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Lear Donnelly Shows Modular/Recyclable Overhead System With ZClip(TM) Fasteners at 1998 SAE Exposition

12 February 1998

Lear Donnelly Shows Modular/Recyclable Overhead System With ZClip(TM) Fasteners at 1998 SAE Exposition

    NOVI, Mich., Feb. 12 -- A totally integrated, one-piece
headliner module promises to slash installation time by up to 50 percent for
vehicle manufacturers.
    The EcoLiner(TM) modular headliner by Lear Donnelly Overhead Systems,
L.L.C. is one of the industry's first 100 percent recyclable headliners which
permits installation from outside the vehicle, thanks to its patented
ZClip(TM) fastening system.
    "We are now able to ship just-in-time and in sequence a fully tested
headliner system that snaps into place without a worker ever getting inside
the vehicle," said Richard Perreault, president, Lear Donnelly Overhead
Systems.
    The ZClip(TM) is a one-piece, bendable plastic, screwless attachment that
closes by folding in on itself without breaking.  This "living hinge door"
snaps into sheet metal and locks into place.
    Assembling conventional headliners requires workers to fasten the
headliner with screws and install components from inside the vehicle, which
creates an assortment of ergonomic problems that can lead to improper
installation and damaged components.
    The Lear Donnelly overhead module, with components such as grab handles,
consoles, speakers, visors and coat hooks in place, can be installed by
workers fastening the ZClips(TM) through the door openings from outside the
vehicle, greatly improving assembly ergonomics.
    "We anticipate this modular approach will reduce assembly tooling, labor
and part numbers while increasing quality, especially in the area of fit and
finish," Perreault said.
    The EcoLiner(TM) is made of a new recyclable material consisting of
100 percent polyester terethalate (PET), which contains 50 percent recycled
content.  The benefit is that scrap or end-of-life headliners can be recycled
into more headliners.
    The EcoLiner(TM) has improved characteristics enabling it to be stiff for
shipping as well as accommodating modular integration of components, yet
flexible enough to avoid creasing during installation.  Its construction
consists of non-woven polyester fabric with lofty fibers for excellent
acoustics.
    Lear Donnelly Overhead Systems, L.L.C. is a 50-50 joint venture between
Southfield, Mich.-based Lear Corporation and Holland, Mich.-based Donnelly
Corporation.  A supplier to nearly every automaker worldwide, Lear Donnelly
designs, develops, markets and manufactures overhead systems, headliners,
overhead consoles and lighting components, vehicle electrification interfaces,
electronic components and assist handles.  The company currently has locations
in four countries:  the United States, United Kingdom, Ireland and the Czech
Republic.
    A Fortune 500 company, Lear Corporation is one of the world's
largest automotive interior suppliers, with 1997 sales of over $7.3 billion.
The company's world-class products are designed, engineered and manufactured
by more than 50,000 employees in over 170 facilities located in 25 countries.
Information about Lear and its products is available on the Internet at
http://www.lear.com.
    Donnelly Corporation is an international automotive supplier,
dedicated to serving customers around the globe with industry-leading
components and systems in automotive mirrors, windows, and interior lighting
and trim.  The company has been based in Holland, Michigan since 1905, and
today has approximately 5,000 employees operating in 11 countries worldwide.

SOURCE  Lear Donnelly Overhead Systems, L.L.C.