Vehicle trim part

Abstract

A vehicle interior component produced in a mold including a first surface and a second surface by a method comprising: placing a pre-formed substrate onto the first surface of the mold; forming a compression-formed structure from the pre-formed substrate by compressing the pre-formed substrate between the first surface of the mold and the second surface of the mold; applying a cover to the compression-formed structure to form a panel assembly providing a surface effect; wherein the pre-formed substrate comprises a reinforced pre-formed substrate.

Description

[0001] This application is a divisional application of Chinese Patent Application No. 201980038464.2, entitled “Vehicle trim parts”, filed on June 27, 2019. Technical Field

[0002] This invention relates to a vehicle trim component. Background Technology

[0003] An airbag is known to be provided in a vehicle, the airbag being configured to deploy on a trim piece and enter the vehicle interior via an airbag slot.

[0004] It would be advantageous to provide an improved decorative component that is configured to provide reinforcement, such as a line / line pattern, at or near the airbag groove on the decorative component. Summary of the Invention

[0005] This invention relates to a trim component for a vehicle interior, the trim component being configured to support an airbag slide and an airbag module, the airbag module providing an airbag configured to deploy into the vehicle interior through an opening, comprising: a structural base providing at least one door established upon airbag deployment to allow the airbag to deploy from the airbag module through the opening. The structural base may include a reinforcement configured to secure the at least one door to the structural base during airbag deployment. The reinforcement may include at least one pin. The reinforcement may include a top pin and a bottom pin. The top pin may include thread weight, and the bottom pin may also include thread weight; the thread weight of the top pin may generally be greater than that of the bottom pin. The top pin may include 210 Tex thread; the bottom pin may include 70 Tex thread. The bottom seam may be configured to separate upon airbag deployment to allow the airbag to deploy from the airbag module through the opening. The top pin may be configured to secure the door to the structural base upon airbag deployment. The top pin can be configured to stretch upon airbag deployment to secure the door to the structural base. The reinforcement can be composed of bonded nylon thread. The reinforcement can be composed of at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fiber, (g) polymer fiber, (h) synthetic fiber. The structural base can include a panel at least partially composed of fibers; the reinforcement can include thread sewn onto the panel. The thread can be pressed into the surface of the panel during compression molding. The panel can include a recess; the thread can be joined to the panel at the recess. The thread and the panel can form a generally continuous surface for the decorative element. The structural base can include a compression-formed component. The compression-formed component can include a recess in the back side of the structural base, configured to create the opening such that the airbag will deploy through the compression-formed component at the opening. The structural base can be at least partially formed of fibers. The decorative element can further include a cover to provide a surface on the front side of the structural base. Contact between the airbag and the at least one door can cause the cover to tear to create an opening for the airbag and facilitate the deployment of the airbag through the opening. The airbag groove can define at least one hinge region for the at least one door; the reinforcement can be positioned adjacent to this hinge region. The structural base can include an generally rigid fiber pad. The decorative component can further include a cover; the cover can include at least one of the following: (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite material of a plastic layer and a textile backing; (e) coated fabric; (f) polyvinyl chloride coated fabric; (g) woven fabric; (h) nonwoven fabric; (i) appliqué; (j) vinyl; (k) foil.

[0006] This invention relates to a vehicle interior component manufactured in a mold comprising a first surface and a second surface by a method comprising: placing a pre-formed substrate on a first surface of the mold; forming a compression-formed structure from the pre-formed substrate by compressing it between the first and second surfaces of the mold; and applying a cover to the compression-formed structure to form a panel assembly providing a surface effect. The pre-formed substrate may include a reinforced pre-formed substrate. The reinforced pre-formed substrate may include a panel and a reinforcement composed at least partially of fibers; the reinforcement may include thread sewn onto the panel. The reinforcement may include at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fiber, (g) polymer fiber, (h) synthetic fiber. The compression-formed structure may include the substrate layer and the reinforcement. The reinforced pre-formed substrate may include a surface effect comprising an generally smooth texture. The surface effect of the panel assembly may generally include the surface effect of the reinforced pre-formed substrate. The step of forming the compression-formed structure may include forming the reinforcement and the pre-formed substrate as generally continuous surfaces. The base layer for the pre-formed substrate may include a fiber pad. The base layer may include a generally rigid fiber pad. The step of forming the compression-formed structure may include forming the base layer into a generally rigid form. The surface effect of the panel assembly may include the generally rigid form of the base layer of the compression-formed structure. The surface effect of the panel assembly may include a generally smooth texture and a generally rigid form. The generally smooth texture of the panel assembly may be provided by (a) the surface effect of the cover and (b) the surface effect of the pre-formed substrate. The cover of the panel assembly may include at least one of the following: (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite material of a plastic layer and a textile backing; (e) coated fabric; (f) polyvinyl chloride coated fabric; (g) woven fabric; (h) nonwoven fabric; (i) appliqué; (j) vinyl; (k) foil. The compression-formed structure may include a shape. The panel assembly may at least partially include the shape of the compression-formed structure. The shape may include a first profile provided by a first surface of the mold and a second profile provided by a second surface of the mold. The base layer for the pre-formed substrate may include a fiber pad. The method may include the step of forming a pre-formed substrate from a generally compressible fiber pad. The pre-formed substrate may comprise natural fibers and resin. The resin may comprise polypropylene and the natural fibers may comprise at least one of: (a) flax; (b) kenaf. The pre-formed substrate may comprise an area weight between 1000 g / m² and 1800 g / m².The pre-formed substrate may have a thickness between 1.5 mm and 4 mm; the compression-formed structure may have a thickness between 0.8 mm and 3 mm. The method may include the step of heating the pre-formed substrate; the pre-formed substrate may be compressed as it cools. The method may include the step of injecting resin into the mold after forming the compression-formed structure to form auxiliary components of the panel assembly.

[0007] This invention relates to a component for a vehicle interior configured to support an airbag module, the airbag module being configured to allow airbag deployment via an airbag slide through a door, the door providing an opening for the airbag into the vehicle interior. The component includes a composite structure comprising a structural base formed of a fiber panel and a cover for the structural base, the cover providing an outer surface. The structural base may include a stitch pattern. The composite structure is configured such that when the airbag deploys from the airbag assembly, the stitch pattern reinforces the door, thereby providing the opening through which the airbag can deploy, while the door remains at least partially attached to the composite structure. The reinforcement may include a group of wires. The stitch pattern may provide reinforcement at the hinge area of ​​the door. The stitch pattern may include a group of wires. The group of wires for the stitch pattern may include a first group of wires and a second group of wires. The group of wires for the stitch pattern may include an upper group of wires and a lower group of wires. The upper group of wires may include a retaining group of wires, and the lower group of wires may include a sacrificial group of wires. The thread group for the stitch pattern may include a retaining thread group configured to be stretched and a sacrificial thread group configured to break. The door can be held at least partially attached to the composite structure by the retaining thread group. The retaining thread can provide reinforcement for the door. The sacrificial thread can be configured to break when the airbag forms a door and opening in the composite structure. The thread group for the stitch pattern may include an upper thread group and a lower thread group; the upper thread can provide a hinge for the door; the lower thread may include a sacrificial thread configured to break when the airbag establishes an opening in the composite structure. The stitch pattern may be disposed on a fiber panel. The stitch pattern may be formed in the structural substrate. The stitch pattern may be formed in the structural substrate such that the stitch pattern is not visible on the outer surface of the cover. The stitch pattern may include a mesh of threads in the fiber panel formed in the structural substrate. The reinforcement provided by the stitch pattern may include reinforcement for the composite structure. The stitch pattern may include a first thread group having a first thread weight and a second thread group having a second thread weight; the first thread weight may be greater than the second thread weight. The stitch pattern may include a retaining thread group of 210 Tex threads and a sacrificial thread group of 70 Tex threads. The retaining thread group is configured to stretch as the airbag deploys through the door for the composite structure. The stitch pattern may include thread groups at least partially sewn into a fiber panel of the structural substrate. The thread groups of the stitch pattern may be pressed into the surface of the fiber panel. The thread groups of the stitch pattern may be pressed into the surface of the fiber panel such that the structural substrate may include a generally flat surface for the cover. The thread groups of the stitch pattern may be pressed into the surface of the fiber panel such that the thread groups are not visible on the outer surface of the cover of the composite structure. The reinforcement may include bonded nylon thread.The reinforcing member may include a group of threads for the stitch pattern, comprising at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fiber, (g) polymer fiber, and (h) synthetic fiber. The member may further include a notch in the structural substrate, the notch being configured to facilitate the creation of an opening for the airbag through the composite structure. The structural substrate may be formed into a shape. The member may further include a feature on the structural substrate. The feature may include an airbag groove. The feature may include a resin-formed feature molded on the structural substrate. The feature may include at least one of the following: (a) the airbag groove; (b) a channel for the airbag; (c) a rib; (d) a set of ribs; (e) a feature adjacent to the reinforcement; (f) a feature at the reinforcement; (g) a feature at the hinge region; (h) a feature at the opening; (i) a feature configured to facilitate the opening; (j) a structure for the door; (k) a set of ribs configured to create a slit for the door; (l) a structure for a double door including the door; (m) the airbag groove at the hinge region; (n) a resin-formed feature. The door may include a double door; the feature may include a slit to facilitate the formation of a double door. The door may include a double door providing an opening for the airbag; the reinforcement may include a hinge region for each door of the double door. The composite structure may further include a foam layer beneath the cover. The reinforcement may include a hinge region configured for the door created by deploying the airbag through the airbag groove. The structural base may include a compression-formed component from the fiber panel. The structural base may include a generally rigid fiber pad. The cover may include at least one of the following: (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite material of a plastic layer and a textile backing; (e) coated fabric; (f) polyvinyl chloride coated fabric; (g) woven fabric; (h) nonwoven fabric; (i) appliqué; (j) vinyl; (k) foil; (l) a coating on the structural base; (m) a paint on the structural base; (n) the outer surface of the structural base. The component may include at least one of the following: a dashboard; a door panel; a trim panel; a decorative component.

[0008] This invention relates to a component for a vehicle interior, the component being configured to support an airbag module configured to allow airbag deployment via an airbag slide through a door, the door providing an opening for the airbag into the vehicle interior. The component includes a composite structure comprising a structural base formed of a fiber panel and a cover for the structural base, the cover providing an outer surface and features formed of resin on the structural base. The structural base may include a reinforcement configured such that the door, established by the deployment of the airbag, remains at least partially attached to the composite structure. The reinforcement may include a thread pattern configured such that when the airbag deploys from the airbag module, the door remains at least partially attached to the composite structure by at least a portion of the thread pattern. The thread pattern may include a first stitch pattern and a second stitch pattern. The thread pattern may include a group of stitches. The thread pattern may include a stitch mesh. The stitch mesh may include a hinge for the door; the stitch mesh for the reinforcement may include a retaining thread group and a sacrificial thread group. The thread pattern for the reinforcement may include a first thread group and a second thread group. The line pattern for the reinforcement may include a retaining line group and a sacrificial line group. The line pattern for the reinforcement may include a strong line group and a weak line group. The line group for the reinforcement may include a retaining line group and a sacrificial line group; the retaining line group may be configured to include the reinforcement after the airbag deploys. The reinforcement may include a hinge area for the door. The reinforcement may include a hinge for the door. The feature may include a resin-formed feature molded on the structural substrate. The feature may include an airbag groove. The resin-formed feature may include at least one of the following: (a) the airbag groove; (b) a channel for the airbag; (c) a rib; (d) a set of ribs; (e) a feature adjacent to the reinforcement; (f) a feature at the reinforcement; (g) a feature at the hinge area; (h) a feature at the opening; (i) a feature configured to facilitate opening; (j) a structure for the door; (k) a set of ribs configured to create a gap for the door; (i) a double-door structure including the door.

[0009] This invention relates to a trim component for a vehicle interior, configured to support an airbag module that provides an airbag for deployment through an opening into the vehicle interior. The trim component is prepared using a mold by a method comprising the steps of: providing a pre-formed base; joining a reinforcement to the pre-formed base in at least one hinge region to form a reinforced pre-formed base; arranging the reinforced pre-formed base on a first surface of the mold; and compressing the reinforced pre-formed base between the first and second surfaces of the mold to form the reinforced pre-formed base into a structural base with a shape. This shape may correspond to a first profile of the first surface and a second profile of the second surface. The structural base may be configured to provide at least one door that is established upon airbag deployment to allow the airbag to deploy from the airbag module through the opening. The reinforcement may be configured to secure the at least one door to the structural base during airbag deployment. The step of joining the reinforcement to the pre-formed base may include sewing at least one of thread or stitch to the pre-formed base. At least one of the thread or the pin may be composed of at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) ceramic fiber, (f) polymer fiber, (g) synthetic fiber. The step of attaching the reinforcement to a pre-formed substrate may include piercing an opening in the pre-formed substrate and attaching a top pin to a bottom pin at the opening in the pre-formed substrate. The top pin may include thread weight, and the bottom pin may also include thread weight; the thread weight of the top pin may generally be greater than that of the bottom pin. The method may include the step of forming a recess in the surface of at least one of the pre-formed substrates; a structural substrate; the recess may be configured to facilitate the deployment of the airbag.

[0010] This invention relates to a method of manufacturing a vehicle trim component configured to support an airbag module, the airbag module providing an airbag for deployment from the airbag module through an opening into the vehicle interior. The method includes the steps of: providing a pre-formed substrate; engaging a reinforcement member to the pre-formed substrate in at least one hinge region to form a reinforced pre-formed substrate; arranging the reinforced pre-formed substrate on a first surface of a mold; and compressing the reinforced pre-formed substrate between the first and second surfaces of the mold to form the reinforced pre-formed substrate into a structural substrate with a shape. This shape may correspond to a first profile of the first surface and a second profile of the second surface. The structural substrate may be configured to provide at least one door that is established upon airbag deployment to allow the airbag to deploy from the airbag module through the opening. The reinforcement member may be configured to secure the door to the structural substrate during airbag deployment.

[0011] This invention relates to a trim component for a vehicle interior, the trim component being configured to support an airbag slide and an airbag module, the airbag module providing an airbag configured to deploy into the vehicle interior through an opening. The component may include a structural base providing front, rear, and at least one door that is established upon airbag deployment to allow the airbag to deploy from the airbag module through the opening. The structural base may include a reinforcement configured to secure the door to the structural base during airbag deployment. The reinforcement may include at least one stitch. The reinforcement may be composed of at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fiber, (g) polymer fiber, (h) synthetic fiber. The structural base may include a panel at least partially composed of fibers. The reinforcement may include thread sewn onto the panel. The structural base may include a compression-formed component. The compression-formed component may include a recess in the back side of the structural base, configured to create the opening through which the airbag will deploy. The structural base may be at least partially formed of fibers. The decorative component may include a cover to provide a surface on the front side of the structural base. Contact between the airbag and the door may cause the cover to tear to create an opening for the airbag, facilitating its deployment.

[0012] This invention relates to a decorative component for a vehicle interior, configured to support an airbag module that provides an airbag for deployment through an opening into the vehicle interior, and is manufactured using a mold by a method. The method may include the steps of: providing a fiber panel; joining a reinforcement to the fiber panel in at least one hinge region to form a reinforced fiber panel; arranging the reinforced fiber panel on a first surface of the mold; compressing the reinforced fiber panel between the first and second surfaces of the mold to form the reinforced fiber panel into a shaped structural base and attaching a structure to one side of the structural base. This shape may correspond to a first profile of the first surface and a second profile of the second surface. The structural base may be configured to provide at least one door that is established upon airbag deployment, allowing the airbag to deploy from the airbag module through the opening. The structure may be configured to support the airbag module and guide the airbag toward the structural base to establish the opening and the door during airbag deployment. The reinforcement may be configured to secure the door to the structural base during airbag deployment. Attaching the reinforcement to the fiber panel may include sewing at least one of the following: thread; stitch. The thread; stitch may consist of at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) ceramic fiber, (f) polymer fiber, (g) synthetic fiber. Attaching the structure to one side of the structural substrate may include injecting resin into the mold. The method may include the step of forming a recess in at least one of the following surfaces: the fiber panel; the reinforced fiber panel; the recess may be configured to facilitate the deployment of the airbag.

[0013] This invention relates to a method of manufacturing a vehicle trim component configured to support an airbag module, the airbag module providing an airbag for deployment from the airbag module through an opening into the vehicle interior. The method may include the steps of: providing a fiber panel; joining a reinforcement to the fiber panel in at least one hinge region to form a reinforced fiber panel; arranging the reinforced fiber panel on a first surface of a mold; compressing the reinforced fiber panel between the first and second surfaces of the mold to form the reinforced fiber panel into a shaped structural base and attaching a structure to one side of the structural base. This shape may correspond to a first profile of the first surface and a second profile of the second surface. The structural base may be configured to provide at least one door that is established upon airbag deployment to allow the airbag to deploy from the airbag module through the opening. The structure may be configured to support the airbag module and guide the airbag toward the structural base to establish the opening and the door during airbag deployment. The reinforcement may be configured to secure the door to the structural base during airbag deployment. Attached Figure Description

[0014] Figure 1A This is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0015] Figure 1B This is a schematic perspective sectional view showing the interior of a vehicle according to an exemplary embodiment.

[0016] Figure 1C This is a schematic perspective view showing a vehicle trim component for a dashboard according to an exemplary embodiment.

[0017] Figures 1D to 1F This is a schematic detailed perspective view of the airbag deployment according to an exemplary embodiment.

[0018] Figure 2A This is a schematic perspective view showing a vehicle trim component for a dashboard according to an exemplary embodiment.

[0019] Figure 2B This is a schematic exploded perspective view showing a vehicle trim component of a dashboard according to an exemplary embodiment.

[0020] Figure 2C This is a schematic partial cross-sectional view showing a vehicle trim component for a dashboard according to an exemplary embodiment.

[0021] Figures 3A to 3F This is a schematic perspective view of a method for forming a reinforced fiber panel according to an exemplary embodiment.

[0022] Figures 4A to 4CThis is a schematic perspective view of a method for forming a structural substrate from a reinforced fiber panel according to an exemplary embodiment.

[0023] Figure 4D It is a schematic perspective cross-sectional view of the structural base according to an exemplary embodiment.

[0024] Figures 4E to 4F This is a schematic perspective cross-sectional view of a decorative component for the interior of a vehicle, according to an exemplary embodiment.

[0025] Figure 5A This is a schematic perspective view of the structural base according to an exemplary embodiment.

[0026] Figure 5B This is a schematic partial perspective view of the structural base according to an exemplary embodiment.

[0027] Figure 5C This is a schematic partial plan view of a reinforcement member for a structural substrate according to an exemplary embodiment.

[0028] Figures 6A to 6C This is a schematic partial cross-sectional view of a method for forming a structural substrate with an airbag groove from a reinforced fiber panel according to an exemplary embodiment.

[0029] Figures 7A to 7E This is a schematic partial cross-sectional view illustrating a method for forming a vehicle interior component of an instrument panel according to an exemplary embodiment.

[0030] Figure 7F This is a schematic partial cross-sectional view showing a vehicle trim component for a dashboard according to an exemplary embodiment.

[0031] Figure 8A This is a schematic partial cross-sectional view showing a vehicle trim component for a dashboard according to an exemplary embodiment.

[0032] Figures 8B to 8D This is a schematic partial cross-sectional view of the airbag deployment according to an exemplary embodiment.

[0033] Figure 8E This is a schematic partial perspective view showing a vehicle trim component of a dashboard according to an exemplary embodiment.

[0034] Figures 9A to 9C This is a partial schematic cross-sectional view of a decorative component for the interior of a vehicle, according to an exemplary embodiment.

[0035] Figure 10A This is a schematic cross-sectional view of a decorative component for the interior of a vehicle, according to an exemplary embodiment.

[0036] Figure 10BThis is a schematic cross-sectional view of a decorative component for the interior of a vehicle, according to an exemplary embodiment.

[0037] Figures 10C to 10D This is a schematic cross-sectional view of the deployment of an airbag through a trim component for the interior of a vehicle, according to an exemplary embodiment.

[0038] Figure 11A This is a schematic flowchart of a method for forming interior components of a vehicle according to an exemplary embodiment.

[0039] Figure 11B This is a schematic flowchart of a method for forming interior components of a vehicle according to an exemplary embodiment.

[0040] Figure 12A and Figure 12B This is a schematic flowchart of a method for forming interior components of a vehicle according to an exemplary embodiment. Detailed Implementation

[0041] See Figure 1A and Figure 1B The image illustrates a vehicle V, which includes an interior I having an instrument panel IP, doors D, and a floor console FC. According to one exemplary embodiment, interior components of the vehicle V (e.g., the instrument panel IP and doors D) may include trim panels composed of fibers and plastics. According to an exemplary embodiment, the instrument panel IP and doors D may provide visible surfaces within the vehicle V's interior. According to one exemplary embodiment, the instrument panel IP and / or doors D may provide at least one airbag behind the visible surface; the instrument panel IP and / or doors D may provide a weakened area to assist the airbag in rupturing through the trim panel during airbag deployment. See also Figures 1D to 1F .

[0042] according to Figures 1C to 1F In the exemplary embodiment illustrated schematically, the dashboard IP may provide a weakened shape / area, shown as a recess R (e.g., line, scribbling, cut, notch, groove, discontinuity, interruption, etc.), to facilitate the deployment of airbag AB through airbag doors ABD. According to one exemplary embodiment, the weakened shape / area may include at least one of a recess or scribbling line behind a visible surface of the dashboard IP; as illustrated schematically, the weakened shape / area may include an "H" shaped pattern (e.g., corresponding to a door, double door, etc., for an airbag to form an airbag door in the panel). See also Figure 1C and Figure 1D-1F According to one exemplary embodiment, the weakened shape / area may include a "U" shaped pattern, a "bow" shaped pattern, or any pattern suitable for airbag deployment.

[0043] According to exemplary embodiments schematically illustrated in 2A-2C, 3A-3F, 4A-4F, 5A-5C, 6A-6C, 7A-7F, 8A-8E, 9A-9C, 10A-10D, 11A-11B, and 12A-12B, a decorative component 1000 can be provided for the interior of a vehicle. This component 1000 (e.g., a composite structure) can be configured to support an airbag channel and an airbag module providing an airbag configured to deploy into the vehicle interior through an opening. The component 1000 (e.g., a composite structure / panel, etc.) may include a structural base 210 providing at least one door established upon airbag deployment to allow the airbag to deploy from the airbag module through the opening. See also Figure 1C-1F And 2A-2C. The structural base 210 may include a reinforcement T (shown as including a line pattern, line group / mesh, etc.) configured to secure at least one door to the structural base 210 during airbag deployment. See, for example... Figure 1C-1F 2B and 8A-8E. The reinforcing member T may include a pin arrangement (e.g., at least one pin, a group of pins, a pin pattern, etc.). As schematically shown according to exemplary embodiments in 2B-2C, 3D-3F, 4C, 5A-5C and 7A-7F, the reinforcing member T may include a top pin TS and a bottom pin BS (e.g., in a pattern including pins, a pin mesh, etc.). See also 2B-2C, 3D-3F, 4C, 5A-5C and 7A-7F. Figures 8A-8E According to an exemplary embodiment, the top pin TS may include thread weight, and the bottom pin BS may include thread weight; the thread weight of the top pin TS can generally be greater than the thread weight of the bottom pin BS; for example, the top pin TS may contain 210 Tex thread; the bottom pin BS may contain 70 Tex thread. Figures 8A-8E As schematically shown, the bottom pin BS is configured to separate upon airbag deployment to allow the airbag to deploy through the opening from the airbag module; the top pin TS is configured to secure the door to the structural base 210 upon airbag deployment. The top pin TS is also configured to stretch upon airbag deployment to secure the door to the structural base 210. The reinforcement T may consist of bonded nylon thread and / or at least one of the following thread materials: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fiber, (g) polymer fiber, (h) synthetic fiber.

[0044] According to Figure 2A-2C and Figures 3A-3F The exemplary embodiments shown schematically depict structural base 210 of a component (e.g., a composite structure) may include a panel at least partially composed of fibers; the reinforcement T may be formed by lines sewn onto the panel (see [reference]). Figure 3D-3F According to Figures 6A-6C and Figures 7A-7CThe exemplary embodiments shown schematically illustrate that the lines / reinforcements T (e.g., pin assemblies, pin patterns / mesh, etc.) can be pressed into the surface of the panel during compression molding. See also Figures 4A-4C For example, in Figures 7D-7E As schematically shown, the panel may include a recess 210d; the line / pattern (e.g., a reinforcement) may be joined to the panel in the recess 210d; the line / pattern and the panel may form a generally continuous surface 1000s for the decorative component 1000.

[0045] According to Figures 4A-4D As schematically indicated in the exemplary embodiments in 6A-6C and 7A-7C, the structural base 210 may include a compression-formed component for a part / decorative part (e.g., a composite structure). As schematically shown, the compression-formed component may include a recess 210r in the back side 210b of the structural base 210, configured to create an opening such that an airbag will deploy through the compression-formed component at the opening. See, for example... Figure 1C-1F And 7A-7C. For example, in Figures 3A-3F As schematically shown in 4A-4D, 6A-6C, 7A-7C, and 8A-8E, the structural substrate 210 for the component can be at least partially formed of fibers (e.g., provided as fiber mats, fiber panels, fiber webs, etc.). As schematically shown, the structural substrate 210 for the composite structure may include a generally rigid fiber mat. See also Figures 3A-3F 4A-4D, 6A-6C and 7A-7C.

[0046] According to Figure 1C-1F As schematically shown in the exemplary embodiments in 7D, the decorative component 1000 may further include a cover C to provide a surface on the front side 210f of the structural base 210; the cover C may include at least one of the following: (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite material of a plastic layer and a textile backing; (e) coated fabric; (f) polyvinyl chloride coated fabric; (g) woven fabric; (h) nonwoven fabric; (i) appliqué; (j) vinyl; (k) foil.

[0047] According to Figures 8A-8E The exemplary embodiments illustrated herein show that, during operation of the airbag and trim member, contact between the airbag and at least one door can cause a tear in the cover C to create an opening for the airbag and facilitate the deployment of the airbag through the opening in the trim member (e.g., via a composite structure); the airbag groove can be configured to define / provide at least one hinge region H for the at least one door; a reinforcement T can be positioned adjacent to the hinge region. See, for example... Figures 5A-5C .

[0048] According to such Figure 2A-2CThe exemplary embodiments schematically shown in 3A-3F, 4A-4F, 5A-5C, 6A-6C, 7A-7F, 8A-8E, 9A-9C, 10A-10D, 11A-11B, and 12A-12B can be used to produce vehicle interior components 1000 in a mold M including a first surface and a second surface by including: placing a pre-formed substrate 210 / 202r on the first surface of the mold; forming a compressed structure / structural substrate 210 from the pre-formed substrate 210 / 202r by compressing the pre-formed substrate 210 / 202r between the first surface and the second surface of the mold; and applying a cover C to the compressed structure 210 to form a panel assembly 210 / C that provides a surface effect. Figures 4A-4C The pre-formed substrate 210 / 202r, schematically shown for the composite structure of the component, may include a reinforced pre-formed substrate (e.g., having reinforcements via thread / stitch patterns, mesh, rope, chain, etc.); the reinforcement T may include thread / material, such as at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fiber, (g) polymer fiber, (h) synthetic fiber. The pre-formed substrate may include a panel at least partially composed of fibers; the reinforcement T may consist of thread sewn onto the panel. See, for example... Figures 3A-3F As schematically illustrated, the compression-formed structure may include a base layer and a reinforcing member T. See, for example... Figures 4A-4D The reinforced pre-formed substrate may include a surface effect comprising an generally smooth texture; the surface effect of the panel assembly may generally include the surface effect of the reinforced pre-formed substrate; the step of forming the compression-formed structure may include forming the reinforcing member T and the pre-formed substrate as generally continuous surfaces 210s. See, for example... Figures 7A-7C The base layer for the pre-formed substrate may include a fiber mat; the base layer may include a generally rigid fiber mat; the step of forming the compression-formed structure may include forming the base layer into a generally rigid form; the surface effect of the panel assembly may include the generally rigid form of the base layer of the compression-formed structure. See, for example... Figures 3A-3F and Figures 4A-4D For example, in Figures 6A-6C and Figures 7A-7F As schematically illustrated, the surface effects of a panel assembly can include an overall smooth texture and an overall rigid form; the overall smooth texture of the panel assembly can be provided by (a) the surface effect of the cover C and (b) the surface effect of the pre-formed substrate. See also Figure 1C-1FAccording to an exemplary embodiment, the cover C of the panel assembly may include at least one of the following: (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite material of a plastic layer and a textile backing; (e) coated fabric; (f) polyvinyl chloride coated fabric; (g) woven fabric; (h) nonwoven fabric; (i) appliqué; (j) vinyl; (k) foil. Figure 1C and 4C As schematically indicated, the compression-formed structure may include a shape; the panel assembly may at least partially include the shape of the compression-formed structure; the shape may include a first profile provided by a first surface of the mold and a second profile provided by a second surface of the mold. See, for example... Figures 4A-4C 6A-6C and 7A-7F. As schematically shown, the base layer for the pre-formed substrate may include a fiber pad; the method may include the step of forming the pre-formed substrate from a generally compressible fiber pad. See, for example... Figures 3A-3F 4A-4D, 6A-6C, and 7A-7F. According to an exemplary embodiment, the pre-formed substrate may include natural fibers and resin; the resin may comprise polypropylene; the natural fibers may include at least one of: (a) flax; (b) kenaf. According to an exemplary embodiment, the pre-formed substrate may include an area weight between 1000 g / m² and 1800 g / m²; the pre-formed substrate may include a thickness between 1.5 mm and 4 mm; the compression-formed structure may include a thickness between 0.8 mm and 3 mm. The method may include the step of heating the pre-formed substrate; compressing the pre-formed substrate as it cools; the method may include the step of injecting resin into the mold after forming the compression-formed structure to form auxiliary components of the panel assembly. See, for example... Figure 11A-11B And 12A-12B.

[0049] according to Figure 2A-2CExemplary embodiments schematically illustrated in 3A-3F, 4A-4F, 5A-5C, 6A-6C, 7A-7F, 8A-8E, 9A-9C, 10A-10D, 11A-11B, and 12A-12B represent a component for a vehicle interior configured to support an airbag module. The airbag module is configured to allow airbag deployment via an airbag slide through a door that provides an opening for the airbag into the vehicle interior. The component may include a composite structure comprising a structural base 210 formed of a fiber panel and a cover C for the structural base 210, the cover providing an outer surface. The structural base 210 may include a stitch pattern. The composite structure is configured such that when the airbag deploys from the airbag assembly, the stitch pattern provides a reinforcement T to the door providing the opening, allowing the airbag to deploy through the opening while the door remains at least partially attached to the composite structure. See, for example... Figure 1C-1F 2A-2C, 8A-8E, and 9A-9C. As per... Figure 2B , 3D Exemplary embodiments in -3F, 4A-4D, 5A-5C, 7A-7F, 8A-8E, and 9A-9C are schematically illustrated, in which the reinforcement T may include groups of threads (e.g., stitch patterns, stitch meshes, etc.); the stitch pattern may provide reinforcement T at the hinge region H of the door; the stitch pattern may include groups of threads (e.g., patterns / meshes). As schematically illustrated, the groups of threads for the stitch pattern may include a first group of threads and a second group of threads; the groups of threads for the stitch pattern may include an upper group of threads and a lower group of threads; the upper group of threads may include a retaining group of threads, and the lower group of threads may include a sacrificial group of threads. See, for example... Figure 2B , 3D -3F, 5A-5C, and 8A-8E / 9A-9C. As schematically indicated, the thread set for the stitch pattern may include a retaining thread set configured to stretch and a sacrificial thread set configured to break; the door may be held at least partially attached to the composite structure by the retaining thread set; the retaining thread may provide a reinforcement T for the door; the sacrificial thread may be configured to rupture when the airbag establishes a door and opening in the composite structure. See, for example... Figure 2B , 3D -3F, 5A-5C, and 8A-8E / 9A-9C. According to an exemplary embodiment, the thread groups for the stitch pattern may include upper thread groups and lower thread groups; the upper thread may provide a hinge for the door; these lower threads may include sacrificial threads configured to rupture when the airbag establishes an opening in the composite structure. See, for example... Figures 8A-8EAs schematically shown according to an exemplary embodiment, a stitch pattern may be provided on the fiber panel; the stitch pattern may be formed in the structural substrate 210; the stitch pattern may be formed in the structural substrate 210 such that the stitch pattern is not visible on the outer surface of the cover C; the stitch pattern may include a mesh of lines in the fiber panel formed in the structural substrate 210. See also Figure 2B , 5A -5C and 7A-7F. (As in...) Figures 8A-8E As schematically illustrated, the reinforcement T provided by the stitch pattern may include a reinforcement for the composite structure; the stitch pattern may include a first group of threads having a first thread weight and a second group of threads having a second thread weight; the first thread weight may be greater than the second thread weight. According to an exemplary embodiment, the stitch pattern may include a retaining group comprising 210 Tex threads and a sacrificial group comprising 70 Tex threads. As schematically shown, the retaining group of threads may be configured to stretch as the airbag deploys through the door for the composite structure; the stitch pattern may include a group of threads at least partially sewn into the fiber panel of the structural substrate 210; the group of threads of the stitch pattern may be pressed into the surface of the fiber panel; the group of threads of the stitch pattern may be pressed into the surface of the fiber panel such that the structural substrate 210 may include a generally flat surface for the cover C; the group of threads of the stitch pattern may be pressed into the surface of the fiber panel such that the group of threads is not visible at the outer surface of the cover C of the composite surface. See, for example... Figures 3A-3F 4A-4D and 7A-7F. According to an exemplary embodiment, the reinforcing member T may include bonded nylon thread; the thread set for the stitch pattern includes at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fiber, (g) polymer fiber, (h) synthetic fiber. According to an exemplary embodiment, the component may further include a notch (e.g., recess, interruption, line, scribe line, etc.) in the structural base 210, the notch being configured to facilitate the creation of an opening for an airbag through the composite structure. Figures 4A-4F As schematically shown, a structural base 210 for a component (e.g., a composite structure) can be formed into a shape; the component may further include features on the structural base 210. (As illustrated in...) Figure 4E-4F As schematically shown, the feature may include an airbag groove and / or a resin-formed feature 220 molded on the structural substrate 210. See also Figures 6A-6CAnd 7A-7F. According to an exemplary embodiment, the feature may include at least one of the following: (a) the airbag groove; (b) a channel for the airbag; (c) a rib; (d) a set of ribs; (e) a feature T adjacent to the reinforcement; (f) a feature at the reinforcement T; (g) a feature at the hinge region; (h) a feature at the opening; (i) a feature configured to facilitate opening; (j) a structure for a door; (k) a set of ribs configured to create a slit for the door; (l) a double-door structure including the door; (m) an airbag groove at the hinge region; (n) a resin-formed feature. As schematically shown, door ABD may include a double door; the feature may include a slit to facilitate the formation of a double door; the door may include a double door providing an opening for the airbag; the reinforcement T may include a hinge region for each door of the double door. See, for example Figure 1C-1F 8A-8E and 9A-9C. As per... Figures 9A-9C As illustrated in the exemplary embodiments, the composite structure may further include a foam layer F beneath the cover C; the reinforcement T may include a hinge region configured to create a door by deploying the airbag via an airbag groove; the structural base 210 may include a compression-formed component from the fiber panel; the structural base 210 may include an generally rigid fiber pad. See also Figures 5A-5C And 8A-8E. According to an exemplary embodiment, the cover C may include at least one of the following: (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite material of a plastic layer and a textile backing; (e) a coated fabric; (f) a polyvinyl chloride coated fabric; (g) a woven fabric; (h) a nonwoven fabric; (i) an appliqué; (j) a vinyl; (k) a foil; (i) a coating on the structural substrate 210; (m) a paint on the structural substrate 210; (n) an outer surface of the structural substrate 210. According to an exemplary embodiment, the component may include at least one of the following: a dashboard; a door panel; a trim panel; a trim component. See, for example, Figure 1A-1F .

[0050] according to Figure 2A-2CExemplary embodiments schematically illustrated in models 3A-3F, 4A-4F, 5A-5C, 6A-6C, 7A-7F, 8A-8E, 9A-9C, 10A-10D, 11A-11B, and 12A-12B provide a component for a vehicle interior configured to support an airbag module configured to allow airbag deployment via an airbag slide through a door, the door providing an opening for access to the airbag within the vehicle interior. The component may include a composite structure comprising a structural base 210 formed of a fiber panel and a cover C for the structural base 210, the cover providing an outer surface and features formed of resin on the structural base 210. The structural base 210 may include a reinforcement T; the reinforcement T may be configured such that the door established by airbag deployment remains at least partially attached to the composite structure. As schematically illustrated according to an exemplary embodiment, the reinforcement T may include a line pattern; the line pattern may be configured such that when the airbag deploys from the airbag module, the door is at least partially attached to the composite structure by at least a portion of the line pattern; the line pattern may include a first pin pattern and a second pin pattern; the line pattern may include pin groups; the line pattern may include a pin mesh; the pin mesh may include a hinge for the door; the pin mesh for the reinforcement T may include retaining line groups and sacrificial line groups; the line pattern for the reinforcement T may include a first line group and a second line group; the line pattern for the reinforcement T may include retaining line groups and sacrificial line groups; the line pattern for the reinforcement T may include strong line groups and weak line groups; the line group for the reinforcement T may include retaining line groups and sacrificial line groups; the retaining line group may be configured to include the reinforcement T after the airbag deploys. See also Figure 1C-1D , 2C, 3D-3F, 4A-4D, 5A-5C, 6A-6C, 7A-7F, 8A-8E, 9A-9C and 10A-10D.

[0051] As schematically shown, the reinforcement T may include a hinge area for the door; the reinforcement T may include a hinge for the door. See, for example... Figures 8A-8E 9A-9C and 10A-10D. According to an exemplary embodiment, the feature may include a resin-formed feature molded on the structural substrate 210; the feature may include an airbag groove (as shown in feature 100 and / or 220r); the resin-formed feature may include at least one of the following: (a) the airbag groove; (b) a channel for the airbag; (c) a rib; (d) a set of ribs; (e) a feature adjacent to the reinforcement T; (f) a feature at the reinforcement T; (g) a feature at the hinge region; (h) a feature at the opening; (i) a feature configured to facilitate opening; (j) a structure for a door; (k) a set of ribs configured to create a slit for the door; (i) a double-door structure including the door. See, for example Figure 1C-1D, 2C, 3D-3F, 4A-4D, 5A-5C, 6A-6C, 7A-7F, 8A-8E, 9A-9C and 10A-10D.

[0052] According to Figure 1C-1F Exemplary embodiments in 6A-6C, 7A-7F, 8A-8E, 9A-9C, and 10A-10D schematically illustrate that reinforcements for the structural substrate / fiber panel of the composite structure / component (e.g., configured for airbag deployment from an airbag groove through an opening established in the composite structure / component) may be provided with a line pattern / arrangement T (e.g., including top and bottom lines shown as reinforcement / line patterns). Comparison Figures 8A-8E (Pattern with reinforcing member T featuring top line TS and bottom line BS) and Figures 9A-9C (A pattern of a composite structure with a foam layer and reinforcing / line pattern T). According to... Figures 3A-3F The exemplary embodiments schematically shown in 4A-4D and 5A-5C provide a fiberboard 202 (e.g., formed pad / board / liner, bulky pad / board / liner, uncompressed pad / liner, woven pad / liner, nonwoven pad, pre-formed pad, compressed pad, etc.) for forming a reinforcement / thread pattern T (e.g., by stitching, sewing, etc. of the thread / fiber). Figures 8A-8E The schematic diagram illustrates how the reinforcing / line pattern T for the composite structure / component helps the airbag AB deploy into the vehicle interior; the top line TS stretches and maintains the connection (e.g., at the opening / door created by the airbag deployment); and the bottom line BS tears / ruptures (e.g., stretching / releasing / separating). (Comparison) Figures 9A-9C (A composite structure having a foam layer and corresponding reinforcements). According to an exemplary embodiment, the reinforcement / line pattern may include lines arranged with variations in pattern / stitch or material or thickness / size, such as variations in strength, variations in Tex values ​​(ranging from 70 Tex to 210 Tex), variations in density, variations in performance / properties, etc.; for example, the reinforcement / line pattern may be configured with tearable / separable top stitches and stretchable / retainable bottom stitches (e.g., a heavy bottom line), or configured with an integral pattern of lines / multi-lines that can exhibit appropriate variations in strength / performance during airbag deployment from the airbag groove / module through the composite structure / component. See, for example... Figure 1C-1F 8D-8E and 9A-9C.

[0053] according to Figure 2A-2CExemplary embodiments schematically illustrated in 3A-3F, 4A-4F, 5A-5C, 6A-6C, 7A-7F, 8A-8E, 9A-9C, 10A-10D, 11A-11B, and 12A-12B provide a decorative component for a vehicle interior configured to support an airbag module that provides an airbag to deploy through an opening into the vehicle interior. This component can be prepared using a mold by a method comprising the steps of: providing a pre-formed substrate; joining a reinforcement T to the pre-formed substrate in at least one hinge region to form a reinforced pre-formed substrate; arranging the reinforced pre-formed substrate on a first surface of the mold; and compressing the reinforced pre-formed substrate between the first and second surfaces of the mold to form the reinforced pre-formed substrate into a structural substrate 210 having a shape. According to the exemplary embodiment shown schematically, the shape of the composite structure / decorative component 1000 may correspond to a first profile of a first surface and a second profile of a second surface; the structural base 210 for the composite structure may be configured to provide at least one door that is established during airbag deployment, allowing the airbag to deploy from the airbag module through the opening; the reinforcing member T for the composite structure may be configured to secure at least one door to the structural base 210 during airbag deployment. See also Figure 1C-1F 2C, 4A-4C, and 6A-6C. According to an exemplary embodiment, the step of joining the reinforcement T to a pre-formed substrate may include sewing at least one of the following: thread; at least one of the following: stitch; the thread or the stitch may be composed of at least one of: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) ceramic fiber, (f) polymer fiber, (g) synthetic fiber. According to an exemplary embodiment, the step of joining the reinforcement T to a pre-formed substrate may include piercing an opening in the pre-formed substrate and joining a top stitch TS to a bottom stitch BS at the opening; the top stitch TS may include thread weight, and the bottom stitch BS may include thread weight; the thread weight of the top stitch TS may generally be greater than the thread weight of the bottom stitch BS. According to an exemplary embodiment, the method may include the step of forming a recess in the surface of at least one of the pre-formed substrates; structural substrate 210; the recess may be configured to facilitate the deployment of the airbag.

[0054] according to Figure 2A-2CExemplary embodiments schematically illustrated in 3A-3F, 4A-4F, 5A-5C, 6A-6C, 7A-7F, 8A-8E, 9A-9C, 10A-10D, 11A-11B, and 12A-12B illustrate a method for producing / manufacturing a vehicle trim component configured to support an airbag module that provides an airbag for deployment from the airbag module through an opening into the interior of the vehicle. The method may include the steps of: providing a pre-formed substrate; engaging a reinforcement T to the pre-formed substrate in at least one hinge region to form a reinforced pre-formed substrate; arranging the reinforced pre-formed substrate on a first surface of a mold; and compressing the reinforced pre-formed substrate between the first and second surfaces of the mold to form the reinforced pre-formed substrate into a structural substrate 210 having a shape. This shape may correspond to a first profile of the first surface and a second profile of the second surface. The structural base 210 may be configured to provide at least one door that is established upon airbag deployment, allowing the airbag to deploy from the airbag module through the opening. The reinforcement T may be configured to secure the door to the structural base 210 during airbag deployment.

[0055] according to Figure 11A The exemplary embodiment shown in the diagram illustrates a method for manufacturing a vehicle trim component 1000 that may include the following steps: providing a base layer (e.g., a fiber pad, etc.) as a base for a pre-formed substrate; forming the pre-formed substrate (e.g., consolidation, compression, merging / fusion, heating / melting, shaping, cutting / sizing, etc.); joining a reinforcement to the pre-formed substrate; pre-treating / heat-strengthening the pre-formed substrate; forming a structural substrate (e.g., a compression / molding-strengthening pre-formed substrate); applying a cover to the structural substrate; and trimming / providing a panel assembly (with a cover on the structural substrate).

[0056] according to Figure 11B The exemplary embodiment shown schematically illustrates a method for manufacturing a vehicle trim component 1000 that may include the following steps: providing a base layer (e.g., a fiber pad, etc.) as a base for a pre-formed base; forming the pre-formed base (e.g., consolidation, compression, merging / fusion, heating / melting, shaping, cutting / sizing, etc.); joining a reinforcement to the pre-formed base; pre-treating / heat-strengthening the pre-formed base; forming a structural base (e.g., a compression / molding-strengthening pre-formed base); joining / forming an airbag groove to / on the structural base; applying a cover to the structural base; and trimming / providing a panel assembly (with a cover on the structural base).

[0057] according to Figure 12A and 12BThe exemplary embodiment shown schematically illustrates a method for manufacturing a vehicle trim component 1000 that may include the following steps: providing a pre-formed substrate, piercing an opening in the pre-formed substrate and engaging a top pin to a bottom pin at the opening, pre-treating / heating the pre-formed substrate having top and bottom pins, compressing / molding / forming the pre-formed substrate and pressing the top and bottom pins into the pre-formed substrate to form a structural substrate, applying a cover to the structural substrate, and trimming / providing a panel assembly (with a cover on the structural substrate).

[0058] Exemplary embodiments

[0059] according to Figure 3A The exemplary embodiment shown schematically may include a fiber mat 202u comprising a combination of fibers (e.g., natural and / or synthetic fibers) and thermoplastic resins (e.g., polypropylene (PP), acrylonitrile-butadiene-styrene (ABS), polycarbonate (PC), etc.). Figure 3B In the exemplary embodiment illustrated schematically, the fiber mat 202u can be trimmed to have a thickness, forming a fiber mat 202t. According to the exemplary embodiment, the fiber mat 202t can be heated to cause liquefaction of the thermoplastic resin. According to... Figure 3C In the exemplary embodiment schematically shown, the heated fiber pad 202t can be partially compressed into the fiber panel 202, the thickness of which is less than the thickness of the fiber pad 202t. Figures 3D to 3F The exemplary embodiments illustrated herein include a reinforcing member T comprising at least one of (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) yarn, (f) ceramic fiber, (g) polymer fiber, (h) synthetic fiber, and (i) stitch, which may be sewn onto the fiber panel 202 to form a reinforced fiber panel 202r.

[0060] according to Figure 4A In the exemplary embodiment illustrated schematically, the reinforced fiber panel 202r can be heated in an oven OV. Figure 4B As schematically shown, a heated reinforced fiber panel 202r can be transferred into a mold having a mold top MT and a mold bottom MB. According to... Figure 4C and Figure 4DThe exemplary embodiment shown schematically illustrates that the component representing the dashboard base 200 can be manufactured by compressing a heated, reinforced fiber panel 202r to form a structural base 210 and injection molding resin onto the compressed, heated, reinforced fiber panel 202r. In this method, recesses 210r can be formed in the structural base 210. These recesses can define a door to be established during airbag deployment, allowing the airbag to deploy from the airbag module through an opening. A reinforcement T can be configured to secure the door to the structural base 210 during airbag deployment.

[0061] according to Figure 4E and 4F In the exemplary embodiment schematically shown, the instrument panel base 200 may have features, shown as plastic ribs 220, provided on the back side of the structural base 210 to improve the structural integrity and rigidity of the structural base 210. The structural base 210 may be configured to support the airbag groove 100 and the airbag module including the airbag. Figure 10A As schematically illustrated, the plastic rib 220 may include a reinforcement 220r to provide structural support; the plastic rib 220 may include a boundary 220b to provide reinforcement and / or dimensional accuracy to the structural base 210. According to an exemplary embodiment, the plastic rib 220 may be placed at any location on the structural base 210 (e.g., along the edge of the structural base 210, in the middle of the structural base 210, etc.). According to an exemplary embodiment, multiple plastic ribs 220 may be placed at various different locations on the structural base 210. According to an exemplary embodiment, the plastic rib 220 can improve the structural integrity of the dashboard base 200. According to an exemplary embodiment, the dashboard base 200 is capable of maintaining structural integrity during airbag deployment; the location / arrangement of the plastic ribs 220 can be used to create strength differences between different areas of the dashboard base 200; the energy required for the airbag to penetrate the vehicle interior components 1000 can be directed to the recess 210r of the structural base 210; during airbag deployment, the plastic rib 220 can prevent or minimize tearing or ripping of the structural base 210 at any location other than the recess 210r. Figure 4F In the exemplary embodiment illustrated schematically, the plastic rib 220 may be formed in a honeycomb pattern to improve structural integrity and rigidity. According to one exemplary embodiment, the plastic rib 220 may be formed in any configuration depending on the specific application (e.g., for attaching auxiliary features such as vents, speakers, or infotainment systems).

[0062] according to Figure 10A-10DThe exemplary embodiment shown schematically illustrates that a trim component 1000 for a vehicle interior may be configured to support an airbag slide and an airbag module providing an airbag AB configured to deploy into the vehicle interior through an opening. The trim component 1000 may include a structural base 200 providing a front side, a rear side, and at least one door established upon airbag AB deployment to allow airbag AB to deploy from the airbag module through the opening. The structural base 200 may include a reinforcement T configured to secure the door to the structural base 200 during airbag AB deployment. The reinforcement T may include at least one stitch. The reinforcement T may be composed of at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fiber, (g) polymer fiber, and (h) synthetic fiber. The structural base 200 may include a panel 202 at least partially composed of fibers. The reinforcement T may consist of thread sewn onto the panel 202. The structural base 200 may include a compression-formed component 210. The compression-formed component 210 may include a recess 210r in the back side of the structural base 200, configured to create an opening through which the airbag AB will deploy. The structural base 200 may be at least partially formed of fibers. The decorative component 1000 may include a cover C to provide a surface on the front side of the structural base 200. Contact between the airbag AB and the door may cause a tear in the cover C to create an opening for the airbag, facilitating the deployment of the airbag AB through this opening.

[0063] according to Figures 3A-3FThe exemplary embodiments schematically shown in 4A-4F and 10A-10D illustrate a trim component 1000 for a vehicle interior configured to support an airbag module that provides an airbag AB for deployment through an opening into the vehicle interior. This airbag module can be fabricated using a mold M by a method. The method may include the steps of: providing a fiber panel 202; joining a reinforcement T to the fiber panel 202 in at least one hinge region to form a reinforced fiber panel 202r; arranging the reinforced fiber panel 202r on a first surface of the mold M; compressing the reinforced fiber panel 202r between a first surface and a second surface of the mold M to form the reinforced fiber panel 202r into a structural base 200 having a defined shape; and attaching a structure 100 to one side of the structural base 200. This shape may correspond to a first profile of the first surface and a second profile of the second surface. The structural base 200 may be configured to provide at least one door that is established upon deployment of the airbag AB to allow the airbag AB to deploy from the airbag module through the opening. Structure 100 may be configured to support the airbag module and guide the airbag AB toward the structural base 200 to create an opening and door during airbag AB deployment. Reinforcement T may be configured to secure the door to the structural base 200 during airbag AB deployment. Joining reinforcement T to fiber panel 202 may include sewing at least one of a thread or stitch to the fiber panel 202. The at least one of the thread or stitch may be composed of at least one of the following: (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) ceramic fiber, (f) polymer fiber, (g) synthetic fiber. Attaching structure 100 to one side of the structural base 200 may include injecting resin into a mold M. The method may include the step of forming a recess 210r in the surface of at least one of the fiber panels 202; the reinforced fiber panel 202r; the recess 210r may be configured to facilitate airbag AB deployment.

[0064] according to Figures 3A-3FExemplary embodiments schematically illustrated in 4A-4F and 10A-10D disclose a method for manufacturing a vehicle trim component 1000 configured to support an airbag module providing an airbag AB for deployment from the airbag module through an opening into the vehicle interior. The method may include the steps of: providing a fiber panel 202; engaging a reinforcement T to the fiber panel 202 in at least one hinge region to form a reinforced fiber panel 202r; arranging the reinforced fiber panel 202r on a first surface of a mold M; compressing the reinforced fiber panel 202r between a first surface and a second surface of the mold to form the reinforced fiber panel 202r into a structural base 200 having a defined shape; and attaching a structure 100 to one side of the structural base. This shape may correspond to a first profile of the first surface and a second profile of the second surface. The structural base 200 may be configured to provide at least one door that is established upon airbag deployment to allow the airbag to deploy from the airbag module through the opening. Structure 100 can be configured to support the airbag module and guide the airbag AB toward the structural base 200 to create an opening and door during airbag AB deployment. The reinforcement T can be configured to secure the door to the structural base 200 during airbag deployment.

[0065] Relevant patent documents - incorporated by reference

[0066] This application incorporates by reference (a) U.S. Patent Application No. 13 / 595,741 (now U.S. Patent No. 8,939,745), filed August 27, 2012, entitled “System and method for manufacturing an avehicle trim component via concurrent compression molding and injection molding”; and (b) U.S. Patent Application No. 8,939,745, filed March 18, 2013, entitled “System and method for manufacturing a vehicle trim component via concurrent compression molding and injection molding”. (c) U.S. Patent Application No. 13 / 846,529 (now U.S. Patent No. 9,149,961) entitled “System and method for mounting an airbag groove assembly within a vehicle trim component”, filed February 27, 2015; (d) U.S. Patent Application No. 14 / 808,938 (now U.S. Patent No. 10,118,325) entitled “Vehicle trim component”, filed July 24, 2015; (e) “Trim component for vehicle interior”, filed October 21, 2016. U.S. Patent Application No. 15 / 331,578 for “INTERIOR”.

[0067] It is important to note that the invention (e.g., inventive concepts, etc.) is described in the specification of this patent document and / or illustrated in the drawings according to exemplary embodiments; these embodiments of the invention are given by way of example only and are not intended to be limiting of the scope of the invention. The construction and / or arrangement of elements embodying the inventive concept in the invention as described in the specification and / or illustrated in the drawings are merely illustrative. Although exemplary embodiments of the invention have been described in detail in this patent document, it will be readily understood by those skilled in the art that equivalents, modifications, variations, etc., of the subject matter of the exemplary and alternative embodiments are possible and are considered to be within the scope of the invention; all such subject matter (e.g., modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the invention. It should also be noted that various modifications, variations, substitutions, alterations, omissions, etc., may be made to the configuration and / or arrangement of exemplary embodiments (e.g., in terms of concept, design, structure, apparatus, form, component, construction, means, function, system, process / method, step, sequence of process / method steps, operation, operating conditions, performance, materials, composition, combination, etc.) without departing from the scope of the invention; all such subject matter (e.g., modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the invention. The scope of the invention is not intended to be limited to the subject matter described in the specification and / or shown in the drawings of this patent document (e.g., details, structure, function, materials, action, steps, sequence, system, result, etc.). It is contemplated that the claims of this patent document will be properly interpreted to cover the full scope of the subject matter of the invention (e.g., including any and all such modifications, variations, embodiments, combinations, equivalents, etc.); it should be understood that the terminology used in this patent document is for the purpose of providing a description of the subject matter of exemplary embodiments and is not intended to limit the scope of the invention.

[0068] Equally important, it should be noted that, according to exemplary embodiments, the invention may include conventional techniques (e.g., those implemented and / or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or may include any other applicable techniques (current and / or future) having the suitability and / or capability to perform the functions and methods / operations described in the specification and / or shown in the drawings. All such techniques (e.g., those implemented as in embodiments, modifications, variations, combinations, equivalents, etc.) are considered to be within the scope of the invention described in this patent document.

Claims

1. A vehicle interior component manufactured in a mold including a first surface and a second surface by a method comprising: Place the pre-formed substrate onto the first surface of the mold; A compression-formed structure is formed from a pre-formed substrate by compressing it between the first surface and the second surface of the mold. The cap is applied to the compression-formed structure to form a panel assembly that provides a surface effect; The pre-formed substrate includes a reinforced pre-formed substrate; The reinforced pre-formed substrate includes a reinforcing member, which includes a top pin and a bottom pin. The top pin and the bottom pin engage at an opening in the pre-formed substrate, and the top pin and the bottom pin have different properties.

2. The vehicle interior component of claim 1, wherein the reinforced pre-formed substrate comprises a fiber panel; wherein the reinforcement consists of threads sewn onto the fiber panel.

3. The vehicle interior component according to claim 1, wherein the compression-formed structure comprises a base layer and the reinforcing member.

4. The vehicle interior component of claim 3, wherein the step of forming the compression-formed structure includes forming the base layer in a generally rigid form.

5. The vehicle interior component of claim 1, wherein the step of forming the compression-formed structure includes forming a reinforcement having a generally continuous surface and the pre-formed substrate.

6. The vehicle interior component of claim 1, wherein the overall smooth texture of the panel assembly is provided by (a) the surface effect of the cover and (b) the surface effect of the pre-formed substrate.

7. The vehicle interior component of claim 1, wherein the panel assembly comprises a composite structure having at least partially the shape of the compression-formed structure; wherein the shape comprises a first profile provided by the first surface of the mold and a second profile provided by the second surface of the mold.

8. The vehicle interior component of claim 1, wherein the pre-formed substrate comprises a resin; wherein the method includes the step of heating the pre-formed substrate, and wherein the pre-formed substrate is compressed when it cools.

9. The vehicle interior component of claim 1, wherein the method includes the step of injecting resin into the mold to form an auxiliary component of the panel assembly after forming the compression-formed structure.

10. A decorative component for a vehicle interior, the decorative component being configured to support an airbag module, the airbag module providing an airbag for deployment through an opening into the vehicle interior, the component being prepared using a mold by a method comprising the following steps: (a) Provide a pre-formed substrate; (b) Joining the reinforcement to a pre-formed substrate in at least one hinge region to form a reinforced pre-formed substrate; (c) Arrange the reinforced pre-formed substrate onto the first surface of the mold; and (d) A pre-formed reinforced substrate is compressed between the first and second surfaces of the mold to form the reinforced pre-formed substrate into a structural substrate with a shape; The shape corresponds to the first contour of the first surface and the second contour of the second surface; The structural base is configured to provide at least one door, which is established when the airbag deploys, so that the airbag can deploy from the airbag module through the opening; The reinforcement is configured to secure the at least one door to the structural base during airbag deployment; The step of attaching the reinforcement to the pre-formed substrate includes piercing an opening in the pre-formed substrate and attaching a top pin to a bottom pin at the opening in the pre-formed substrate, the top pin and the bottom pin having different properties.

11. The decorative component of claim 10, wherein the step of joining the reinforcement to the pre-formed substrate comprises sewing at least one of the thread or stitches to the pre-formed substrate.

12. A method of manufacturing a vehicle trim component, the vehicle trim component being configured to support an airbag module, the airbag module providing an airbag for deployment from the airbag module through an opening into the interior of the vehicle, the method comprising the steps of: (a) Provide a pre-formed substrate; (b) Joining the reinforcement to a pre-formed substrate in at least one hinge region to form a reinforced pre-formed substrate; (c) Arrange the reinforced pre-formed substrate onto the first surface of the mold; and (d) A pre-formed reinforced substrate is compressed between the first and second surfaces of the mold to form the reinforced pre-formed substrate into a structural substrate with a shape; The shape corresponds to the first contour of the first surface and the second contour of the second surface; The structural base is configured to provide at least one door, which is established when the airbag deploys, so that the airbag can deploy from the airbag module through the opening; The reinforcement is configured to secure the door to the structural base during airbag deployment; The step of attaching the reinforcement to the pre-formed substrate includes piercing an opening in the pre-formed substrate and attaching a top pin to a bottom pin at the opening in the pre-formed substrate, the top pin and the bottom pin having different properties.

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