multiple

headliner assemblies for different portions of the roof. Further, the headliner assembly (100) may include a headliner (4) which is adapted to be fixed to the roof. The headliner (4) may be configured to insulate the cabin of the vehicle from heat and noise. Furthermore, the headliner assembly (100) may include a plurality of locking members [not shown in Figs] which may be defined on the headliner (4). The plurality of locking members may be configured to lock the headliner (4) with the roof of the vehicle, that is the plurality of locking members may be adapted to fix with the receiving portions of the roof to support the headliner (4) with the roof of the vehicle. In an embodiment, the plurality of locking members may be defined on the headliner (4) at predefined locations which correspond to the location of the receiving portions of the roof to fix the headliner (4).
Further, the headliner assembly (100) may include a support block (1). In an illustrated embodiment, one support block (1) is depicted, however, this should not be considered as a limitation as more than one support block (1) may be provided in the headliner assembly (100). The support block (1) may be fixed at predefined locations on the headliner (4) such that sufficient support may be provided to the headliner (4) upon fixing the headliner (4) with the roof of the vehicle. In an embodiment, the location of the support block (1) on the headliner (4) may be of a predefined shape and dimension of the headliner (4). Further considering the shape and dimension of the roof onto which the headliner (4) may be fixed. The support block (1) may be adapted to rigidly secure the headliner (4) with the roof of the vehicle. That is, the support block (1) may be provided in gaps which may be formed between the headliner (4) and the roof. In an embodiment, the support block (1) may also be provided at portions of the headliner assembly (100) where gaps may not be present between the headliner (4) and the roof. The support block (1) may be configured to rigidly fix to the headliner (4) and in-turn with the roof and prevents damage to the headliner (4) due to external forces as well as preventing sagging of the headliner (4). In an embodiment, the support block (1) may be made of a soft material which may deform and exhibit resilient properties. For example, the support block (1) may be made of a foam material, a polymeric material and the like which are soft and resilient in nature.
Referring now to Figs. 1 and 2, the support block (1) may include a plurality of surfaces or faces based on the shape and dimensional requirement. In an embodiment, the support block (1) may be defined with a first surface (6) on one side of the support block (1). The first surface (6) may be

configured to be adhesively bonded to the headliner (4). That is, the first surface (6) may be adapted to receive adhesive material (3) such that the first surface (6) of the support block (1) may be adhesively bonded to the headliner (4). In an embodiment, the first surface (6) of the support block (1) may be shaped to define a profile which may correspond to the profile of a portion of the headliner (4) to which the support block (1) may be fixed.
Further, the support block (1) may include a plurality of provisions (2) which may be defined on the first surface (6). In an embodiment, the plurality of provisions (2) may be defined within the first surface (6) of the support block (1). Each of the plurality of provisions (2) may be located at predefined locations on the first surface (6) of the support block (1). The predefined location of the plurality of provisions (2) may be determined based on the size, shape, dimension of the support block (1) as well as the amount of adhesive bonding required between the support block (1) and the headliner (4). The plurality of provisions (2) may be defined with a channel (2a) [as seen in Figs. 1 and 3] which may extend into the support block (1). The channel (2a) may be adapted to channelize the adhesive material (3) from the first surface (6) when the adhesive material (3) is received by the first surface (6). Furthermore, the plurality of provisions (2) may be defined with a chamber (2b) [as seen in Figs. 1 and 3]. The chamber (2b) may be positioned at an internal portion of the support block (1) and may extend from an end of the channel (2a) which may be away from the first surface (6) of the support block (1). The chamber (2b) may be adapted to receive the adhesive material (3) from the first surface (6) through the channel (2a).
Referring now to Fig. 4, the plurality of provisions (2) and the first surface (6) of the support block (1) may be configured to receive the adhesive material (3) such that the adhesive material (3) on top of the first surface (6) and within the plurality of provisions (2) may form a single adhesive layer (5). That is, the adhesive material (3) on the first surface (6), the adhesive material (3) in the channel (2a) and in the chamber (2b) together form the single adhesive layer (5). Such single adhesive layer (5) may be adapted to adhere to the headliner (4) of the headliner assembly (100). In an embodiment, the single adhesive layer (5) which may be received on the first surface (6) of the support block (1) may be defined with a profile extending from one end of the first surface (6) to another end of the first surface (6) through the plurality of provisions (2). This single adhesive layer (5) may form a self-riveted layer (5) which provides rigid interlocking of the adhesive material (3) with the support block (1). In an embodiment, the plurality of provisions (2) having

the channel (2a) and the chamber (2b) may resemble a mushroom shape or a profile which resembles a rivet, thereby such shape of the plurality of provisions (2) may facilitate interlocking of the adhesive material (3) with the first surface (6) of the support block (1).
Referring back to Figs. 1 and 4, the support block (1) may include a second surface (7) which may be defined opposite to the first surface (6). The second surface (7) may be adapted to engage with the roof of the vehicle when the headliner (4) may be fixed to the roof. The engagement of the second surface (7) with the roof of the vehicle upon fixing of the headliner (4) facilitates rigid and sturdy fixing of the headliner (4) with the roof of the vehicle.
The configuration of the support block (1) having the plurality of provisions (2) defined in the first surface (6) facilitates formation of the single adhesive layer (5) with the first surface (6) and the plurality of provisions (2). The single adhesive layer (5) provide interlocking of the adhesive layer
(5) with the support block (1) thereby retaining adhesion between the adhesive material (3) and the support block (1) even after prolonged periods of time, thereby preventing separation of the support block (1) and the headliner (4). The single adhesive layer (5) formed on the first surface
(6) as well as within the plurality of provisions (2) rigidly fix the support block (1) onto the headliner (4), and mitigates separation of the support block (1) and the headliner (4), thereby preventing the headliner (4) from sagging and deformation.
It should be noted that in an exemplary embodiment, as seen in the Figs. 1-4 the features, construction, position and connections should not be construed as a limitation as the headliner assembly (100) and the support block (1) may include any other type of features, construction, position, and connections which may work with other combinations.
In an operational embodiment, during assembling the headliner assembly (100), initially, the support block (1) may be manufactured to be defined with the required dimension and the requires shape and profile. Further, the support block (1) may be manufactured to be defined with the plurality of provisions (2). Furthermore, the adhesive material (3) may be applied on to the first surface (6) of the support block (1). The adhesive material (3) applied on the first surface (6) may be spread across the length and breadth of the first surface (6) such that the first surface (6) and the plurality of provisions (2) may be completely covered by the adhesive material (3). Upon

applying the adhesive material (3), the adhesive material (3) may form the single adhesive layer (5). Upon formation of the single adhesive layer (5), the support block (1) may be positioned in contact with the headliner (4), such that the first surface (6) having the single adhesive layer (5) may contact the headliner (4), which may lead to adhesive bonding of the support block (1) with the headliner (4). Further, upon adhesion between the support block (1) and the headliner (4), the headliner (4) may be fixed to the roof of the vehicle such that the second surface (7) of the support block (1) may contact the roof.
In an embodiment, the support block (1) is simple in construction and easy to manufacture. Further, the headliner (4) having the support block (1) does not require regular maintenance results in low operational and manufacturing costs.
It should be imperative that the support block, the headliner assembly and any other elements or features described in the above detailed description should not be considered as a limitation with respect to the figures. Rather, variation to such device and system should be considered within the scope of the detailed description.
Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such

phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope.

Referral Numerals:

Reference Number Description
100 Headliner assembly
1 Support block
2 Provision
2a Channel
2b Chamber
3 Adhesive material
4 Headliner
5 Adhesive layer
6 First surface
7 Second surface

We Claim:
1. A support block (1) for a headliner assembly (100) of a vehicle, the support block (1)
comprising:
a first surface (6) defined on one side of the support block (1), wherein the first surface (6) is configured to be adhesively bonded to a headliner (4);
a plurality of provisions (2) defined on the first surface (6) of the support block (1), wherein the first surface (6) and the plurality of provisions (2) are configured to receive adhesive material (3) to form a single adhesive layer (5) to adhere to the headliner (4) of the vehicle; and
a second surface (7) defined opposite to the first surface (6), adapted to engage with a roof of the vehicle.
2. The support block (1) as claimed in claim 1, wherein the plurality of provisions (2) are defined with a channel (2a) extending into the support block (1), to channelize the adhesive material (3) from the first surface (6).
3. The support block (1) as claimed in claim 2, wherein the plurality of provisions (2) are defined with a chamber (2b) extending from an end of the channel (2a) away from the first surface (6), to receive the adhesive material (3).
4. The support block (1) as claimed in claim 1, wherein the first surface (6) of the support block (1) is shaped to define a profile corresponding to the profile of a portion of the headliner (4).
5. The support block (1) as claimed in claim 1, wherein the single adhesive layer (5) received on the first surface (6) of the support block is defined with a profile extending from one end of the first surface (6) to another end of the first surface (6) through the plurality of provisions (2).

6. The support block (1) as claimed in claim 1, wherein the single adhesive layer (5) formed through the channel (2a) and the chamber (2b) of the plurality of provisions (2) provides interlocking of the adhesive material (3) with the support block (1).
7. A headliner assembly (100) for a roof of a vehicle, comprising;
a headliner (4);
a plurality of locking members defined on the headliner (4) and configured to lock the headliner (4) with the roof; and
at least one support block (1) fixed to the headliner (4) and adapted to engage with the roof, the at least one support block (1) comprising:
a first surface (6) defined on one side of the support block (1),wherein the first surface (6) is configured to be adhesively bonded to the headliner (4);
a plurality of provisions (2) defined on the first surface (6) of the support block (1), wherein the first surface (6) and the plurality of provisions (2) are configured to receive adhesive material (3) to form a single adhesive layer (5) to adhere to the headliner (4) of the vehicle; and
a second surface (7) defined opposite to the first surface (6), adapted to engage with the roof of the vehicle.
8. The headliner assembly (100) as claimed in claim 7, wherein the plurality of provisions (2) are defined with a channel (2a) extending into the support block (1), to channelize the adhesive material (3) from the first surface (6).
9. The headliner assembly (100) as claimed in claim 8, wherein the plurality of provisions (2) are defined with a chamber (2b) extending from an end of the channel (2a) away from the first surface (6), to receive the adhesive material (3).