Component for vehicle interior

Abstract

A component for a vehicle interior comprising a composite structure is disclosed. The composite structure may comprise a cover and an intermediate layer and a base; the intermediate layer provides a compressible layer between the cover and the base; the intermediate layer and the base and / or the cover may comprise a mono-material; the intermediate layer may comprise a structure / pad formed by molding / injection molding and configured to provide comfort to an occupant of the vehicle interior (e.g. to simulate performance of conventional foam material); the mono-material may be configured to facilitate recyclability of the composite structure; the mono-material may comprise a polymer material such as in polyolefin group or a thermoplastic elastomeric group or an elastomeric group or a polymer family compatible as the mono-material to facilitate recycling of the composite structure. A method of manufacturing the composite structure is also disclosed; the method may provide for improved efficiency.

Description

PATENT APPLICATIONCOMPONENT FOR VEHICLE INTERIORCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and incorporates by reference in full U.S. Provisional Patent Application No. 63 / 642,202 titled “COMPONENT FOR VEHICLE INTERIOR” filed May 3, 2024.FIELD

[0002] The present invention relates to a component for a vehicle interior comprising a composite structure comprising a cover and an intermediate layer and a base.BACKGROUND

[0003] It is known to provide a component for a vehicle interior such as a door panel comprising an armrest.

[0004] It would be advantageous to provide an improved component for a vehicle interior comprising a composite structure configured to provide improved recyclability with suitable performance with the component.

[0005] It would be advantageous to provide a method of producing an improved component for a vehicle interior comprising a composite structure configured to provide improved recyclability with improved manufacturing efficiency.

[0006] It would be advantageous to provide an improved component for a vehicle interior comprising a composite structure configured to provide suitable performance using a thermoplastic material and / or a mono-material.

[0007] It would be advantageous to provide an improved component for a vehicle interior comprising a composite structure configured to provide improved recyclability using a thermoplastic material and / or mono-material.SUMMARY

[0008] The present invention relates to a component for a vehicle interior comprising a composite structure comprising a cover and an intermediate layer and a base; the intermediate layer may be configured to provide a compressible layer between the cover and the base; the intermediate layer and the base may comprise a mono-material; the intermediate layer and the cover and the base may comprise a mono-material; the intermediate layer may comprise a pad configured to provide comfort to an occupant of the vehicle interior; the mono-material may be configured to facilitate recyclability of the composite structure; the mono-material may comprise a polymer material configured for recyclability; the polymer material configured for recyclability as a sub- assembly may be selected from a group of polymer materials; the group of polymer materials may comprise a polyolefin group and / or a thermoplastic elastomeric group and / or an elastomeric group and / or a thermoplastic elastomer (TPE, TPV) and / or a thermoplastic urethane (TPU) and / or a rubber / synthetic rubber (ethylene propylene diene monomer / EPDM blend) and / or soft polyvinyl chloride and / or a polymer family compatible as the mono-material to facilitate recycling of the composite structure; the group of polymer materials may comprise the mono-material for recyclability of the composite structure as a complete sub-assembly; the mono-material may comprise a single material group; the intermediate layer may be configured to provide a surface effect at the cover; the surface effect at the cover may comprise at least one of softness and / or deep softness and / or compressibility and / or deformability and / or elastic deformability and / or concealment of the intermediate layer; the pad may comprise a structure that may comprise a set of projections; the projections may comprise walls; the walls may comprise lines; the set of projections may comprise a set of parallel lines and / or a set of wavy lines; the set of projections may comprise a set of parallel lines and / or a set of wavy lines and / or a set of angled lines and / or a set of perpendicular lines and / or a set of curved lines and / or a set of generally circle-shaped lines and / or a honeycomb shape and / or a set of cells and / or a set of open cells and / or a set of flexible walls and / or a set of ribs; the intermediate layer may comprise a compressible structure that may comprise a default form; the compressible structure may be configured to deform under force and to return to the default form when not under force; the compressible structure may comprise a set of projections that may comprise a default form; the set of projections may be configured to bend when force is applied and to return to the default form when not under force; the set of projections may be configured to bend under pressure and return to the default form when pressure is released; the set of projections may be aligned at approximately 45 degrees relative to the cover; the setof projections may comprise joints; the set of projections may comprise joints connecting projections; the set of projections may comprise walls and connection points between walls; the connection points between walls may comprise joints; the joints may comprise flexible joints; the projections may comprise walls; the walls may comprise curved walls; each joint may comprise a connection of at least two walls; the pad may be injection-molded and demoldable; the set of projections may comprise angled walls configured to be in alignment with a direction of demolding; the pad may comprise a thickness greater than 10 mm; the intermediate layer may comprise a molded layer; the intermediate layer may comprise an injection- molded layer; the intermediate layer may comprise an injection-molded flexible layer; the intermediate layer may comprise an injection-molded compressible layer configured to simulate performance of a foam layer; the intermediate layer may comprise an injection-molded compressible layer; the intermediate layer may comprise an injection- molded compressible layer that may comprise a base layer and a set of projections; the intermediate layer may comprise a compressible pad that may comprise a base layer and a set of flexible projections; the intermediate layer may comprise a set of projections configured to bend to provide compressibility; the intermediate layer may comprise a set of projections configured to buckle to provide compressibility; the intermediate layer may comprise a flexible structure; the intermediate layer may comprise a flexible structure that may comprise a compressible pad; the intermediate layer may comprise a flexible structure that may comprise a base layer and a set of projections from the base layer; the intermediate layer may be configured to perform like a foam layer; the intermediate layer may comprise a compressible structure configured to operate like a foam layer; the intermediate layer may comprise an injection-molded layer configured to perform like a pad; the intermediate layer may comprise a pad; the intermediate layer may comprise an injection-molded pad; the pad may be configured to provide a cushion; the intermediate layer may comprise an injection- molded cushion layer; the intermediate layer may comprise a structure configured to simulate a foam pad; the intermediate layer may comprise a base layer and a set of structures configured to simulate a foam pad; the intermediate layer may comprise a projection arrangement; the intermediate layer may comprise a cell structure; the intermediate layer may comprise a set of cells; the intermediate layer may comprise a network of cells; the intermediate layer may comprise a network of projections; each projection of the network of projections may comprise a cell structure; the intermediate layer may comprise a set of walls; the intermediate layer may comprise a set of walls that may comprise a set of cells; the intermediate layer may comprise a set of walls in a pattern; the intermediate layer maycomprise a set of walls that may comprise a pattern of projections; the intermediate layer may comprise a compressible layer that may comprise a set of walls; the intermediate layer may comprise a set of walls that may comprise a linear alignment; the intermediate layer may comprise cell walls in linear alignment; the intermediate layer may comprise walls in linear alignment; the intermediate layer may comprise walls in linear alignment to facilitate removal of the intermediate layer from a mold tool; the intermediate layer may comprise a base layer and a set of projections; the intermediate layer may comprise a base layer and a set of projections in linear alignment; the set of projections may comprise a set of walls; the set of projections may comprise a set of walls that may comprise walls at a first length and walls at a second length; the intermediate layer may comprise a first region and a second region; the first region may comprise a first set of walls in a first pattern; the second region may comprise a second set of walls in a second pattern; the first pattern may be different from the second pattern; the intermediate layer may comprise a layer configured to provide performance of a foam material; the intermediate layer may comprise a layer configured to provide performance of a polyurethane foam material; the intermediate layer may comprise a structure configured to provide cushion effect; the intermediate layer may comprise a structure of cells configured to provide compressibility; the intermediate layer may comprise a structure configured to provide structural integrity and compressibility; the structure may comprise a structure of cells; the structure may comprise a structure of walls; the structure may comprise a pattern of cells; the structure may comprise a pattern of cells having walls; the structure may comprise an irregular pattern; the structure may comprise a regular pattern; the structure may comprise a uniform pattern; the structure may comprise a set of curved walls; the structure may comprise a set of projections that may comprise a pattern of curved walls; the pattern of curved walls may comprise a pattern of cells; the cells may comprise open cells; the intermediate layer may comprise tube-shaped structures; the intermediate layer may comprise a pattern of tube-shaped structures; the intermediate layer may comprise a pattern of open cells; the intermediate layer may comprise a base layer and a set of projections that may comprise a pattern of open cells; the intermediate layer may comprise a molded layer that may comprise a set of projections that may comprise a pattern of open cells; the intermediate layer may comprise a molded layer that may comprise a set of projections that may comprise a first pattern of open cells and a second pattern of open cells; the intermediate layer may comprise a molded layer that may comprise a thermoplastic material; the molded layer may comprise an injection-molded layer that may comprise a set of projections; the set of projections may comprise a compressible structure; the set ofprojections may comprise a set of flexible cells providing a compressible structure; the compressible structure may be configured to simulate a foam pad; the compressible structure may comprise a thermoplastic elastomer material; the compressible structure may comprise an injection-molded thermoplastic material; the compressible structure may comprise a set of aligned projections that may comprise an elastomeric material; the intermediate layer may comprise a set of aligned projections that may comprise a set of flexible cells providing a compressible structure; the set of flexible cells may comprise a set of flexible walls; the set of flexible walls may comprise walls having a first length and walls having a second length; the set of flexible walls may comprise a set of aligned walls projecting from a base layer; the base layer of the intermediate layer may comprise the cover; the base layer may comprise an outer surface and an inner surface providing a set of projections; the outer surface may comprise an exterior surface; the composite structure may comprise an injection-molded structure; the cover and the intermediate layer may be integrally formed; the composite structure may be integrally formed; the composite structure may comprise an injection- molded structure; the intermediate layer of the composite structure may comprise an injection- molded structure between the cover and the base; the intermediate layer may be compressible between the cover and the base; the base may comprise a substrate; the base may comprise a carrier; the intermediate layer may comprise a thermoplastic material; the intermediate layer may comprise a thermoplastic polymer material; the intermediate layer may comprise a thermoplastic resin material; the intermediate layer may comprise a thermoplastic elastomer material; the intermediate layer may comprise a thermoplastic polymer material configured to facilitate recyclability; the intermediate layer may comprise a thermoplastic material configured to simulate performance of foam material; the intermediate layer may comprise a thermoplastic material formed by injection molding; the cover and the base and the intermediate layer may comprise a thermoplastic material; the intermediate layer may comprise a thermoplastic elastomer material; the composite structure comprising the cover and base and intermediate layer may comprise a thermoplastic material; the composite structure may comprise a plastic -based mono-material structure; the mono-material structure may be formed from a thermoplastic material; the mono-material structure may be formed from a polymer-based mono-material; the mono-material may comprise a thermoplastic material; the mono-material may comprise a thermoplastic resin material; the composite structure may comprise a thermoplastic cover and the base and the intermediate layer may comprise a thermoplastic material; the cover and the base and the intermediate layer may comprise a thermoplastic material; the intermediate layer may comprise a material that maycomprise the same material family as the cover; the intermediate layer may comprise a material from the same material family as the cover and the base; the intermediate layer may comprise an injection-molded structure configured to function as a replacement for a foam structure; the intermediate layer may comprise an injection-molded structure that may comprise a thermoplastic material configured to function as a replacement for a foam material; the intermediate layer may comprise a pad that may comprise a moldable polyolefin soft structure; the intermediate layer may comprise a rib structure; the intermediate layer may comprise a structure that may comprise projections at an angle of approximately 10 to 45 degrees to the normal direction for compression of the composite structure; the composite structure with the compressible intermediate layer may be configured to provide a soft feeling at the cover; the composite structure may be configured to provide compressibility when under a force in a load direction at the cover; the composite structure may be configured to bend with a soft feeling continuously at the cover; the intermediate layer may comprise a structure that may be configured to be substantially visually imperceptible at the cover; the intermediate layer may comprise a structure concealed at an external surface of the cover; the intermediate layer may comprise a molded structure that may be configured to be demoldable from a mold tool; the intermediate layer may comprise a molded structure that may be configured to conceal and / or reduce visibility of tool / sink marks from molding; the composite structure may be configured to conceal the intermediate layer under the cover; the intermediate layer may comprise a structure providing a bendable structure to provide compressibility at the cover; the intermediate layer may comprise a compressible structure having a thickness in a range of approximately 10 to 15 mm and / or approximately 3 to 25 mm; the intermediate layer may comprise a layer that may comprise projections having walls with a size in a range of approximately 10 to 15 mm and / or approximately 3 to 25 mm; the intermediate layer may comprise a set of projections that may comprise walls in a thickness of approximately 0.8 to 2.5 mm; the intermediate layer may comprise a structure providing a deep soft comfort pad; the intermediate layer may comprise a structure that may be easily moldable and demoldable; the intermediate layer may comprise a structure configured to simulate a foam material in softness and appearance; the intermediate layer may comprise a structure configured to simulate a foam material in weight; the intermediate layer may comprise a structure configured to simulate a foam material in look and feel under the cover; the intermediate layer may comprise a material having a Shore A value in a range of approximately 50 to 70; the composite structure may be configured to facilitate formation by molding; formation by molding may comprise injection molding; formation by molding maycomprise injection molding in a mold tool; formation by molding may comprise molding from a resin material; the resin material may comprise a thermoplastic material; the resin material may comprise a thermoplastic elastomer; formation by molding may comprise demolding; demolding may comprise removal by a suction device; demolding may comprise removal by a vacuum suction device; the composite structure may comprise a sandwich structure; the sandwich structure may comprise a compressible structure; the cover may be formed from a first material; the intermediate layer may be formed from a second material; the composite structure may comprise a base providing a carrier formed from a third material; the first material and the second material may be compatible for recycling; the first material and the second material may comprise a mono-material; the first material and the second material and the third material may comprise a mono-material; the mono-material may be compatible for recycling; the composite structure may be configured to provide a surface effect at the cover; the surface effect may comprise substantial concealment of the intermediate layer at the cover; the surface effect may comprise a composite effect of an effect of the intermediate layer and an effect of the cover; the effect of the intermediate layer may comprise a pattern; the intermediate layer may comprise a structure configured to provide the pattern; the structure may comprise a set of projections; the pattern provided by the set of projections may comprise an open-cell pattern; the effect of the cover may comprise a texture; the texture may be formed at an exterior surface of the cover; the intermediate layer may comprise a semi-rigid structure; the intermediate layer may comprise a structure configured to deform elastically from a default form; the structure of the intermediate layer may be configured to deform elastically from a default form under a force and to return to the default form when the force is removed; the structure of the intermediate layer may comprise a semi-rigid structure configured to deform elastically from a default form under a force; the semi-rigid structure may comprise a set of projections; the set of projections may comprise a set of semi-rigid projections configured to deform elastically from a default form under a force; the semi-rigid projections may comprise semi-rigid walls configured to deform elastically from a default form under a force; the structure of the intermediate layer may comprise a semi-rigid injection-molded structure; the structure of the intermediate layer may comprise a semi-rigid injection-molded structure configured to deform elastically under a force; the structure of the intermediate layer may comprise a semirigid injection-molded structure configured to substantially simulate the performance of a foam material; the structure of the intermediate layer may comprise a semi-rigid injection- molded structure configured to substantially simulate the performance of a polyurethanefoam material; the structure of the intermediate layer may comprise a semi-rigid injection- molded structure configured to substantially simulate the performance of a polyurethane foam material of the same form; the cover may be formed on the intermediate layer; the cover may be applied to the intermediate layer; the cover may be bonded to the intermediate layer; the cover may be attached to the intermediate layer; the cover may be provided on a base layer of the intermediate layer; the cover may comprise an exterior surface; the cover may comprise an exterior surface configured to conceal the structure of the intermediate layer; the exterior surface may comprise an effect that may comprise a texture; the cover may comprise a decorative layer; the texture may be configured to conceal the structure of the intermediate layer; the intermediate layer may comprise a set of projections configured to fit within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may comprise a set of projections configured to secure within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may comprise a set of projections configured to retain within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may be fit into a recess in the base to position the intermediate layer within the base; the intermediate layer may comprise a set of projections configured to fit within a set of recesses in the base to position the intermediate layer on the base; the intermediate layer may comprise a set of projections configured to be fit within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may comprise a set of projections fit within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may comprise a set of projections fit with a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may be retained to the cover by a set of projections configured to fit with a set of recesses; the intermediate layer may comprise the set of projections; the composite structure comprising the intermediate layer and the cover and the base may comprise a mono-material; the composite structure may comprise an armrest; the composite structure may comprise a trim panel; the composite structure may comprise a door for a console.

[0009] The present invention relates to a component for a vehicle interior configured to provide an armrest comprising a cover and a pad and a base; the pad may be configured to provide comfort to the occupant; the pad may be configured to provide a surface effect at the cover; the cover and the pad and the base may comprise a polymer material configured for recyclability or configured to reduce the carbon dioxide footprint; the polymer material configured for recyclability may be selected from a group of polymer materials that maycomprise a polyolefin group, a thermoplastic elastomeric group, an elastomeric group, etc.; the group of polymer materials may comprise a mono-material for recyclability as a complete sub-assembly; the mono-material may comprise a single material group; the surface effect may comprise at least one of softness, deep softness, compression, elastic deformation, etc.; the pad may comprise a structure; the structure may comprise a set of projections and / or a set of ribs; the set of projections may comprise a set of walls arranged as parallel lines and / or wavy lines and / or angled lines and / or perpendicular lines and / or circles and / or a honeycomb shape and / or a set of ribs; the set of projections may comprise walls provided as angled lines configured to bend under pressure and return when pressure is released; the walls may be inclined by 45 degrees to prevent breakage under pressure; the set of projections may comprise joints; the joints may be configured to connect walls of the set of projections; the walls may comprise curved ribs; each joint may comprise a connection of three walls; the pad may be injection-molded and demoldable; angled lines of the walls may be configured to run in a same direction to enable demolding; the pad may comprise a thickness greater than 10 mm.

[0010] The present invention relates to a method of producing in a forming tool a component for a vehicle interior comprising an armrest comprising the steps of providing a mold and injection molding a pad in a shape and demolding the pad; the mold may comprise a base section and an upper section; the step of demolding the pad may comprise a step of gripping the pad with a gripper; the gripper may be configured to support deforming of the pad; the gripper may comprise a cushion; the cushion may be configured to replicate the shape of the pad and pull the pad from the mold by using suction; the gripper may comprise a vacuum gripper; the gripper may comprise a suction device.

[0011] The present invention relates to a component for a vehicle interior configured to provide an armrest comprising a cover and an intermediate layer / pad and a base. The pad may be configured to provide a surface effect. The cover, the pad and the base may comprise a polymer material. The polymer material may be configured for recyclability and to reduce the carbon dioxide footprint. The polymer material may be selected from a group of polymer materials and may comprise a mono-material or a single material group. The surface effect may comprise at least one of (a) softness, (b) deep softness, (c) compression, (d) elastic deformation. The pad may comprise a structure wherein the structure may comprise a set of ribs. The set of ribs may be arranged in (a) parallel lines, (b) wavy lines, (c) angled lines, (d) perpendicular lines, (e) circles, (f) honeycomb shape. The set of ribs in angled lines may be configured to bend under pressure and return when pressure is released. The ribs may beinclined by 45 degrees to prevent breakage under pressure. The set of ribs may comprise joints, wherein the joints may be configured as a second set of ribs. The second set of ribs may comprise curved ribs. Each joint may comprise a connection of three ribs. The pad may be injection-molded and may be demoldable. The angled lines of the ribs may be configured to run in the same direction to enable a demolding. The pad may comprise a thickness greater than 10 mm.

[0012] The component may comprise at least one of (a) a door panel; (b) a floor console; (c) a seat component. The composite structure of the component may comprise a polymer material configured for recyclability as a sub-assembly selected from a group of polymer materials comprising a polyolefin group and / or a thermoplastic elastomeric group and / or an elastomeric group and / or a thermoplastic elastomer (TPE, TPV) and / or a thermoplastic urethane (TPU) and / or a rubber / synthetic rubber (ethylene propylene diene monomer / EPDM blend) and / or soft polyvinyl chloride and / or a polymer family compatible as the monomaterial to facilitate recycling of the composite structure. The composite structure may comprise an intermediate layer comprising a molded structure that is configured to conceal (reduce / minimize) sink marks from molding and / or to conceal and / or reduce visibility of tool / sink marks from molding. The intermediate layer may comprise a compressible structure having a thickness in a range of approximately 10 to 15 mm or approximately 3 to 25 mm (e.g. for instrument panel 3-10 mm, for door panel armrest 10-20 mm, for floor console armrest 15-25mm). The intermediate layer may comprise a set of projections comprising walls in a thickness of approximately 0.8 mm to 2.5 mm.FIGURES

[0013] FIGURE 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0014] FIGURE IB is a schematic perspective cut-away view of a vehicle showing a vehicle interior according to an exemplary embodiment.

[0015] FIGURE 1C is a schematic perspective view of a vehicle interior according to an exemplary embodiment.

[0016] FIGURES 2A and 2B are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0017] FIGURES 3A and 3B are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0018] FIGURES 4A and 4B are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0019] FIGURE 5 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0020] FIGURE 6 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0021] FIGURES 7 A and 7B are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0022] FIGURE 8A is a schematic perspective view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0023] FIGURE 8B is a schematic detail view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0024] FIGURE 9A is a schematic perspective view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0025] FIGURE 9B is a schematic detail view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0026] FIGURE 10 A is a schematic perspective view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0027] FIGURE 10B is a schematic detail view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0028] FIGURES 11 A and 1 IB are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0029] FIGURE 12A is a schematic perspective view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0030] FIGURE 12B is a schematic detail view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0031] FIGURE 13 A is a schematic perspective view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0032] FIGURE 13B is a schematic detail view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0033] FIGURE 14A is a schematic perspective view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0034] FIGURE 14B is a schematic detail view of a component for a vehicle interior showing an intermediate layer according to an exemplary embodiment.

[0035] FIGURES 15A through 15D are schematic section views of a composite structure of component for a vehicle interior according to an exemplary embodiment.

[0036] FIGURES 16A through 16C are schematic section views of a composite structure of component for a vehicle interior according to an exemplary embodiment.

[0037] FIGURES 17A through 17C are schematic section views of a composite structure of component for a vehicle interior according to an exemplary embodiment.

[0038] FIGURE 18 A is a schematic section view of a composite structure of a component for a vehicle interior according to an exemplary embodiment.

[0039] FIGURE 18B is a schematic plan view of a component for a vehicle interior according to an exemplary embodiment.

[0040] FIGURE 19 is a schematic section view of a composite structure of a component for a vehicle interior according to an exemplary embodiment.

[0041] FIGURE 20 is a schematic section view of a composite structure of a component for a vehicle interior according to an exemplary embodiment.

[0042] FIGURE 21 is a schematic section view of a composite structure of a component for a vehicle interior according to an exemplary embodiment.

[0043] FIGURE 22 is a schematic section view of a composite structure of a component for a vehicle interior according to an exemplary embodiment.

[0044] FIGURE 23 is a schematic section view of a composite structure of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0045] FIGURE 24 is a schematic section view of a composite structure of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0046] FIGURE 25 is a schematic section view of a composite structure of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0047] FIGURE 26 is a schematic section view of a composite structure of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0048] FIGURE 27 is a schematic section view of a composite structure of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0049] FIGURES 28A through 28C are schematic detail views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0050] FIGURES 29A through 29C are schematic detail views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0051] FIGURES 30A through 30C are schematic detail views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0052] FIGURES 31A through 31C are schematic detail views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0053] FIGURE 32 is schematic detail view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0054] FIGURES 32A through 32F are schematic detail views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0055] FIGURE 33A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0056] FIGURE 33B is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0057] FIGURE 33C is a schematic exploded view of a component for a vehicle interior according to an exemplary embodiment.

[0058] FIGURE 34A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0059] FIGURE 34B is a schematic exploded view of a component for a vehicle interior according to an exemplary embodiment.

[0060] FIGURES 35 A through 35E are schematic perspective views of a composite structure of a component for a vehicle interior according to an exemplary embodiment.

[0061] FIGURE 36A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0062] FIGURE 36B is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0063] FIGURE 36C is a schematic exploded view of a component for a vehicle interior according to an exemplary embodiment.

[0064] FIGURE 36D is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0065] FIGURE 37 A is a schematic perspective view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0066] FIGURE 37B is a schematic section view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0067] FIGURES 37C and 37D are schematic detailed views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0068] FIGURE 38 A is a schematic perspective view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0069] FIGURE 38B is a schematic section view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0070] FIGURES 38C and 38D are schematic detailed views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0071] FIGURE 39A is a schematic perspective view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0072] FIGURE 39B is a schematic section view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0073] FIGURES 39C and 39D are schematic detailed views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0074] FIGURES 40A through 40E are schematic section views of a method to produce a component for a vehicle interior according to an exemplary embodiment.

[0075] FIGURE 41 A is a schematic perspective view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0076] FIGURE 41B is a schematic section view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0077] FIGURES 42A through 42H are schematic section views of a method to produce a component for a vehicle interior according to an exemplary embodiment.

[0078] FIGURES 43A through 43E are schematic section views of a method to produce a component for a vehicle interior according to an exemplary embodiment.

[0079] FIGURE 44A is a schematic perspective view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0080] FIGURE 44B is a schematic section view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0081] FIGURES 45A and 45B are schematic plan views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0082] FIGURES 45C and 45D are schematic section views of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0083] FIGURE 45E is a schematic plan view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0084] FIGURE 45F is a schematic perspective view of an intermediate layer of a component for a vehicle interior according to an exemplary embodiment.

[0085] FIGURE 46A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0086] FIGURE 46B is a schematic exploded view of a component for a vehicle interior according to an exemplary embodiment.

[0087] FIGURE 46C is a schematic exploded view of a component for a vehicle interior according to an exemplary embodiment.

[0088] FIGURES 47 A through 47C are schematic section views of a method to assemble a component for a vehicle interior according to an exemplary embodiment.

[0089] FIGURE 48A is a schematic flow diagram of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0090] FIGURES 48B and 48C are schematic flow diagrams of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0091] FIGURE 49A is a schematic flow diagram of a method for recycling a component for a vehicle interior according to an exemplary embodiment.

[0092] FIGURE 49B is a schematic flow diagram of a method for recycling a component for a vehicle interior according to an exemplary embodiment.

[0093] FIGURES 50A and 50B are schematic section views of a component for a vehicle interior showing an armrest according to an exemplary embodiment.

[0094] FIGURE 50C is a schematic section views of a component for a vehicle interior showing an armrest pad according to an exemplary embodiment.

[0095] FIGURES 51A and 5 IB are schematic section views of a component for a vehicle interior showing an armrest according to an exemplary embodiment.DESCRIPTION

[0096] Referring to FIGURES 1A-1C, a vehicle V is shown with an interior VI comprising components such as an instrument panel IP, console shown as floor console FC, door panel DP, etc. According to an exemplary embodiment as shown schematically in FIGURES 1C, 2A-2B, 3A-3B, 4A-4B, 5 and 6, the component C may comprise a composite structure CS such as an armrest AR for door panel DP and door for floor console FC; the composite structure CS may comprise a cover T with an exterior surface TX configured to present a visual effect (e.g. texture, decorative effect, etc.) and a base / substrate shown as carrier B / SB and an intermediate layer shown as structure NL. See also FIGURES 33A-33C, 34A-34B, 35A-35E and 36A-36D.

[0097] As indicated schematically in FIGURES 7A-7B, 8A-8B, 9A-9B, 10A-10B, 11A-11B, 12A-12B, 13A-13B and 14A-14B, the intermediate layer / structure NL may comprise a semi-rigid compressible / flexible layer FMX configured to simulate the comfort / feel (e.g. softness, etc.) of a conventional foam material. See also FIGURES 50A-50C (composite structure with compressible intermediate layer FMX) and 51A-51B (showing composite structure with foam material FM).

[0098] According to an exemplary embodiment as shown in FIGURES 7A-7B, 8A-8B, 9A- 9B, 10A-10B, 11A-11B, 12A-12B, 13A-13B, 14A-14B and 45 A-45F, the composite structure CS with the intermediate layer comprising the structure NL / FMX may comprise projections PR such as flexible walls WL connecting at intersections shown as joint / junction WJ in various shapes / forms (e.g. cells, wall structures, cell structures, etc.) from a base layer BL to provide a flexible / compressible semi-rigid structure configured to perform as a compressible material / structure to provide elastic deformation under a force for the composite structure of the component (e.g. deformation from default form under load and restoration / return to default form after load is removed). See also FIGURES 3A-3B, 4A-4B, 15A-15D, 16A-16C, 17A-17C, 35D-35E and 5OA-5OC.

[0099] As indicated schematically in FIGURES 18A-18B, 19, 20, 21, 22, 23, 24, 25, 26, 27, 35A-35E, 37A-37D, 38A-38D, 39A-39D and 45A-45F, the structure NL / FMX may comprise form / forms of a wide variety of configurations (e.g. shape, size, contour, etc.) with flexible semi-rigid projections PR providing flexible semi-rigid walls WL of a wide variety of configurations (e.g. size, width, thickness, length, shape, form, curvature, linearity / non- linearity, intersection, uniformity / disuniformity, etc.) to provide a pattern PT of a wide variety of configurations (e.g. shape, form, uniformity / non-uniformity, cells, wall structures, cell structures, etc.) to provide a wide variety of flexible semi-rigid structure configurations to perform / function as a compressible material / structure for the composite structure CS of the component C. See also FIGURES 28A-28C, 29A-29C, 30A-30C, 31A-31C, 32 and 32A- 32F.

[0100] According to an exemplary embodiment as shown schematically in FIGURES 28A- 28C, 29A-29C, 30A-30C, 31A-31C, 32 and 32A-32F, the configuration of cells / walls of structure NL / FMX may comprise variations of patterns PT of cells / walls such as linear / diagonal pattern PTa, curved / connected pattern PTb, linear / open pattern PTc, curved / diagonal pattern PTd, curved-cell / linear pattern PTe, linear / joined pattern PTf and other patterns (e.g. irregular, regular, wavy-line, honeycomb, etc.). See also FIGURES 18A- 18B, 19, 20, 21, 22, 23, 24, 25, 26, 27, 37A-37D, 38A-38D, 39A-39D and 45A-45F. As indicated schematically, the forms / patterns, etc. of the elements / features and structure of theintermediate layer NL / FMX of the composite structure CS may be modified to provide variations of performance for use in the component C.

[0101] According to an exemplary embodiment FIGURES 40A-40E, 41A-41B, 42A- 42H,43A-43E, 44A-44B, 45A-45F and 48A-48C, the structure NL configured to provide intermediate layer for composite structure of component may be produced in a process comprising the step of forming in a mold tool M comprising a mold top MT and mold bottom MB (with cavity) and injection-molding resin R then removing the structure NL from the mold bottom MB with a tool shown as vacuum / suction tool MX (e.g. soft / flexible grip, solid / rigid grip, etc.); as indicated schematically, projections PR of the structure NL are formed at a transverse orientation from a base layer BL to facilitate injection-molding formation in the mold tool (FIGURES 40C-40E and 42A-42H) and to facilitate vacuum / suction removal from the mold tool (FIGURES 43A-43E and 44A-44B). See also FIGURES 18A-18B, 19, 20, 21, 22, 23, 37B, 38B, and 39B.

[0102] According to an exemplary embodiment as shown schematically in FIGURES 7A-7B, 8A-8B, 11A-11B, 15A-15D, 16A-16C, 17A-17C, 35D-35E and 50A-50C, the flexible semirigid projections / walls PR / WL of the flexible semi-rigid compressible structure NL / FMX are configured to bend (e.g. fold, bucket, twist, etc.) to facilitate elastic deformation at the surface of the composite structure CS. According to an exemplary embodiment as indicated FIGURES 5OA-5OC and 51A-51B, the component with composite structure with cover T and base B / SB and intermediate layer shown as structure NL / FMX (see FIGURES 50A-50C) is configured to perform as a component with conventional foam such as polyurethane foam NL / FM (see FIGURES 51A-51B).

[0103] According to an exemplary embodiment as shown schematically in FIGURES, the composite structure may comprise an intermediate layer / structure comprising a semi-rigid compressible structure (e.g. soft, deep soft, pad, cushion, etc.) of a recyclable / sustainable (e.g. environmentally-friendly, etc.) construction that is suitable for manufacture / production for a vehicle interior component; the composite structure may comprise an intermediate layer / structure that is configured to provide similar feel / fit / form (e.g. comfort, mass / weight values, softness, etc.) to conventional foam materials for vehicle interior components; the intermediate layer / structure of the composite structure may comprise an injection-molded structure / pad that provides for efficient manufacturing (e.g. reduced process time, equipment / operation, post-processing requirements, cost advantages, etc.) and suitable performance in the component with a similar material / mono-material construction facilitating recycling at end-of-life of the component. Compare FIGURES 49A (exemplary embodimentof recycling process for mono-material component with intermediate layer / construction) and 49B (exemplary embodiment of recycling process for conventional component with foam material). See also FIGURES 40A-40E, 42A-42H, 43A-43E and 48A-48C.

[0113] According to an exemplary embodiment as indicated schematically in FIGURES 3A- 3B, 4A-4B, 5, 6, 48A-48C and 49A, the component with composite structure may comprise a mono-material of the intermediate layer and base and / or cover to facilitate recyclability of the composite structure; the mono-material may comprise a polymer material configured for recyclability; the polymer material may be selected from a group of polymer materials such as a polyolefin group or a thermoplastic elastomeric group or an elastomeric group or a polymer family compatible as the mono-material to facilitate recycling of the composite structure; a mono-material for recyclability of the composite structure may permit recycling as a complete sub-assembly; the mono-material may comprise a single material group. The cover and / or the base with the intermediate layer NL may comprise a thermoplastic material; the intermediate layer NL may comprise a thermoplastic elastomer material; the base and / or the cover may be disassembled from the intermediate layer / structure for recycling of the composite structure; the intermediate layer NL and cover and / or base may comprise the same material family.Exemplary Embodiments - A

[0104] According to an exemplary embodiment as indicated schematically in FIGURES 1C, 2A-2B, 3A-3B, 4A-4B, 5, 6, 7A-7B, 8A-8B, 9A-9B, 10A-10B, 11A-1 IB, 12A-12B, 13A- 13B, 14A-14B and 18A-18B, a component C for a vehicle interior VI may comprise a composite structure CS comprising a cover T and an intermediate layer NL and a base B / SB; the intermediate layer NL may be configured to provide a compressible layer shown as a pad FMX between the cover T and the base B / SB of the composite structure CS; the pad FMX may be configured to provide comfort to an occupant of the vehicle interior.

[0105] According to an exemplary embodiment as shown schematically in FIGURES 1C, 2A-2B, 3A-3B, 4A-4B, 5, 6, 7A-7B, 8A-8B, 9A-9B, 10A-10B, 11A-11B, 12A-12B, 13A- 13B, 14A-14B, 15A-15D, 16A-16C, 17A-17C, 24, 25, 26, 27, 35A-35E, 36A-36D, 37A-37D, 38A-38D, 39A-39D, 45A-45F and 50A-50C, the intermediate layer NL of the composite structure CS may be configured to provide a surface effect at the exterior surface TX of the cover T; the surface effect at the cover T may comprise at least one of softness and / or deep softness and / or compressibility and / or deformability and / or elastic deformability and / or concealment of the intermediate layer NL; the compressible structure / pad NL / FMX may comprise a structure that may comprise a set of projections PR from a base layer BL; the projections PR may comprise walls WL; the projections PR may comprise a set of open cells and / or a set of flexible walls WL provided in a pattern PT. See also FIGURES 18A-18B, 19, 20, 21, 22, 23, 32 and 32A-32F.

[0106] As indicated schematically in FIGURES 1C, 2A-2B, 3A-3B, 4A-4B and 36A-36D, the intermediate layer NL may comprise a structure that may be configured to be substantially visually imperceptible at the exterior surface TX of cover T ; the intermediate layer may comprise a structure NL / FMX concealed at the exterior surface TX of the cover T. As indicated schematically in FIGURES 3A-3B, 4A-4B, 5, 6, 15A-15D, 16A-16C, 17A-17C, 35A-35D and 50A-50C, the composite structure CS with the compressible intermediate layer NL may be configured to provide a soft feeling of compressibility when under a force in a load direction at the cover; the composite structure CS may be configured to bend and / or buckle with a soft feeling continuously at the cover; the structure NL / FMX of the intermediate layer may comprise a semi-rigid / non-rigid compressible structure with semi- rigid / non-rigid projections / walls. See FIGURES 3A-3B, 4A-4B, 7A-7B, 11A-11B, 15A- 15D, 16A-16C, 17A-17C, 18A-18B, 35A-35E and 50A-50C.

[0107] As indicated schematically in FIGURES 40A-40E, 41A-41B, 42A-42E, 43A-43B and 48A-48C, the intermediate layer NL may comprise a molded structure that may be configuredto be demoldable from a mold tool; the intermediate layer NL may comprise a molded structure that may be configured to conceal sink marks from molding; the intermediate layer NL may comprise a structure providing a bendable structure to provide compressibility at the cover. See FIGURES 3A-3B, 4A-4B, 7A-7B, 11A-11B, 15A-15D, 16A-16C, 17A-17C, 18A-18B, 35A-35E and 5OA-5OC. As indicated schematically in FIGURES 40A-40E and 42A-42E, the structure / pad of the intermediate layer may be injection-molded and demoldable; the set of projections PR may comprise angled walls configured to be in alignment with a direction of demolding. See also FIGURES 48A-48C.

[0108] As indicated schematically in FIGURES 2A-2B, 3A-3B, 4A-4B, 7A-7B, 11A-11B, 15A-15D, 16A-16C, 17A-17C, 18A-18B, 35A-35E and 50A-50C, the component C with composite structure CS comprising intermediate layer may comprise a compressible structure NL that may comprise a default form; the compressible structure NL / FMX may be configured to deform under force and to return to the default form when not under force; the compressible structure NL / FMX may comprise a set of projections that may comprise a default form; the set of projections PR may be configured to bend when force is applied and to return to the default form when not under force; the set of projections PR may be configured to bend under pressure and return to the default form when pressure is released; the set of projections PR may comprise junctions / joints WJ at walls and connection points between walls; connection points between walls may comprise flexible joints providing a flexible structure. See also FIGURES 18A-18B, 19, 20, 21, 22, 23, 24, 25, 26, 27, 32, 32A- 32F, 37A-37D, 38A-38D, 39A-39D and 45A-45F.

[0109] As indicated in FIGURES 40A-40E, 41A-41B, 42A-42H, 43A-43E and 44A-44B, the intermediate layer NL may comprise a molded layer; the intermediate layer NL may comprise an injection-molded layer; the intermediate layer NL may comprise an injection- molded flexible layer FMX; the intermediate layer NL / FMX may comprise an injection- molded compressible layer configured to simulate performance of a foam layer; the intermediate layer NL may comprise an injection-molded compressible layer. Compare FIGURES 5OA-5OC (intermediate layer NL / FMX) and FIGURES 51A-51B (foam material FM). As indicated schematically in the FIGURES, the intermediate layer may comprise an injection-molded compressible layer NL / FMX that may comprise a base layer BL and a set of flexible projections PR configured to bend to provide compressibility; the intermediate layer NL may comprise a flexible structure FMX; the intermediate layer NL may comprise a flexible structure that may comprise a compressible pad FMX; the intermediate layer NL may comprise a cell structure of projections PR provided in a pattern PT; the intermediate layerNL may comprise a set of cells; each projection PR of the network of projections may comprise a cell structure; the intermediate layer NL may comprise a set of walls; the intermediate layer NL may comprise a set of walls that may comprise a pattern PT of projections; the structure NL / FMX may comprise a set of projections that may comprise a pattern PT; the intermediate layer NL may comprise tube-shaped structures. See FIGURES 18A-18B, 19, 20, 21, 22, 23, 24, 25, 26, 27, 32, 32A-32F, 37A-37D, 38A-38D, 39A-39D and 45A-45F. As shown schematically, the intermediate layer NL may comprise a molded layer that may comprise a thermoplastic material; the molded layer may comprise an injection- molded layer that may comprise a set of projections PR / WL; the set of projections may comprise a compressible structure; the set of projections may comprise a set of flexible cells PR / WL providing a compressible structure in a pattern PT; the compressible structure NL / FMX may be configured to simulate a foam pad; the compressible structure NL / FMX may comprise a thermoplastic elastomer material; the compressible structure NL / FMX may comprise an injection-molded thermoplastic material; the compressible structure NL / FMX may comprise a set of aligned projections that may comprise an elastomeric material; the intermediate layer NL may comprise a set of aligned projections that may comprise a set of flexible cells providing a compressible structure; the set of flexible cells PR / WL may comprise a set of flexible walls; the set of flexible walls WL may comprise walls having variable length, thickness, etc.; the set of flexible walls WL may comprise a set of aligned walls projecting from a base layer BL; the base layer BL of the intermediate layer NL may comprise the cover; the base layer BL may comprise an outer surface and an inner surface providing a set of projections PR.

[0110] As indicated schematically in FIGURES 2A-2B, 3A-3B, 4A-4B, 5 and 6, the component C may comprise an exterior surface TX for the cover T ; the base B / SB may comprise a substrate; the base B / SB may comprise a carrier; the intermediate layer NL may comprise a thermoplastic material; the intermediate layer NL may comprise a thermoplastic polymer material; the intermediate layer NL may comprise a thermoplastic resin material; the intermediate layer NL may comprise a thermoplastic elastomer material; the intermediate layer NL may comprise a thermoplastic polymer material configured to facilitate recyclability; the intermediate layer NL may comprise a thermoplastic material configured to simulate performance of foam material; the intermediate layer NL may comprise a thermoplastic material formed by injection molding. See FIGURES 48A-48C.

[0111] According to an exemplary embodiment as indicated schematically in FIGURES 48A-48C and 49A, the component with composite structure may comprise a mono-materialof the intermediate layer and base and / or cover to facilitate recyclability of the composite structure; the mono-material may comprise a polymer material configured for recyclability; the polymer material configured for recyclability as a sub-assembly may be selected from a group of polymer materials may comprise a polyolefin group or a thermoplastic elastomeric group or an elastomeric group or a polymer family compatible as the mono-material to facilitate recycling of the composite structure CS; the group of polymer materials may comprise the mono-material for recyclability of the composite structure CS as a complete sub-assembly; the mono-material may comprise a single material group. The cover T and the base B / SB and the intermediate layer NL may comprise a thermoplastic material; the intermediate layer NL may comprise a thermoplastic elastomer material; the composite structure CS comprising the cover T and base B / SB and intermediate layer NL may comprise a thermoplastic material; the composite structure CS may comprise a plastic-based monomaterial structure; the mono-material structure NL / FMX may be formed from a thermoplastic material; the mono-material structure NL / FMX may be formed from a polymer-based monomaterial; the mono-material may comprise a thermoplastic material; the mono-material may comprise a thermoplastic resin material; the composite structure CS may comprise a thermoplastic cover T and the base B / SB and the intermediate layer NL may comprise a thermoplastic material; the cover T and the base B / SB and the intermediate layer NL may comprise a thermoplastic material; the intermediate layer NL may comprise a material that may comprise the same material family as the cover.

[0112] As indicated schematically in FIGURES 3A-3B, 4A-4B, 5 and 6, the cover T may be formed on the intermediate layer NL; the cover T may be applied to the intermediate layer NL; the cover T may be bonded to the intermediate layer NL; the cover T may be attached to the intermediate layer NL; the cover T may be provided on a base layer BL of the intermediate layer NL; the cover T may comprise an exterior surface TX; the cover T may comprise an exterior surface TX configured to conceal the structure of the intermediate layer NL; the exterior surface TX may comprise an effect that may comprise a texture; the cover T may comprise a decorative layer; the texture may be configured to conceal the structure of the intermediate layer NL.

[0113] As indicated schematically in FIGURES 33A-33C, 34A-34B, 46A-46C and 47A-47C, the composite structure CS may comprise an intermediate layer / structure NL comprising a set of projections PN configured to fit within a set of recesses in the base B / SB to position the intermediate layer NL within the base B / SB for assembly; the intermediate layer NL may comprise a set of projections PN configured to secure within a set of recesses in the baseB / SB to position the intermediate layer NL within the base B / SB; the intermediate layer NL may comprise a set of projections PN configured to retain within a set of recesses in the base B / SB to position the intermediate layer NL within the base B / SB; the intermediate layer NL may be fit into a recess in the base B / SB to position the intermediate layer NL with the base B / SB; the intermediate layer NL may comprise a set of projections PN configured to fit within a set of recesses in the base B / SB to position the intermediate layer NL on the base B / SB; the intermediate layer NL may comprise a set of projections PN configured to be fit within a set of recesses in the base B / SB to position the intermediate layer NL within the base B / SB; the intermediate layer NL may comprise a set of projections PN fit within a set of recesses in the base B / SB to position the intermediate layer NL with the base B / SB; the intermediate layer NL may comprise a set of projections PN fit with a set of recesses in the base B / SB to position the intermediate layer NL within the base B / SB; the intermediate layer NL may be retained to the cover by a set of projections PN configured to fit with a set of recesses; the intermediate layer NL may comprise the set of projections PN.Exemplary Embodiments - B

[0114] According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior may comprise a composite structure comprising a cover and an intermediate layer and a base; the intermediate layer may be configured to provide a compressible layer between the cover and the base; the intermediate layer and the base may comprise a mono-material; the intermediate layer and the cover and the base may comprise a mono-material; the intermediate layer may comprise a structure / pad configured to provide comfort to an occupant of the vehicle interior.

[0115] According to an exemplary embodiment as shown schematically in the FIGURES, the mono-material may be configured to facilitate recyclability of the composite structure; the mono-material may comprise a polymer material configured for recyclability; the polymer material configured for recyclability as a sub-assembly may be selected from a group of polymer materials may comprise a polyolefin group or a thermoplastic elastomeric group or an elastomeric group or a polymer family compatible as the mono-material to facilitate recycling of the composite structure; the group of polymer materials may comprise the monomaterial for recyclability of the composite structure as a complete sub-assembly; the monomaterial may comprise a single material group.

[0116] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer may be configured to provide a surface effect at the cover; the surface effect at the cover may comprise at least one of softness and / or deep softness and / or compressibility and / or deformability and / or elastic deformability and / or concealment of the intermediate layer; the pad may comprise a structure that may comprise a set of projections; the projections may comprise walls; the walls may comprise lines; the set of projections may comprise a set of parallel lines and / or a set of wavy lines; the set of projections may comprise a set of parallel lines and / or a set of wavy lines and / or a set of angled lines and / or a set of perpendicular lines and / or a set of curved lines and / or a set of generally circle-shaped lines and / or a honeycomb shape and / or a set of cells and / or a set of open cells and / or a set of flexible walls and / or a set of ribs; the intermediate layer may comprise a compressible structure that may comprise a default form; the compressible structure may be configured to deform under force and to return to the default form when not under force; the compressible structure may comprise a set of projections that may comprise a default form; the set of projections may be configured to bend when force is applied and to return to the default form when not under force; the set of projections may be configured to bend under pressure and return to the default form when pressure is released; the set of projections may be aligned atapproximately 45 degrees relative to the cover; the set of projections may comprise joints; the set of projections may comprise joints connecting projections; the set of projections may comprise walls and connection points between walls; connection points between walls may comprise joints; the joints may comprise flexible joints; the projections may comprise walls; walls may comprise curved walls; each joint may comprise a connection of at least two walls; the pad may be injection-molded and demoldable; the set of projections may comprise angled walls configured to be in alignment with a direction of demolding; the pad may comprise a thickness greater than 10 mm.

[0117] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer may comprise a molded layer; the intermediate layer may comprise an injection- molded layer; the intermediate layer may comprise an injection-molded flexible layer; the intermediate layer may comprise an injection-molded compressible layer configured to simulate performance of a foam layer; the intermediate layer may comprise an injection- molded compressible layer; the intermediate layer may comprise an injection- molded compressible layer that may comprise a base layer and a set of projections; the intermediate layer may comprise a compressible pad that may comprise a base layer and a set of flexible projections; the intermediate layer may comprise a set of projections configured to bend to provide compressibility; the intermediate layer may comprise a set of projections configured to buckle to provide compressibility; the intermediate layer may comprise a flexible structure; the intermediate layer may comprise a flexible structure that may comprise a compressible pad; the intermediate layer may comprise a flexible structure that may comprise a base layer and a set of projections from the base layer; the intermediate layer may be configured to perform like a foam layer; the intermediate layer may comprise a compressible structure configured to operate like a foam layer; the intermediate layer may comprise an injection-molded layer configured to perform like a pad; the intermediate layer may comprise a pad; the intermediate layer may comprise an injection-molded pad; the pad may be configured to provide a cushion; the intermediate layer may comprise an injection- molded cushion layer; the intermediate layer may comprise a structure configured to simulate a foam pad; the intermediate layer may comprise a base layer and a set of structures configured to simulate a foam pad; the intermediate layer may comprise a projection arrangement; the intermediate layer may comprise a cell structure; the intermediate layer may comprise a set of cells; the intermediate layer may comprise a network of cells; the intermediate layer may comprise a network of projections; each projection of the network ofprojections may comprise a cell structure; the intermediate layer may comprise a set of walls; the intermediate layer may comprise a set of walls that may comprise a set of cells.

[0118] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer may comprise a set of walls in a pattern; the intermediate layer may comprise a set of walls that may comprise a pattern of projections; the intermediate layer may comprise a compressible layer that may comprise a set of walls; the intermediate layer may comprise a set of walls that may comprise a linear alignment; the intermediate layer may comprise cell walls in linear alignment; the intermediate layer may comprise walls in linear alignment; the intermediate layer may comprise walls in linear alignment to facilitate removal of the intermediate layer from a mold tool; the intermediate layer may comprise a base layer and a set of projections; the intermediate layer may comprise a base layer and a set of projections in linear alignment; the set of projections may comprise a set of walls; the set of projections may comprise a set of walls that may comprise walls at a first length and walls at a second length; the intermediate layer may comprise a first region and a second region; the first region may comprise a first set of walls in a first pattern; the second region may comprise a second set of walls in a second pattern; the first pattern may be different from the second pattern.

[0119] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer may comprise a layer configured to provide performance of a foam material; the intermediate layer may comprise a layer configured to provide performance of a polyurethane foam material; the intermediate layer may comprise a structure configured to provide cushion effect; the intermediate layer may comprise a structure of cells configured to provide compressibility; the intermediate layer may comprise a structure configured to provide structural integrity and compressibility; the structure may comprise a structure of cells; the structure may comprise a structure of walls; the structure may comprise a pattern of cells; the structure may comprise a pattern of cells having walls; the structure may comprise an irregular pattern; the structure may comprise a regular pattern; the structure may comprise a uniform pattern; the structure may comprise a set of curved walls; the structure may comprise a set of projections that may comprise a pattern of curved walls; the pattern of curved walls may comprise a pattern of cells; the cells may comprise open cells; the intermediate layer may comprise tube-shaped structures; the intermediate layer may comprise a pattern of tube-shaped structures; the intermediate layer may comprise a pattern of open cells; the intermediate layer may comprise a base layer and a set of projections that may comprise a pattern of open cells; the intermediate layer may comprise a molded layer thatmay comprise a set of projections that may comprise a pattern of open cells; the intermediate layer may comprise a molded layer that may comprise a set of projections that may comprise a first pattern of open cells and a second pattern of open cells; the intermediate layer may comprise a molded layer that may comprise a thermoplastic material; the molded layer may comprise an injection-molded layer that may comprise a set of projections; the set of projections may comprise a compressible structure; the set of projections may comprise a set of flexible cells providing a compressible structure; the compressible structure may be configured to simulate a foam pad.

[0120] According to an exemplary embodiment as shown schematically in the FIGURES, the compressible structure may comprise a thermoplastic elastomer material; the compressible structure may comprise an injection- molded thermoplastic material; the compressible structure may comprise a set of aligned projections that may comprise an elastomeric material; the intermediate layer may comprise a set of aligned projections that may comprise a set of flexible cells providing a compressible structure; the set of flexible cells may comprise a set of flexible walls; the set of flexible walls may comprise walls having a first length and walls having a second length; the set of flexible walls may comprise a set of aligned walls projecting from a base layer; the base layer of the intermediate layer may comprise the cover; the base layer may comprise an outer surface and an inner surface providing a set of projections; the outer surface may comprise an exterior surface; the composite structure may comprise an injection-molded structure; the cover and the intermediate layer may be integrally formed; the composite structure may be integrally formed; the composite structure may comprise an injection-molded structure.

[0121] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer of the composite structure may comprise an injection-molded structure between the cover and the base; the intermediate layer may be compressible between the cover and the base; the base may comprise a substrate; the base may comprise a carrier; the intermediate layer may comprise a thermoplastic material; the intermediate layer may comprise a thermoplastic polymer material; the intermediate layer may comprise a thermoplastic resin material; the intermediate layer may comprise a thermoplastic elastomer material; the intermediate layer may comprise a thermoplastic polymer material configured to facilitate recyclability; the intermediate layer may comprise a thermoplastic material configured to simulate performance of foam material; the intermediate layer may comprise a thermoplastic material formed by injection molding; the cover and the base and the intermediate layer may comprise a thermoplastic material; the intermediate layer mayT1comprise a thermoplastic elastomer material; the composite structure comprising the cover and base and intermediate layer may comprise a thermoplastic material; the composite structure may comprise a plastic-based mono-material structure; the mono-material structure may be formed from a thermoplastic material; the mono-material structure may be formed from a polymer-based mono-material; the mono-material may comprise a thermoplastic material; the mono-material may comprise a thermoplastic resin material; the cover and the base and the intermediate layer may comprise a thermoplastic material; the base and the intermediate layer may comprise a thermoplastic material; the intermediate layer may comprise a material that may comprise the same material family as the cover; the intermediate layer may comprise a material from the same material family as the cover and the base; the intermediate layer may comprise an injection-molded structure configured to function as a replacement for a foam structure; the intermediate layer may comprise an injection- molded structure that may comprise a thermoplastic material configured to function as a replacement for a foam material; the intermediate layer may comprise a pad that may comprise a moldable polyolefin soft structure.

[0122] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer may comprise a rib structure; the intermediate layer may comprise a structure that may comprise projections at an angle of approximately 10 to 45 degrees to the normal direction for compression of the composite structure; the composite structure with the compressible intermediate layer may be configured to provide a soft feeling at the cover; the composite structure may be configured to provide compressibility when under a force in a load direction at the cover; the composite structure may be configured to bend with a soft feeling continuously at the cover; the intermediate layer may comprise a structure that may be configured to be substantially visually imperceptible at the cover; the intermediate layer may comprise a structure concealed at an external surface of the cover; the intermediate layer may comprise a molded structure that may be configured to be demoldable from a mold tool; the intermediate layer may comprise a molded structure that may be configured to conceal sink marks from molding; the composite structure may be configured to conceal the intermediate layer under the cover; the intermediate layer may comprise a structure providing a bendable structure to provide compressibility at the cover.

[0123] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer may comprise a compressible structure having a thickness in a range of approximately 10 to 15 mm; the intermediate layer may comprise a layer that may comprise projections having walls with a size in a range of approximately 10 to 15 mm; theintermediate layer may comprise a set of projections that may comprise walls in a thickness of approximately 0.8 to 2.5 mm; the intermediate layer may comprise a structure providing a deep soft comfort pad; the intermediate layer may comprise a structure that may be easily moldable and demoldable; the intermediate layer may comprise a structure configured to simulate a foam material in softness and appearance; the intermediate layer may comprise a structure configured to simulate a foam material in weight; the intermediate layer may comprise a structure configured to simulate a foam material in look and feel under the cover; the intermediate layer may comprise a material having a Shore A value in a range of approximately 50 to 70.

[0124] According to an exemplary embodiment as shown schematically in the FIGURES, the composite structure may be configured to facilitate formation by molding; formation by molding may comprise injection molding; formation by molding may comprise injection molding in a mold tool; formation by molding may comprise molding from a resin material; the resin material may comprise a thermoplastic material; the resin material may comprise a thermoplastic elastomer; formation by molding may comprise demolding; demolding may comprise removal by a suction device; demolding may comprise removal by a vacuum suction device; the composite structure may comprise a sandwich structure; the sandwich structure may comprise a compressible structure; the cover may be formed from a first material; the intermediate layer may be formed from a second material; the composite structure may comprise a base providing a carrier formed from a third material; the first material and the second material may be compatible for recycling; the first material and the second material may comprise a mono-material; the first material and the second material and the third material may comprise a mono-material; the mono-material may be compatible for recycling.

[0125] According to an exemplary embodiment as shown schematically in the FIGURES, the composite structure may be configured to provide a surface effect at the cover; the surface effect may comprise substantial concealment of the intermediate layer at the cover; the surface effect may comprise a composite effect of an effect of the intermediate layer and an effect of the cover; the effect of the intermediate layer may comprise a pattern; the intermediate layer may comprise a structure configured to provide the pattern; the structure may comprise a set of projections; the pattern provided by the set of projections may comprise an open-cell pattern; the effect of the cover may comprise a texture; the texture may be formed at an exterior surface of the cover.

[0126] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer may comprise a semi-rigid structure; the intermediate layer may comprise a structure configured to deform elastically from a default form; the structure of the intermediate layer may be configured to deform elastically from a default form under a force and to return to the default form when the force is removed; the structure of the intermediate layer may comprise a semi-rigid structure configured to deform elastically from a default form under a force; the semi-rigid structure may comprise a set of projections; the set of projections may comprise a set of semi-rigid projections configured to deform elastically from a default form under a force; the semi-rigid projections may comprise semi-rigid walls configured to deform elastically from a default form under a force; the structure of the intermediate layer may comprise a semi-rigid injection-molded structure; the structure of the intermediate layer may comprise a semi-rigid injection-molded structure configured to deform elastically under a force; the structure of the intermediate layer may comprise a semirigid injection-molded structure configured to substantially simulate the performance of a foam material; the structure of the intermediate layer may comprise a semi-rigid injection- molded structure configured to substantially simulate the performance of a polyurethane foam material; the structure of the intermediate layer may comprise a semi-rigid injection- molded structure configured to substantially simulate the performance of a polyurethane foam material of same form.

[0127] According to an exemplary embodiment as shown schematically in the FIGURES, the cover may be formed on the intermediate layer; the cover may be applied to the intermediate layer; the cover may be bonded to the intermediate layer; the cover may be attached to the intermediate layer; the cover may be provided on a base layer of the intermediate layer; the cover may comprise an exterior surface; the cover may comprise an exterior surface configured to conceal the structure of the intermediate layer; the exterior surface may comprise an effect that may comprise a texture; the cover may comprise a decorative layer; the texture may be configured to conceal the structure of the intermediate layer.

[0128] According to an exemplary embodiment as shown schematically in the FIGURES, the intermediate layer may comprise a set of projections configured to fit within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may comprise a set of projections configured to secure within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may comprise a set of projections configured to retain within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may be fit into a recess in the baseto position the intermediate layer within the base; the intermediate layer may comprise a set of projections configured to fit within a set of recesses in the base to position the intermediate layer on the base; the intermediate layer may comprise a set of projections configured to be fit within a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may comprise a set of projections fit within a set of recesses in the base to position the intermediate layer with the base; the intermediate layer may comprise a set of projections fit with a set of recesses in the base to position the intermediate layer within the base; the intermediate layer may be retained to the cover by a set of projections configured to fit with a set of recesses; the intermediate layer may comprise the set of projections.

[0129] According to an exemplary embodiment as shown schematically in the FIGURES, the composite structure comprising the intermediate layer and the cover and the base may comprise a mono-material; the composite structure may comprise an armrest; the composite structure may comprise a trim panel; the composite structure may comprise a door for a console.

[0130] According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior configured to provide an may comprise a cover and a pad and a base; the pad may be configured to provide comfort to the occupant; the pad may be configured to provide a surface effect at the cover; the cover and the pad and the base may comprise a polymer material configured for recyclability or configured to reduce the carbon dioxide footprint; the polymer material configured for recyclability may be selected from a group of polymer materials that may comprise a polyolefin group, a thermoplastic elastomeric group, an elastomeric group, etc.; the group of polymer materials may comprise a mono-material for recyclability as a complete sub-assembly; the mono-material may comprise a single material group; the surface effect may comprise at least one of softness, deep softness, compression, elastic deformation, etc.; the pad may comprise a structure; the structure may comprise a set of projections and / or a set of ribs; the set of projections may comprise a set of walls arranged as parallel lines and / or wavy lines and / or angled lines and / or perpendicular lines and / or circles and / or a honeycomb shape and / or a set of ribs; the set of projections may comprise walls provided as angled lines configured to bend under pressure and return when pressure is released; the walls may be inclined by 45 degrees to prevent breakage under pressure; the set of projections may comprise joints; the joints may be configured to connect walls of the set of projections; the walls may comprise curved ribs; each joint may comprise a connection of three walls; the pad may be injection-molded anddemoldable; angled lines of the walls may be configured to run in a same direction to enable demolding; the pad may comprise a thickness greater than 10 mm.

[0131] According to an exemplary embodiment, the composite structure may comprise a polymer material configured for recyclability as a sub-assembly selected from a group of polymer materials comprising a polyolefin group and / or a thermoplastic elastomeric group and / or an elastomeric group and / or a thermoplastic elastomer (TPE, TPV) and / or a thermoplastic urethane (TPU) and / or a rubber / synthetic rubber (ethylene propylene diene monomer / EPDM blend) and / or soft polyvinyl chloride and / or a polymer family compatible as the mono-material to facilitate recycling of the composite structure. The composite structure may comprise an intermediate layer comprising a molded structure that is configured to conceal (reduce / minimize) sink marks from molding and / or to conceal and / or reduce visibility of tool / sink marks from molding. The intermediate layer may comprise a compressible structure having a thickness in a range of approximately 10 to 15 mm or approximately 3 to 25 mm (e.g. for instrument panel 3-10 mm, for door panel armrest 10-20 mm, for floor console armrest 15-25mm). The intermediate layer may comprise a set of projections comprising walls in a thickness of approximately 0.8 mm to 2.5 mm.

[0132] As indicated schematically, the component may comprise composite structure comprising a cover and an intermediate layer and a base; the intermediate layer may be configured to provide a compressible layer between the cover and the base; the intermediate layer and the base may comprise a mono-material; the intermediate layer and the cover and the base may comprise a mono-material; the intermediate layer may comprise a pad configured to provide comfort to an occupant of the vehicle interior; the mono-material may be configured to facilitate recyclability of the composite structure; the mono-material may comprise a polymer material configured for recyclability; the polymer material configured for recyclability as a sub-assembly may be selected from a group of polymer materials may comprise a polyolefin group or a thermoplastic elastomeric group or an elastomeric group or a polymer family compatible as the mono-material to facilitate recycling of the composite structure. As indicated schematically, the cover may comprise decorative material, cover material, foil, decor foil, synthetic leather, film, fabric, leather, stitchable material / sheet, etc. ; the base / carrier may comprise a resin, plastic, polypropylene material, etc.

[0133] According to an exemplary embodiment as shown schematically in the FIGURES, a method of producing in a forming tool a component for a vehicle interior comprising an armrest may comprise the steps of providing a mold and injection molding a pad in a shape and demolding the pad; the mold may comprise a base section and an upper section; the stepof demolding the pad may comprise a step of gripping the pad with a gripper; the gripper may be configured to support deforming of the pad; the gripper may comprise a cushion; the cushion may be configured to replicate the shape of the pad and pull the pad from the mold by using suction; the gripper may comprise a vacuum gripper; the gripper may comprise a suction device.Exemplary Embodiments - C

[0134] As shown schematically in the FIGURES, a component for a vehicle interior configured to provide an armrest comprising a cover and an intermediate layer / pad and a base. The pad may be configured to provide a surface effect. The cover, the pad and the base may comprise a polymer material. The polymer material may be configured for recyclability and to reduce the carbon dioxide footprint. The polymer material may be selected from a group of polymer materials and may comprise a mono-material or a single material group. The surface effect may comprise at least one of (a) softness, (b) deep softness, (c) compression, (d) elastic deformation. The pad may comprise a structure wherein the structure may comprise a set of ribs. The set of ribs may be arranged in (a) parallel lines, (b) wavy lines, (c) angled lines, (d) perpendicular lines, (e) circles, (f) honeycomb shape. The set of ribs in angled lines may be configured to bend under pressure and return when pressure is released. The ribs may be inclined by 45 degrees to prevent breakage under pressure. The set of ribs may comprise joints, wherein the joints may be configured as a second set of ribs. The second set of ribs may comprise curved ribs. Each joint may comprise a connection of three ribs. The pad may be injection-molded and may be demoldable. The angled lines of the ribs may be configured to run in the same direction to enable a demolding. The pad may comprise a thickness greater than 10 mm.

[0135] According to an exemplary embodiment, the component may comprise at least one of (a) a door panel; (b) a floor console; (c) a seat component.* * *

[0136] It is important to note that the present inventions (e.g. inventive concepts, etc.) have been described in the specification and / or illustrated in the FIGURES of the present patent document according to exemplary embodiments; the embodiments of the present inventions are presented by way of example only and are not intended as a limitation on the scope of the present inventions. The construction and / or arrangement of the elements of the inventive concepts embodied in the present inventions as described in the specification and / or illustrated in the FIGURES is illustrative only. Although exemplary embodiments of the present inventions have been described in detail in the present patent document, a person of ordinary skill in the art will readily appreciate that equivalents, modifications, variations, etc. of the subject matter of the exemplary embodiments and alternative embodiments are possible and contemplated as being within the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. It should also be noted that various / other modifications, variations, substitutions, equivalents, changes, omissions, etc. may be made in the configuration and / or arrangement of the exemplary embodiments (e.g. in concept, design, structure, apparatus, form, assembly, construction, means, function, system, process / method, steps, sequence of process / method steps, operation, operating conditions, performance, materials, composition, combination, etc.) without departing from the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. The scope of the present inventions is not intended to be limited to the subject matter (e.g. details, structure, functions, materials, acts, steps, sequence, system, result, etc.) described in the specification and / or illustrated in the FIGURES of the present patent document. It is contemplated that the claims of the present patent document will be construed properly to cover the complete scope of the subject matter of the present inventions (e.g. including any and all such modifications, variations, embodiments, combinations, equivalents, etc.); it is to be understood that the terminology used in the present patent document is for the purpose of providing a description of the subject matter of the exemplary embodiments rather than as a limitation on the scope of the present inventions.

[0137] It is also important to note that according to exemplary embodiments the present inventions may comprise conventional technology (e.g. as implemented and / or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or maycomprise any other applicable technology (present and / or future) with suitability and / or capability to perform the functions and processes / operations described in the specification and / or illustrated in the FIGURES. All such technology (e.g. as implemented in embodiments, modifications, variations, combinations, equivalents, etc.) is considered to be within the scope of the present inventions of the present patent document.

Claims

CLAIMSThe invention claimed is:

1. A component for a vehicle interior comprising: a composite structure comprising a cover and an intermediate layer and a base; wherein the intermediate layer is configured to provide a compressible layer between the cover and the base; wherein the composite structure comprising the intermediate layer and the base comprises a mono-material.

2. The component of Claim 1 wherein the intermediate layer comprises a pad configured to provide comfort to an occupant of the vehicle interior.

3. The component of Claim 1 wherein the mono-material is configured to facilitate recyclability of the composite structure.

4. The component of Claim 1 wherein the mono-material comprises a polymer material configured for recyclability.

5. The component of Claim 4 wherein the polymer material configured for recyclability as a sub-assembly is selected from a group of polymer materials comprising a polyolefin group and / or a thermoplastic elastomeric group and / or an elastomeric group and / or a thermoplastic elastomer (TPE, TPV) and / or a thermoplastic urethane (TPU) and / or a rubber / synthetic rubber (ethylene propylene diene monomer / EPDM blend) and / or soft polyvinyl chloride and / or a polymer family compatible as the mono-material to facilitate recycling of the composite structure.

6. The component of Claim 5 wherein the group of polymer materials comprises the mono-material for recyclability of the composite structure as a complete sub-assembly.

7. The component of Claim 1 wherein the mono-material comprises a single material group.

8. The component of Claim 1 wherein the intermediate layer is configured to provide a surface effect at the cover.

9. The component of Claim 8 wherein the surface effect at the cover comprises at least one of softness and / or deep softness and / or compressibility and / or deformability and / or elastic deformability and / or concealment of the intermediate layer.

10. The component of Claim 2 wherein the pad comprises a structure comprising a set of projections.

11. The component of Claim 10 wherein the projections comprise walls.

12. The component of Claim 11 wherein the walls comprise lines.

13. The component of Claim 10 wherein the set of projections comprises a set of parallel lines and / or a set of wavy lines.

14. The component of Claim 10 wherein the set of projections comprises a set of parallel lines and / or a set of wavy lines and / or a set of angled lines and / or a set of perpendicular lines and / or a set of curved lines and / or a set of generally circle-shaped lines and / or a honeycomb shape and / or a set of cells and / or a set of open cells and / or a set of flexible walls and / or a set of ribs.

15. The component of Claim 1 wherein the intermediate layer comprises a compressible structure comprising a default form.

16. The component of Claim 15 wherein the compressible structure is configured to deform under force and to return to the default form when not under force.

17. The component of Claim 15 wherein the compressible structure comprises a set of projections comprising a default form.

18. The component of Claim 17 wherein the set of projections is configured to bend when force is applied and to return to the default form when not under force.

19. The component of Claim 17 wherein the set of projections are configured to bend under pressure and return to the default form when pressure is released.

20. The component of Claim 17 wherein the set of projections is aligned at approximately 45 degrees relative to the cover.

21. The component of Claim 10 wherein the set of projections comprises joints.

22. The component of Claim 10 wherein the set of projections comprises joints connecting projections.

23. The component of Claim 10 wherein the set of projections comprises walls and connection points between walls.

24. The component of Claim 23 wherein connection points between walls comprise joints.

25. The component of Claim 21 wherein joints comprise flexible joints.

26. The component of Claim 10 wherein the projections comprise walls.

27. The component of Claim 26 wherein the walls comprise curved walls.

28. The component of Claim 21 wherein each joint comprises a connection of at least two walls.

29. The component of Claim 2 wherein the pad is injection-molded and demoldable.

30. The component of Claim 10 wherein the set of projections comprises angled walls configured to be in alignment with a direction of demolding.

31. The component of Claim 2 wherein the pad comprises a thickness greater than 10 mm.

32. The component of Claim 1 wherein the intermediate layer comprises a molded layer.

33. The component of Claim 1 wherein the intermediate layer comprises an injection- molded layer.

34. The component of Claim 1 wherein the intermediate layer comprises an injection- molded flexible layer.

35. The component of Claim 1 wherein the intermediate layer comprises an injection-molded compressible layer configured to simulate performance of a foam layer.

36. The component of Claim 1 wherein the intermediate layer comprises an injection- molded compressible layer.

37. The component of Claim 1 wherein the intermediate layer comprises an injection- molded compressible layer comprising a base layer and a set of projections.

38. The component of Claim 1 wherein the intermediate layer comprises a compressible pad comprising a base layer and a set of flexible projections.

39. The component of Claim 1 wherein the intermediate layer comprises a set of projections configured to bend to provide compressibility.

40. The component of Claim 1 wherein the intermediate layer comprises a set of projections configured to buckle and / or to bend to provide compressibility.

41. The component of Claim 1 wherein the intermediate layer comprises a flexible structure.

42. The component of Claim 1 wherein the intermediate layer comprises a flexible structure comprising a compressible pad.

43. The component of Claim 1 wherein the intermediate layer comprises a flexible structure comprising a base layer and a set of projections from the base layer.

44. The component of Claim 1 wherein the intermediate layer is configured to perform like a foam layer.

45. The component of Claim 1 wherein the intermediate layer comprises a compressible structure configured to operate like a foam layer.

46. The component of Claim 1 wherein the intermediate layer comprises an injection-molded layer configured to perform like a pad.

47. The component of Claim 1 wherein the intermediate layer comprises a pad.

48. The component of Claim 1 wherein the intermediate layer comprises an injection- molded pad.

49. The component of Claim 47 wherein the pad is configured to provide a cushion.

50. The component of Claim 1 wherein the intermediate layer comprises an injection- molded cushion layer.

51. The component of Claim 1 wherein the intermediate layer comprises a structure configured to simulate a foam pad.

52. The component of Claim 1 wherein the intermediate layer comprises a base layer and a set of structures configured to simulate a foam pad.

53. The component of Claim 1 wherein the intermediate layer comprises a projection arrangement.

54. The component of Claim 1 wherein the intermediate layer comprises a cell structure.

55. The component of Claim 1 wherein the intermediate layer comprises a set of cells.

56. The component of Claim 1 wherein the intermediate layer comprises a network of cells.

57. The component of Claim 1 wherein the intermediate layer comprises a network of projections.

58. The component of Claim 57 wherein each projection of the network of projections comprises a cell structure.

59. The component of Claim 1 wherein the intermediate layer comprises a set of walls.

60. The component of Claim 1 wherein the intermediate layer comprises a set of walls comprising a set of cells.

61. The component of Claim 1 wherein the intermediate layer comprises a set of walls in a pattern.

62. The component of Claim 1 wherein the intermediate layer comprises a set of walls comprising a pattern of projections.

63. The component of Claim 1 wherein the intermediate layer comprises a compressible layer comprising a set of walls.

64. The component of Claim 1 wherein the intermediate layer comprises a set of walls comprising a linear alignment.

65. The component of Claim 1 wherein the intermediate layer comprises cell walls in linear alignment.

66. The component of Claim 1 wherein the intermediate layer comprises walls in linear alignment.

67. The component of Claim 1 wherein the intermediate layer comprises walls in linear alignment to facilitate removal of the intermediate layer from a mold tool.

68. The component of Claim 1 wherein the intermediate layer comprises a base layer and a set of projections.

69. The component of Claim 1 wherein the intermediate layer comprises a base layer and a set of projections in linear alignment.

70. The component of Claim 68 wherein the set of projections comprises a set of walls.

71. The component of Claim 68 wherein the set of projections comprises a set of walls comprising walls at a first length and walls at a second length.

72. The component of Claim 1 wherein the intermediate layer comprises a first region and a second region.

73. The component of Claim 72 wherein the first region comprises a first set of walls in a first pattern.

74. The component of Claim 72 wherein the second region comprises a second set of walls in a second pattern.

75. The component of Claim 72 wherein the first pattern is different from the second pattern.

76. The component of Claim 1 wherein the intermediate layer comprises a layer configured to provide performance of a foam material.

77. The component of Claim 1 wherein the intermediate layer comprises a layer configured to provide performance of a polyurethane foam material.

78. The component of Claim 1 wherein the intermediate layer comprises a structure configured to provide cushion effect.

79. The component of Claim 1 wherein the intermediate layer comprises a structure of cells configured to provide compressibility.

80. The component of Claim 1 wherein the intermediate layer comprises a structure configured to provide structural integrity and compressibility.

81. The component of Claim 80 wherein the structure comprises a structure of cells.

82. The component of Claim 80 wherein the structure comprises a structure of walls.

83. The component of Claim 80 wherein the structure comprises a pattern of cells.

84. The component of Claim 80 wherein the structure comprises a pattern of cells having walls.

85. The component of Claim 80 wherein the structure comprises an irregular pattern.

86. The component of Claim 80 wherein the structure comprises a regular pattern.

87. The component of Claim 80 wherein the structure comprises a uniform pattern.

88. The component of Claim 80 wherein the structure comprises a set of curved walls.

89. The component of Claim 80 wherein the structure comprises a set of projections comprising a pattern of curved walls.

90. The component of Claim 89 wherein the pattern of curved walls comprises a pattern of cells.

91. The component of Claim 90 wherein the cells comprise open cells.

92. The component of Claim 1 wherein the intermediate layer comprises tubeshaped structures.

93. The component of Claim 1 wherein the intermediate layer comprises a pattern of tube-shaped structures.

94. The component of Claim 1 wherein the intermediate layer comprises a pattern of open cells.

95. The component of Claim 1 wherein the intermediate layer comprises a base layer and a set of projections comprising a pattern of open cells.

96. The component of Claim 1 wherein the intermediate layer comprises a molded layer comprising a set of projections comprising a pattern of open cells.

97. The component of Claim 1 wherein the intermediate layer comprises a molded layer comprising a set of projections comprising a first pattern of open cells and a second pattern of open cells.

98. The component of Claim 1 wherein the intermediate layer comprises a molded layer comprising a thermoplastic material.

99. The component of Claim 98 wherein the molded layer comprises an injection- molded layer comprising a set of projections.

100. The component of Claim 99 wherein the set of projections comprises a compressible structure.

101. The component of Claim 99 wherein the set of projections comprises a set of flexible cells providing a compressible structure.

102. The component of Claim 101 wherein the compressible structure is configured to simulate a foam pad.

103. The component of Claim 101 wherein the compressible structure comprises a thermoplastic elastomer material.

104. The component of Claim lOlwherein the compressible structure comprises an injection-molded thermoplastic material.

105. The component of Claim 101 wherein the compressible structure comprises a set of aligned projections comprising an elastomeric material.

106. The component of Claim 1 wherein the intermediate layer comprises a set of aligned projections comprising a set of flexible cells providing a compressible structure.

107. The component of Claim 106 wherein the set of flexible cells comprises a set of flexible walls.

108. The component of Claim 107 wherein the set of flexible walls comprises walls having a first length and walls having a second length.

109. The component of Claim 107 wherein the set of flexible walls comprises a set of aligned walls projecting from a base layer.

110. The component of Claim 109 wherein the base layer of the intermediate layer comprises the cover.

111. The component of Claim 109 wherein the base layer comprises an outer surface and an inner surface providing a set of projections.

112. The component of Claim 111 wherein the outer surface comprises an exterior surface.

113. The component of Claim 1 wherein the composite structure comprises an injection-molded structure.

114. The component of Claim 1 wherein the cover and the intermediate layer are integrally formed.

115. The component of Claim 1 wherein the composite structure is integrally formed.

116. The component of Claim 1 wherein the composite structure comprises an injection- molded structure.

117. The component of Claim 1 wherein the intermediate layer of the composite structure comprises an injection-molded structure between the cover and the base.

118. The component of Claim 1 wherein the intermediate layer is compressible between the cover and the base.

119. The component of Claim 1 wherein the base comprises a substrate.

120. The component of Claim 1 wherein the base comprises a carrier.

121. The component of Claim 1 wherein the intermediate layer comprises a thermoplastic material.

122. The component of Claim 1 wherein the intermediate layer comprises a thermoplastic polymer material.

123. The component of Claim 1 wherein the intermediate layer comprises a thermoplastic resin material.

124. The component of Claim 1 wherein the intermediate layer comprises a thermoplastic elastomer material.

125. The component of Claim 1 wherein the intermediate layer comprises a thermoplastic polymer material configured to facilitate recyclability.

126. The component of Claim 1 wherein the intermediate layer comprises a thermoplastic material configured to simulate performance of foam material.

127. The component of Claim 1 wherein the intermediate layer comprises a thermoplastic material formed by injection molding.

128. The component of Claim 1 wherein the cover and the base and the intermediate layer comprise a thermoplastic material.

129. The component of Claim 128 wherein the intermediate layer comprises a thermoplastic elastomer material.

130. The component of Claim 1 wherein the composite structure comprising the cover and base and intermediate layer comprises a thermoplastic material.

131. The component of Claim 1 wherein the composite structure comprises a plastic-based mono-material structure.

132. The component of Claim 1 wherein the mono-material structure is formed from a thermoplastic material.

133. The component of Claim 1 wherein the mono-material structure is formed from a polymer-based mono-material.

134. The component of Claim 1 wherein the mono-material comprises a thermoplastic material.

135. The component of Claim 1 wherein the mono-material comprise a thermoplastic resin material.

136. The component of Claim 1 wherein the composite structure comprises a thermoplastic cover and the base and the intermediate layer comprise a thermoplastic material.

137. The component of Claim 1 wherein the cover and the base and the intermediate layer comprise a thermoplastic material.

138. The component of Claim 1 wherein the intermediate layer comprises a material comprising the same material family as the cover.

139. The component of Claim 1 wherein the intermediate layer comprises a material from the same material family as the cover and the base.

140. The component of Claim 1 wherein the intermediate layer comprises an injection- molded structure configured to function as a replacement for a foam structure.

141. The component of Claim 1 wherein the intermediate layer comprises an injection- molded structure comprising a thermoplastic material configured to function as a replacement for a foam material.

142. The component of Claim 1 wherein the intermediate layer comprises a pad comprising a moldable polyolefin soft structure.

143. The component of Claim 1 wherein the intermediate layer comprises a rib structure.

144. The component of Claim 1 wherein the intermediate layer comprises a structure comprising projections at an angle of approximately 10 to 45 degrees to the normal direction for compression of the composite structure.

145. The component of Claim 1 wherein the composite structure with the compressible intermediate layer is configured to provide a soft feeling at the cover.

146. The component of Claim 1 wherein the composite structure is configured to provide compressibility when under a force in a load direction at the cover.

147. The component of Claim 1 wherein the composite structure is configured to bend with a soft feeling continuously at the cover.

148. The component of Claim 1 wherein the intermediate layer comprises a structure that is configured to be substantially visually imperceptible at the cover.

149. The component of Claim 1 wherein the intermediate layer comprises a structure concealed at an external surface of the cover.

150. The component of Claim 1 wherein the intermediate layer comprises a molded structure that is configured to be demoldable from a mold tool.

151. The component of Claim 1 wherein the intermediate layer comprises a molded structure that is configured to conceal and / or reduce visibility of tool / sink marks from molding.

152. The component of Claim 1 wherein the composite structure is configured to conceal the intermediate layer under the cover.

153. The component of Claim 1 wherein the intermediate layer comprises a structure providing a bendable structure to provide compressibility at the cover.

154. The component of Claim 1 wherein the intermediate layer comprises a compressible structure having a thickness in a range of approximately 10 to 15 mm and / or approximately 3 to 25 mm.

155. The component of Claim 1 wherein the intermediate layer comprises a layer comprising projections having walls with a size in a range of approximately 10 to 15 mm.

156. The component of Claim 1 wherein the intermediate layer comprises a set of projections comprising walls in a thickness of approximately 0.5 mm to 2 mm.

157. The component of Claim 1 wherein the intermediate layer comprises a structure providing a deep soft comfort pad.

158. The component of Claim 1 wherein the intermediate layer comprises a structure that is easily moldable and demoldable.

159. The component of Claim 1 wherein the intermediate layer comprises a structure configured to simulate a foam material in softness and appearance.

160. The component of Claim 1 wherein the intermediate layer comprises a structure configured to simulate a foam material in weight.

161. The component of Claim 1 wherein the intermediate layer comprises a structure configured to simulate a foam material in look and feel under the cover.

162. The component of Claim 1 wherein the intermediate layer comprises a material having a Shore A value in a range of approximately 50 to 70.

163. The component of Claim 1 wherein the composite structure is configured to facilitate formation by molding.

164. The component of Claim 163 wherein formation by molding comprises injection molding.

165. The component of Claim 163 wherein formation by molding comprises injection molding in a mold tool.

166. The component of Claim 163 wherein formation by molding comprises molding from a resin material.

167. The component of Claim 166 wherein the resin material comprises a thermoplastic material.

168. The component of Claim 166 wherein the resin material comprises a thermoplastic elastomer.

169. The component of Claim 163 wherein formation by molding comprises demolding.

170. The component of Claim 169 wherein demolding comprises removal by a suction device.

171. The component of Claim 169 wherein demolding comprises removal by a vacuum suction device.

172. The component of Claim 1 wherein the composite structure comprises a sandwich structure.

173. The component of Claim 172 wherein the sandwich structure comprises a compressible structure.

174. The component of Claim 1 wherein the cover is formed from a first material.

175. The component of Claim 174 wherein the intermediate layer is formed from a second material.

176. The component of Claim 175 wherein the composite structure comprises a base providing a carrier formed from a third material.

177. The component of Claim 175 wherein the first material and the second material are compatible for recycling.

178. The component of Claim 175 wherein the first material and the second material comprise a mono-material.

179. The component of Claim 176 wherein the first material and the second material and the third material comprise a mono-material.

180. The component of Claim 179 wherein the mono-material is compatible for recycling.

181. The component of Claim 1 wherein the composite structure is configured to provide a surface effect at the cover.

182. The component of Claim 181 wherein the surface effect comprises substantial concealment of the intermediate layer at the cover.

183. The component of Claim 181 wherein the surface effect comprises a composite effect of an effect of the intermediate layer and an effect of the cover.

184. The component of Claim 183 wherein the effect of the intermediate layer comprises a pattern.

185. The component of Claim 1 wherein the intermediate layer comprises a structure configured to provide the pattern.

186. The component of Claim 185 wherein the structure comprises a set of projections.

187. The component of Claim 186 wherein the pattern provided by the set of projections comprises an open-cell pattern.

188. The component of Claim 181 wherein the effect of the cover comprises a texture.

189. The component of Claim 188 wherein the texture is formed at an exterior surface of the cover.

190. The component of Claim 1 wherein the intermediate layer comprises a semirigid structure.

191. The component of Claim 1 wherein the intermediate layer comprises a structure configured to deform elastically from a default form.

192. The component of Claim 1 wherein the structure of the intermediate layer is configured to deform elastically from a default form under a force and to return to the default form when the force is removed.

193. The component of Claim 1 wherein the structure of the intermediate layer comprises a semi-rigid structure configured to deform elastically from a default form under a force.

194. The component of Claim 193 wherein the semi-rigid structure comprises a set of projections.

195. The component of Claim 194 wherein the set of projections comprises a set of semi-rigid projections configured to deform elastically from a default form under a force.

196. The component of Claim 195 wherein the semi-rigid projections comprise semi-rigid walls configured to deform elastically from a default form under a force.

197. The component of Claim 1 wherein the structure of the intermediate layer comprises a semi-rigid injection-molded structure.

198. The component of Claim 1 wherein the structure of the intermediate layer comprises a semi-rigid injection- molded structure configured to deform elastically under a force.

199. The component of Claim 1 wherein the structure of the intermediate layer comprises a semi-rigid injection- molded structure configured to substantially simulate the performance of a foam material.

200. The component of Claim 1 wherein the structure of the intermediate layer comprises a semi-rigid injection- molded structure configured to substantially simulate the performance of a polyurethane foam material.

201. The component of Claim 1 wherein the structure of the intermediate layer comprises a semi-rigid injection- molded structure configured to substantially simulate the performance of a polyurethane foam material of same form.

202. The component of Claim 1 wherein the cover is formed on the intermediate layer.

203. The component of Claim 1 wherein the cover is applied to the intermediate layer.

204. The component of Claim 1 wherein the cover is bonded to the intermediate layer.

205. The component of Claim 1 wherein the cover is attached to the intermediate layer.

206. The component of Claim 1 wherein the cover is provided on a base layer of the intermediate layer.

207. The component of Claim 1 wherein the cover comprises an exterior surface.

208. The component of Claim 1 wherein the cover comprises an exterior surface configured to conceal the structure of the intermediate layer.

209. The component of Claim 208 wherein the exterior surface comprises an effect comprising a texture.

210. The component of Claim 1 wherein the cover comprises a decorative layer.

211. The component of Claim 209 wherein the texture is configured to conceal the structure of the intermediate layer.

212. The component of Claim 1 wherein the intermediate layer comprises a set of projections configured to fit within a set of recesses in the base to position the intermediate layer within the base.

213. The component of Claim 1 wherein the intermediate layer comprises a set of projections configured to secure within a set of recesses in the base to position the intermediate layer within the base.

214. The component of Claim 1 wherein the intermediate layer comprises a set of projections configured to retain within a set of recesses in the base to position the intermediate layer within the base.

215. The component of Claim 1 wherein the intermediate layer is fit into a recess in the base to position the intermediate layer within the base.

216. The component of Claim 1 wherein the intermediate layer comprises a set of projections configured to fit within a set of recesses in the base to position the intermediate layer on the base.

217. The component of Claim 1 wherein the intermediate layer comprises a set of projections configured to be fit within a set of recesses in the base to position the intermediate layer within the base.

218. The component of Claim 1 wherein the intermediate layer comprises a set of projections fit within a set of recesses in the base to position the intermediate layer with the base.

219. The component of Claim 1 wherein the intermediate layer comprises a set of projections fit with a set of recesses in the base to position the intermediate layer within the base.

220. The component of Claim 1 wherein the intermediate layer is retained to the cover by a set of projections configured to fit with a set of recesses.

221. The component of Claim 220 wherein the intermediate layer comprises the set of projections.

222. The component of Claim 1 wherein the composite structure comprising the intermediate layer and the cover and the base comprises a mono-material.

223. The component of Claim 1 wherein the composite structure comprises an armrest.

224. The component of Claim 1 wherein the composite structure comprises a trim panel.

225. The component of Claim 1 wherein the composite structure comprises a door for a console.

226. A component for a vehicle interior configured to provide an armrest comprising; a cover; a pad; a base; wherein the pad is configured to provide comfort to the occupant; wherein the pad is configured to provide a surface effect at the cover.

227. The component of Claim 226 wherein the cover and the pad and the base comprise a polymer material configured for recyclability or configured to reduce the carbon dioxide footprint.

228. The component of Claim 227 wherein the polymer material configured for recyclability is selected from a group of polymer materials comprising (a) a polyolefin group; (b) a thermoplastic elastomeric group; (c) an elastomeric group.

229. The component of Claim 228 wherein the group of polymer materials comprises a mono-material for recyclability as a complete sub-assembly; wherein the monomaterial comprises a single material group.

230. The component of Claim 226 wherein the surface effect comprises at least one of (a) softness, (b) deep softness, (c) compression, (d) elastic deformation.

231. The component of Claim 226 wherein the pad comprises a structure wherein the structure comprises a set of projections and / or a set of ribs.

232. The component of Claim 231 wherein the set of projections comprises a set of walls arranged as (a) parallel lines and / or (b) wavy lines and / or (c) angled lines and / or (d) perpendicular lines and / or (e) circles and / or (f) honeycomb shape; (g) a set of ribs.

233. The component of Claim 231 wherein the set of projections comprises walls provided as angled lines configured to bend under pressure and return when pressure is released; wherein the walls are inclined by 45 degrees to prevent breakage under pressure.

234. The component of Claim 231 wherein the set of projections comprises joints; wherein the joints are configured to connect walls of the set of projections.

235. The component of Claim 234 wherein the walls comprise curved ribs.

236. The component of Claim 234 wherein each joint comprises a connection of three walls.

237. The component of Claim 226 wherein the pad is injection-molded and demoldable.

238. The component of Claim 232 wherein angled lines of the walls are configured to run in a same direction to enable demolding.

239. The component of Claim 226 wherein the pad comprises a thickness greater than 10 mm.

240. A method of producing in a forming tool a component for a vehicle interior comprising an armrest comprising the steps of: providing a mold; injection molding a pad in a shape; demolding the pad; wherein the mold comprises a base section and an upper section; wherein the step of demolding the pad comprises a step of gripping the pad with a gripper.

241. The method of Claim 240 wherein the gripper is configured to support deforming of the pad.

242. The method of Claim 240 wherein the gripper comprises a cushion; wherein the cushion is configured to replicate the shape of the pad and pull the pad from the mold by using suction.

243. The method of Claim 240 wherein the gripper comprises a vacuum gripper.

244. The method of Claim 240 wherein the gripper comprises a suction device.

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