The advantages of ventilating the passenger space via a headliner are known and proven. This paper presents a practical solution for an air-condition-headliner for the VW T 4 minibus in two versions: an injection molded channel-version with additional heat insulation and a chamber-version, made using the headliner-PU sandwich material.
In both cases the air channeling components are glued on the reverse side of the actual headliner; the reverse side of the headliner therefore acts as an air channelling component.
The design principles, the air channelling concepts and the assembly of the two versions are discussed. The entire modular headliner is fastened to the body using clips.
Since the headliner sandwich material must be adapted to provide the additional special properties of an air channelling component, the structure and production of the panel material is described for a continuous PU foam process.