Component for vehicle interior

Abstract

A component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may include a structural substrate including a fiber panel. The fiber panel may include a base region having a nominal thickness and a weakened region including a recess formed in the fiber panel; the weakened region may include a reduced thickness. The profile of the weakened region / recess may include, for example, a shape / form having a bottom and a set of walls. The profile may include a width and / or thickness of the material. The recess may guide formation of the airbag door at the weakened region and may have reduced visibility outside the component. A structure such as a molded resin member may be disposed near the recess. The profile may include a variable shape / form (e.g., depth, width, etc.). The component may include a trim panel, an instrument panel, a door panel, or a strut.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to the following patent applications and incorporates their entireties by reference: (a) U.S. Provisional Patent Application No. 63 / 368,115, filed on July 11, 2022, entitled “COMPONENT FOR VEHICLE INTERIOR”; (b) U.S. Provisional Patent Application No. 63 / 427,088, filed on November 21, 2022, entitled “COMPONENT FOR VEHICLE INTERIOR”.

[0002] This application is related to the following patent applications, which are incorporated herein by reference in their entirety: (a) PCT / International Patent Application No. PCT / US2012 / 052534, filed on August 27, 2012, entitled "SYSTEM AND METHOD FOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSION FORMING AND INJECTION MOLDING"; (b) PCT / International Patent Application No. PCT / US2013 / 056751, filed on August 27, 2013, entitled "SYSTEM AND METHOD FOR MOUNTING AN AIRBAG CHUTE ASSEMBLY WITHIN AVEHICLE TRIM COMPONENT"; (c) PCT / International Patent Application No. PCT / US2013 / 056752, filed on August 27, 2013, entitled "SYSTEM AND METHOD FOR MOUNTING AN AIRBAG CHUTE ASSEMBLY WITHIN AVEHICLE TRIM COMPONENT"; and (d) PCT / International Patent Application No. PCT / US2013 / 056753, filed on June 21, 2017, entitled "TRIM COMPONENT FOR VEHICLE INTERIOR" VEHICLE INTERIOR)” PCT / International Patent Application No. PCT / US2017 / 038572. Technical Field

[0003] The invention relates to a component for a vehicle interior. Background Art

[0004] It is known to provide a component for use in a vehicle interior that is configured to facilitate deployment of an airbag through an opening formed as an airbag door in the component.

[0005] It would be advantageous to provide an improved component including a panel including a weakened area, such as a recess, configured to guide the formation of an opening for deployment of an airbag through the component. Summary of the invention

[0006] The present invention relates to a component for a vehicle interior, the component being configured to facilitate deployment of an airbag through an airbag door, the airbag door comprising a structural substrate, the structural substrate comprising a fiber panel. The fiber panel may include a base region and a weakened region. The weakened region may include a recess having a profile. The profile of the recess may include a bottom and a set of walls. The fiber panel has a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide the formation of the airbag door at the weakened region of the fiber panel during deployment of the airbag. The weakened region may include a generally H-shaped region. The weakened region may include a generally U-shaped region. The fiber panel may include an inner surface and an outer surface; the recess including the profile may be formed in the inner surface of the fiber panel. The recess may be configured to form a seam for an opening through the weakened region of the fiber panel of the airbag door. The profile may include a multi-sided form. The multi-sided form may include a bottom and a set of side walls. The multi-sided form may include a generally trapezoidal form. The profile may include a variable depth. The profile may include a transition region. The transition region may include a transition into the profile. The transition region may include a transition to a generally trapezoidal cross-section of the profile. The transition region may include a generally curved form. The transition region may include a feature formed adjacent the recess; the feature may include a ridge segment. The transition region may include a thickness less than the nominal thickness of the base region of the fiber panel. The transition region may include a thickness greater than the nominal thickness of the base region of the fiber panel. The fiber panel may have a nominal average thickness in the base region and a reduced thickness in the weakened region. The recess of the weakened region may include a central recess and a set of lateral recesses; the weakened region may include a set of lateral recesses connected by the central recess; the central recess may include a connecting segment. The weakened region may include a set of segments. The set of segments may include a set of lateral segments connected by a centerline. The recess may include a formed recess. The recess may include a notch. The recess may include a groove; the groove may be formed in the fiber panel. The groove may include a central groove and a set of lateral grooves; the weakened region may include a set of lateral grooves connected by the central groove; the central groove may include a connecting segment. The profile may include a transition region into the groove. The groove may include a wavy line. The bottom may include a generally flat bottom. The set of walls may include a set of flat tapered walls adjacent to the bottom. The profile may include a generally curved form. The profile may include a circular form including a bottom and a set of walls adjacent to the bottom. The profile may include a multi-segment form. The profile may include a transition region from a base region to a weakened region. The profile may be formed to provide a weakened region in a fiber panel. The component may include a structure formed on a fiber panel; the structure may include an injection molded resin; the structure may include a set of ribs at a weakened region of the fiber panel; the set of ribs may be configured to guide the formation of an airbag door. The fibers of the fiber panel may be at least partially fused with the resin of the structure. The fiber panel may include a compression formed fiber panel.The component may include a panel, the panel including a fiber panel; the panel may include at least one of the following: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The recess may include at least one of the following: (a) a tear line configured to establish an opening for deploying the airbag; (b) a weakening line configured to form an opening for deploying the airbag. The component may include a cover on the fiber panel; the weakened area is generally not visible at the cover. The reduced thickness at the bottom of the profile of the recess may be between 0.4 mm and 0.85 mm. The nominal width of the bottom of the profile of the recess may include between about 0.4 mm and 0.6 mm. The nominal width of the bottom of the profile of the recess may include between about 0.2 mm and 2.0 mm. The recess may include a width across the profile; the width across the profile may be between about 5 mm and about 6 mm. The recess may include a width across the profile; the width across the profile may be greater than 2 mm. The nominal thickness of the fiber panel at the base area may be between about 1.5 mm and 1.7 mm. The component may include a structure formed on the fiber panel; the structure may include at least one rib; the at least one rib may include a group of ribs at a weakened area of ​​the fiber panel. At least one rib may include a nominal height between about 2.5 mm and about 3.5 mm. The at least one rib may include a nominal width between about 1.5 mm and about 2.0 mm. The distance between the group of ribs may include a nominal width between about 5 mm and about 7 mm. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal width on the profile may be in the range of between about 5 and about 12. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal thickness at the base area may be in the range of between about 1.5 and 4. The ratio between the nominal width at the bottom of the profile of the recess and the nominal width on the profile of the recess may be in the range of between about 1.5 and about 12. The ratio between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be in the range of between about 1 and 5. The ratio between the nominal thickness of the base region of the fiber panel and the nominal width on the profile of the recess may be greater than 2. The ratio between the nominal reduced thickness at the bottom of the profile of the recess divided by the nominal thickness at the base region may be in the range between about 1.5 and 4. The ratio between the nominal width at the bottom of the profile of the recess and the nominal width on the profile of the recess may be in the range between about 1.5 and about 12. The ratio between the nominal thickness of the base region of the fiber panel and the nominal width on the profile of the recess may be in the range between about 1 and 5. The ratio between the nominal thickness of the base region of the fiber panel and the nominal width on the profile of the recess may be greater than 2. The ratio between the nominal width at the bottom of the profile of the recess and the nominal thickness at the bottom of the recess may be in the range between about 1 and 2.The ratio relationship between the nominal width at the bottom of the recess profile and the nominal thickness at the bottom of the recess may be in the range of about 0.5 to 3. The nominal width at the bottom of the recess profile may be in the range of about 0.5 and 3 times the nominal thickness at the bottom of the recess. The nominal width across the recess profile may be about 1 to 5 times greater than the nominal thickness of the base area of ​​the fiber panel. The nominal thickness of the base area of ​​the fiber panel may be in the range of about 1.5 to 3.5 times greater than the nominal thickness of the bottom of the recess. The nominal thickness of the base area of ​​the fiber panel may be in the range of about 2 to 4 times greater than the nominal width of the bottom of the recess. The nominal width across the recess profile may be in the range of about 1 to 12 times greater than the nominal thickness of the bottom of the recess. The nominal width of the bottom of the recess profile may include between about 0.2 mm and 2.0 mm. The component may include at least one of the following: (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.

[0007] The present invention relates to a component for a vehicle interior, the component being configured to facilitate deployment of an airbag through an airbag door, the airbag door comprising a fiber panel, the fiber panel comprising a base area and a weakened area. The weakened area may include a recess having a multi-sided profile. The multi-sided profile of the recess may include a bottom and a set of walls. The fiber panel has a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide the formation of the airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel. The component may include a cover on the fiber panel. The component may include a structure formed on the fiber panel; the structure may include an injection molded resin. The structure may include a set of ribs at the weakened area of ​​the fiber panel; the set of ribs may be configured to guide the formation of the airbag door.

[0008] The present invention relates to a component for a vehicle interior, the component being configured to facilitate deployment of an airbag, the airbag comprising a panel, the panel comprising fibers. The panel may include a front side providing a surface and a rear side configured to contact the airbag to form an opening for deployment of the airbag. The panel may include a recess in the rear side of the panel to establish an opening for deployment of the airbag and for direct deployment of the airbag through the panel. The front side of the panel may include a substantially planar surface opposite the recess. The panel comprising fibers may include a compressed fiber panel; the recess may be formed as a depression in the rear side of the panel or a notch in the rear side of the panel. The recess may be formed in a mold by: (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) penetrating the material of the fiber panel at the rear side with a protrusion of the mold to push the material of the fiber panel aside, thereby forming the recess in the rear side and maintaining a continuous surface at the front side. The recess may include a path, the path including at least one of the following: (a) a continuous wave portion including a periodic function; (b) a sinusoidal shape. The panel may include at least one of: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The panel may include a resin rib formed on the panel adjacent to a recess at the rear side of the panel; the resin rib may be configured to guide the deployment of the airbag through the panel. The resin rib may extend from the recess below the rear side of the panel. The recess may include a path including a connecting segment between substantially parallel segments; the connecting segment may include a substantially sinusoidal shape; the panel may include a rib of the connecting segment adjacent to the recess at the rear side of the panel; the rib may include a substantially sinusoidal shape. The rib may include a first rib on one side of the connecting segment and a second rib on an opposite side of the connecting segment. The recess may include a cavity including a cross-sectional profile; the cross-sectional profile of the cavity may include a depth within the panel. The cross-sectional profile of the cavity may include a set of facets; the set of facets may include a first set of connected facets opposite a second set of connected facets. The group of facets may include a bottom facet connecting the first group of connected facets and the second group of connected facets; the bottom facet may include a surface substantially parallel to the front side of the panel. The cross-sectional profile of the cavity may include at least one of the following: (a) a bevel; (b) a fillet; (c) a chamfer. The cross-sectional profile of the cavity may include a wall and a bottom surface; the bottom surface may be substantially parallel to the surface of the front side of the panel. The cross-sectional profile of the cavity may include at least one inclined surface connecting the wall and the bottom surface. The wall may include at least two substantially planar surfaces. The wall may include a first surface and a second surface; the second surface may extend from the bottom surface to the first surface; the first surface may extend from the second surface to the back side of the panel. The wall may include a first substantially planar wall connected to a second substantially planar wall at a certain radius.The recess may include a width at the rear side of the panel; and the bottom surface may include a width smaller than the width of the recess at the rear side of the panel.

[0009] The present invention relates to a component for a vehicle interior, the component being configured to facilitate deployment of an airbag and comprising a panel of fabric. The panel may include a front side providing a surface and a rear side configured to contact an airbag to form an opening for deployment of the airbag. The panel may include a recess formed as a depression in the rear side of the panel to establish an opening for deployment of the airbag and for deployment of the airbag directly through the panel. The front side of the panel may include a substantially planar surface opposite the recess. The recess may be formed as a notch in the rear side of the panel; the recess may include a depth within the panel. The recess may include a set of facets; the set of facets may include a bottom facet connecting a first set of connected facets and a second set of connected facets; the bottom facet may include a surface substantially parallel to the front side of the panel. The recess may include a wall and a bottom surface and at least one inclined surface connecting the wall and the bottom surface.

[0010] The present invention relates to a vehicle interior component formed in a mold and configured to facilitate deployment of an airbag from an airbag module including a panel, the panel including a fiber panel. The fiber panel may include a base area and a weakened area. The weakened area may include a recess. The recess may include a multi-sided profile. The multi-sided profile of the recess may include a bottom and a set of walls. The fiber panel has a reduced thickness in a groove at the bottom of the profile. The profile of the recess may be configured to guide the formation of an airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel. The recess may be formed by: (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) using a protrusion of the mold to penetrate the material of the fiber panel at the rear side to push the material of the fiber panel aside, thereby forming a recess in the rear side and maintaining a continuous surface at the front side; and (c) filling the recess of the mold with material of the fiber panel to form a protrusion at the rear side. The panel may include at least one of: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The recess may include a notch configured to guide the deployment of the airbag through the panel. The feature may include a protrusion configured to provide a projection to the notch.

[0011] The present invention relates to a method for manufacturing a vehicle interior component, comprising: (a) providing a mold comprising a first surface and a second surface, the second surface comprising protrusions and recesses; (b) placing a fiber panel comprising a first side and a second side on the first surface of the mold; (c) compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; (d) penetrating the material of the fiber panel at the first side of the panel, wherein the protrusions of the second surface of the mold push the material of the fiber panel aside to form a recess in the first side of the fiber panel and maintain a continuous surface at the second side of the fiber panel; and (e) filling the recess of the second surface of the mold with material of the fiber panel to form a protrusion on the first side of the fiber panel. The fiber panel may include a base area and a weakened area. The weakened area may include a recess. The recess may include a recess. The recess may include a multi-sided profile. The multi-sided profile of the recess may include a bottom and a set of walls. The fiber panel has a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide formation of an airbag door at a weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel.The method may include the step of injecting resin into the mold at the recess of the second surface of the mold to form a rib.

[0012] The present invention relates to a component for a vehicle interior, the component being configured to facilitate deployment of an airbag and comprising a panel comprising a fiber. The panel may include a front side providing a surface and a rear side configured to contact an airbag to form an opening for deployment of the airbag. The panel may include a recess formed as a depression in the rear side of the panel to establish an opening for deployment of the airbag and for deployment of the airbag directly through the panel. The front side of the panel may include a substantially planar surface opposite the recess. The recess may be formed as a notch in the rear side of the panel. The recess may be formed in a mold by: compressing at least a first portion of a fiber panel between a first surface and a second surface of the mold; and penetrating the material of the fiber panel at the rear side with a protrusion of the mold to push the material of the fiber panel aside, thereby forming the recess in the rear side and maintaining a continuous surface at the front side. The recess may include a generally H-shaped arrangement including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape. The recess may include a generally U-shaped arrangement including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape. The recess may include a path including a continuous wave portion including a periodic function. The recess may include a path having a sinusoidal shape. The panel may include at least one of: a resin; a thermoplastic resin; polypropylene; acrylonitrile butadiene styrene; polycarbonate. The panel may include a rib adjacent to the recess at a rear side of the panel. The rib may be configured to guide the airbag to deploy through the panel. The rib may be formed on the panel. The rib may include a resin material. The rib may extend from the recess. The rib may include a height below the rear side of the panel; the recess may include a cavity in the panel including a depth. The recess may include a path including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape; the panel may include a rib adjacent to the connecting segment of the recess at a rear side of the panel; the rib may include a generally sinusoidal shape. The component may include a first rib on one side of the connecting segment and a second rib on an opposite side of the connecting segment. The rib may include a resin material, and the rib may extend from the recess. The recess may include a cavity having a cross-sectional profile. The profile of the cavity may include a depth within the panel. The profile of the cavity may include a set of facets. The set of facets may include a first set of connected facets opposite to a second set of connected facets. The set of facets may include a bottom facet connecting the first set of connected facets and the second set of connected facets. The bottom facet may include a surface substantially parallel to the front side of the panel. The profile of the cavity may include an inclined surface. The profile of the cavity may include a multi-faceted shape. The profile of the cavity may include at least one of the following: (a) a bevel; (b) a fillet; (c) a chamfer. The profile of the cavity may include a wall and a bottom surface. The profile of the cavity may include at least one inclined surface connecting the wall and the bottom surface. The bottom surface may be substantially parallel to the surface of the front side of the panel. The wall may include at least two substantially planar surfaces.The wall may include a first surface and a second surface; the second surface may extend from the bottom surface to the first surface. The first surface may extend from the second surface to the rear side of the panel. The wall may include a first generally planar wall connected to a second generally planar wall. The recess may include a width at the rear side of the panel; the bottom surface includes a width that is less than the width of the recess at the rear side of the panel. The recess may include at least one of: (a) a tear line configured to establish an opening for deploying the airbag; (b) a weakening line configured to form an opening for deploying the airbag. The component may include at least one of: (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.

[0013] The present invention also relates to a method of manufacturing a component, which may include: providing a mold including a first surface and a second surface including a protrusion; placing a fiber panel including a first side and a second side on the first surface of the mold; compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; and using the protrusion of the second surface of the mold to penetrate the material of the fiber panel at the first side of the panel to push the material of the fiber panel aside, thereby forming a recess in the first side of the fiber panel and maintaining a continuous surface at the second side of the fiber panel. The method may include the step of injecting resin into the mold at the recess of the second surface of the mold to form a rib. The recess may be configured to establish an opening in the vehicle interior component for deploying an airbag through the vehicle interior component. BRIEF DESCRIPTION OF THE DRAWINGS

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

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

[0016] Figure 2A is a schematic perspective view of components for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0017] Figure 2B is a schematic partial perspective view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0018] Figure 2C is a schematic partial perspective view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0019] Figure 3 is a schematic partial cross-sectional view of an airbag deployment according to an exemplary embodiment.

[0020] Figures 4A-4Cis a schematic partial perspective view of an airbag deployment according to an exemplary embodiment.

[0021] Figures 4D-4F is a schematic partial perspective view of an airbag deployment according to an exemplary embodiment.

[0022] Figure 4G-4I is a schematic partial perspective view of an airbag deployment according to an exemplary embodiment.

[0023] Figure 4J-4L is a schematic partial perspective view of an airbag deployment according to an exemplary embodiment.

[0024] Figure 5A is a schematic perspective view of components for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0025] Figure 5B is a schematic cross-sectional view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0026] Figure 5C is a schematic partial cross-sectional perspective view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0027] Figure 5D is a schematic partial cross-sectional view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0028] Fig. 6A is a schematic perspective view of components for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0029] Figure 6B is a schematic exploded perspective view of components for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0030] Figure 6C is a schematic cross-sectional view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0031] Fig. 7A is a schematic perspective view of a fiber mat according to an exemplary embodiment.

[0032] Figure 7B is a schematic partial cross-sectional view of a fiber mat according to an exemplary embodiment.

[0033] Figure 8 is a schematic perspective view of a trimmed fiber mat according to an exemplary embodiment.

[0034] Fig.9A is a schematic perspective view of a consolidated fiber mat according to an exemplary embodiment.

[0035] Fig. 9B is a schematic partial cross-sectional view of a consolidated fiber mat according to an exemplary embodiment.

[0036] Figures 10A to 10C is a schematic perspective view of a compressed fiber mat formed into an instrument panel according to an exemplary embodiment.

[0037] Fig. 10D is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0038] Fig.10E is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0039] Fig.10F is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0040] Figure 10G is a schematic partial cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0041] Fig.11A is a schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0042] Fig. 11B is a schematic perspective view of an airbag chute for a component in a vehicle interior according to an exemplary embodiment.

[0043] Fig. 12A is a schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0044] Fig. 12B is a schematic perspective view of an airbag chute for a component in a vehicle interior according to an exemplary embodiment.

[0045] Fig.13A is a schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0046] Fig. 13B is a schematic partial cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0047] Fig. 13C is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0048] Fig.14A is a schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0049] Fig. 14Bis a schematic partial cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0050] Fig. 14C is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0051] Fig.15A is a schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0052] Fig. 15B is a schematic partial cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0053] Fig. 15C is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0054] Fig.16A is a schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0055] Fig. 16B is a schematic partial cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0056] Fig. 16C is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0057] Fig.17 is a schematic partial cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0058] Fig.18A is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0059] Fig.18B is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0060] Fig.19 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0061] Fig. 20A is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0062] Fig. 20B is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0063] Fig.21 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0064] Fig.22A is a schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0065] Fig. 22B is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0066] Fig.23A is a schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0067] Fig. 23B is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0068] Fig.24A is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0069] Figures 24B to 24D is a schematic cutaway sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0070] Fig.25A is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0071] Figures 25B to 25D is a schematic cutaway sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0072] Fig.26A is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0073] Figures 26B to 26C is a schematic cutaway sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0074] Fig.27A is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0075] Figures 27B to 27C is a schematic cutaway sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0076] Fig.28A is a schematic perspective view of components for a vehicle interior according to an exemplary embodiment.

[0077] Fig.28B is a schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0078] FIG. 28C to FIG. 28Dis a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0079] Fig.29A is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0080] Figures 29B to 29C is a schematic cutaway sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0081] Fig.29D is a schematic cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0082] Figures 29E to 29F is a schematic cutaway sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0083] Figures 30A to 30E is a schematic cross-sectional view of a forming process for a vehicle interior trim component according to an exemplary embodiment.

[0084] Figures 31A to 31E is a schematic cross-sectional view of a forming process for a vehicle interior trim component according to an exemplary embodiment.

[0085] Fig.32A is a schematic partial perspective view of a mold for forming a vehicle interior trim component according to an exemplary embodiment.

[0086] Fig.32B is a schematic partial perspective cross-sectional view of a mold for forming a vehicle interior trim component according to an exemplary embodiment.

[0087] Figures 33A to 33F is a schematic partial cross-sectional view of a forming process for a vehicle interior trim component according to an exemplary embodiment.

[0088] Fig.34A is a schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0089] Fig.34B is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0090] Fig.35A is a schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0091] Fig.35B is a schematic cross-sectional view of a conventional vehicle interior trim component according to an exemplary embodiment.

[0092] Fig.35Cis a schematic cut-away cross-sectional view of a conventional vehicle interior trim component according to an exemplary embodiment. DETAILED DESCRIPTION

[0093] See also Figure 1A-1B and 2A-2C, showing a vehicle V including a vehicle interior I according to an exemplary embodiment; the interior I of the vehicle V includes seats for vehicle passengers and components C schematically shown as an instrument panel IP, door panels DP, bottom console PC, steering wheel SW and other decorative / panel components.

[0094] As per Figure 1B , 2A -2C and 3, the exemplary embodiment schematically shows that the component C includes a panel PL, the panel PL includes a cover T providing an outer surface and a weakened area shown as a recess RS, and the recess RS is configured to facilitate the formation of an airbag door ABD when the airbag AB is deployed (e.g., from an airbag module / inflator) into the vehicle interior. See also Figures 4A-4L . As per Figure 2A As schematically shown in the exemplary embodiment of FIG. , the weakened area shown as a recess RS provided in the panel PL having the cover T may be configured to be not easily visible outside the component C shown as the instrument panel IP (eg, not easily visible on the outer surface). See also Figure 2B-2C and 3. As per Figure 3 As schematically shown in the exemplary embodiment of FIG, a weakened area shown as a recess RS provided in a panel PL having a cover T may be configured to facilitate deployment of an airbag through an airbag door ABD formed in a directional position on / in a component C shown as an instrument panel IP. See also Figure 2B-2C .

[0095] As per Figure 2B As schematically shown in the exemplary embodiment of FIG, a weakened area shown as a recess RS may be provided in a panel PL with a cover T for deploying an airbag at an upper region of a component C shown as an instrument panel IP (e.g. towards the head / body of a seated occupant of the vehicle). See also Figures 4A-4L and 6A.

[0096] As per Figure 2C As schematically shown in an exemplary embodiment in FIG. , a weakened area shown as a recess RS may be provided in a panel PL with a cover T for deploying an airbag at a lower area of ​​a component C shown as an instrument panel IP, for example at the level of the knees of a seated occupant of the vehicle. See also Figures 28A-28B .

[0097] As per Figure 2B , 4A-4C and 4G-4I, the weakened area shown as a recess RS can be provided in a generally H-shaped manner in the panel PL of the component C shown as the instrument panel IP, the recess RS being configured to form an airbag door ABD when the airbag AB is deployed. See also Figures 22A-22B , 23A-23B, 24A-24D, 25A-25D, 26A-26C and 27A-27C.

[0098] As per Figure 2C , 4D -4F and 4J-4L, the weakened area shown as a recess RS can be provided in a generally U-shaped form in the panel PL shown as part C of the instrument panel IP, the recess RS being configured to form an airbag door ABD when the airbag AB is deployed. See also Figures 28A-28D and 29A-29F.

[0099] As per Figure 2B and 4G -4L, a weakened area shown as a recess RS can be provided in a substantially linear form in a panel PL shown as a component C of an instrument panel IP, said recess RS being configured to form an airbag door ABD when the airbag AB is deployed. See also Figure 5A , 11A , 22A-22B, 23A-23B and 28A-28B.

[0100] As per Figure 2C and 4A -4F, a weakened area shown as a recess RS can be provided in a generally variable form (shown as a wavy line form) in a panel PL shown as a component C of an instrument panel IP, said recess RS being configured to form an airbag door ABD when the airbag AB is deployed. See also Fig. 12A and 34A .

[0101] As per Figure 2A , 3 4A-4L, the weakened area shown as a recess RS provided in the panel PL with the cover T can be configured to be not easily visible outside the component C (e.g., not easily visible at the outer surface), and can be configured to facilitate deployment of the airbag through the airbag door ABD formed in a directional position on / in the component C (e.g., formed to deploy in a directional position). See also Figure 1B , 2B -2C.

[0102] As per Figure 2AAs shown in the exemplary embodiment of FIG. 1 , the component C can be manufactured with a configuration of a panel PL having a recess RS that does not produce a visible indication of a weakened area on the outside of the component C. Figures 35A-35C As schematically shown in , the configuration of a panel PLx having recesses RSx that produce protrusions PRx at the surface can produce a visible indication of a weakened area at the exterior of the component Cx; such a visible indication of a weakened area is generally undesirable.

[0103] As per Figures 5A-5D As schematically shown in the exemplary embodiments of FIGS. 6A-6C , the structural substrate (e.g., form / structure) of the panel PL of the cover T with the component C can be configured to provide a weakened area shown as a recess RS, the form of which is configured to be not easily visible on the exterior of the component and to facilitate deployment of the airbag from the airbag chute ABH through the airbag door ABD formed in a directional position on / in the component. See also Figure 3 and 4A -4L.

[0104] like Figures 5B-5D The weakened area of ​​the recess RS of the panel PL shown as a fiber panel, schematically shown in FIG, may be configured to provide a profile shown as comprising a shape / form. See also Figures 13A-13C , 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 19 and 34B.

[0105] like Figures 5B-5D As shown in FIGS. 13A-13C , the shape / form of the outline of the recess RS in the panel PL may include a bottom RT and sidewalls RW and a transition RX. Figures 20A-20B and 30A-30E.

[0106] like Figures 14A-14C As shown, the shape / form of the profile of the recess RS in the panel PL may comprise a substantially continuously curved form RC.

[0107] like Figures 15A-15C As shown, the shape / form of the outline of the recess RS in the panel PL may include a bottom RT and sidewalls RW.

[0108] like Figures 16A-16C As shown, the shape / form of the profile of the recess RS in the panel PL may include a bottom RT and side walls RW as well as a raised area shown as a ridge RZ. Figures 31A-31E .

[0109] like Figure 5D , 13Cand 14C, 18A-18B, 19 and 34B, and the shape / form of the contour of the recess RS in the panel PL may include forms such as a multi-sided / multi-segment form (e.g., a flat form) or a curved form or a composite form with segments of different forms (e.g., flat, curved, etc.); the contour may include a transition section; the contour may include a substantially symmetrical form or an asymmetrical form; the contour may include a substantially constant depth or a substantially variable depth.

[0110] like Figure 5C The shape / form of the profile of the recess RS for the panel PL, schematically shown in Table A, may include overall / nominal / effective dimensions for the bottom RT and side walls RW and a transition RX relative to the overall nominal / effective dimensions of the panel PL, which is shown as a fiber panel FP formed from a fiber mat FM. See also Figure 7A-7B , 8 and 9A-9B.

[0111] like Figures 5B-5D , 13A-13C, 14A-14C, 15A-15C and 16A-16C, the configuration of the panel PL having a weakened area for the recess RS may include a shape / form of the contour of the recess RS in the panel PL having a multi-segment form (e.g. having a bottom RT and / or side walls RW) and / or having a curved form RC (including having a bottom / sides) and / or a transition section RX and / or having a formed structure (e.g. a rib / multiple ribs RB); the configuration of the panel PL having a weakened area for the recess RS may include a physical / proportional relationship related to the shape / form of the panel PL and the shape / form of the contour of the recess RS in the panel PL, such as having a multi-segment form (e.g. having a bottom RT and / or side walls RW) and / or a curved form RC (including having a bottom / sides) and / or a transition section RX and / or having a formed structure, such as a rib / multiple ribs RB. See also Figure 10G , 17 , 18A-18B, 19, 20A-20B and 34B.

[0112] like Figure 3 and 4A -4L, the panel of component C includes a weakened area provided by a recess RS; the weakened area may include a variety of shapes / forms provided by the shape / form of the recess; the configuration of the panel with the weakened area / recess may be configured to guide the formation of an airbag door at a location on the panel. Figures 5A-5D, 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, the weakened area can be provided along the segments of the recess RS in the panel PL, including the central / main segment and the connecting interface and the lateral / side segments. See also Figures 22A-22B , 23A-23B, 24A-24D, 25A-25C, 26A-26C, 27A-27C, 28A-28B and 29A-29F (schematic diagrams of the variation of the weakened area along the segments of the recess RS in the panel PL, including in the central / main segment and the connecting interface and lateral / side segments).

[0113] As per Figures 4A-4C , 22A-22B, 23A-23B, 24A-24D, 25A-25D, 26A-26C and 27A-27C, the recess RS may include a generally H-shaped groove having side / lateral segments and a center / connecting segment (e.g., intersecting / connecting with the lateral segments); each segment / section of the recess / groove may include a profile having a shape / form. See also Figures 11A-11B and 12A-12B. The panel may be configured to guide the formation of the opening at / along the recess of the weakened region in a generally H-shaped form (e.g., to provide an airbag door at a set of hinged flaps / doors). See Figures 4A-4C and 4G-4I.

[0114] As in Figures 4D-4F , 28A-28D and 29A-29F, the recess RS may include a generally U-shaped groove having a generally continuous form from a central segment to a lateral segment; each segment / section of the recess / groove may include a profile having a shape / form. See also Fig.34A The panel may be configured to direct the opening to be formed in a generally U-shaped form at / along a recess for the weakened area (eg, to provide an airbag door as a single door or hinged flap). See Figures 4D-4F and 4J-4L.

[0115] like Figures 5B-5D , 10G, 17, 18A-18B, 19 and 34B, the panel PL may be provided with a structure such as a rib RB (e.g., an injection molded rib) at / near the recess RS in the panel PL; as schematically shown, the structure / rib RB may include a transition RX provided to the sidewall RW and bottom RT of the profile of the recess RS. See also Figures 33A-33F .like Fig.18B As shown, the structure / rib RB is separated from the recess RS in the panel PL; as schematically shown, a gap / region RG may be provided between the structure / rib RB and the transition RX to the sidewalls RW and bottom RT of the profile of the recess RS.

[0116] like Figures 5B-5D , 10D-10G, 11A-11B, 12A-12B, 17, 18A-18B, 19, 20A-20B, 21, 32A-32B, 33A-33F and 34B, the component may include a structure SR, which is shown as including one or more ribs RB at or near a recess RS in the panel PL. Fig.19 , 20A -20B, 21 and 33A-33F, the structure may include a molded resin RB formed with a panel PL shown as a fiber panel FP including fibers; the molded resin may include an injection molded resin; the injection molded resin may be configured to mix / fuse with the fibers of the fiber panel. See also Figure 7A-7B , 8, 9A-9B, 10G, 17, 18A-18B, 19 and 34B.

[0117] According to Figures 5B-5D , 10G, 17, 18A-18B, 19, 20A-20B, 21, 32A-32B and 34B, the molded / plastic structure SR / RB on the fiber panel FP / PL may include any of a variety of forms / features having various sizes and variations in physical relationship to the panel PL and features such as a recess RS on the panel PL. See also Figures 10D-10F , 11B and 12B. Figures 6A-6C , 10D-10G, 11B and 12B, the structure SR may include or be configured to be assembled with the airbag chute ABH.

[0118] like Figure 7A-7B , 8, 9A-9B, 10A-10B, 30A-30E, 31A-31E and 33A-33F, a method / process of forming a component may include heating a fiber mat (e.g., in an oven OV) and providing a fiber mat FM in a mold tool (shown as including a mold top / bottom arrangement MT / MB) to compression form a structural substrate into a compression-formed fiber panel FP, which is shown as a panel PL in component form (and has features such as recesses, voids, ridges, etc.); a weakened area shown as a recess RS may be formed in the panel FP / PL by, for example, a tool including a protrusion PN; the shape / form of the protrusion PN may generally provide the shape / form of the recess RS in the panel FP / PL. See. Figures 30A-30E, 31A-31E and 33A-33F.

[0119] like Figures 16A-16C , 20A-20B, 21 and 31A-31E schematically shown, the shape / form of the contour of the recess RS in the panel PL of the component C may not completely conform to the shape / form of the tool (e.g., the protrusion PN) to form the contour of the recess RS in the panel PL; Fig.31D and 31E As shown, the material of panel PL can flow into a form shown as ridges after forming and / or provide a form having a varying profile (shown as sloped / tapered sidewalls for the form) regardless of the shape / form of the tool (shown as a vertical wall form).

[0120] like Figure 7A-7B , 8 and 9A-9B, the fiber mat FM may include a generally nominal thickness (shown as thickness tFM); the fiber panel FP / PL formed from the fiber mat FM may include a base region providing a generally nominal thickness (shown as thickness tFP) and features (e.g., recesses, voids, ridges, etc.) having a thickness that varies from the nominal / effective thickness of the base region; features such as forming features that provide a profile of a recess RS in the fiber panel FP / PL may include desired shapes / sizes (e.g., nominal thickness / depth, width, angles, curvatures, etc.) and variations formed in the formed component / components. See also Tables A and Figures 5B-5D , 13A-13C, 14A-14C, 15A-15C and 16A-16C.

[0121] like Figures 33A-33F As schematically shown in , the method / process of forming a component may include forming a molded structure SR, such as a rib / ribs RB (eg, by molding, injection molding, etc.) on a panel FP / PL formed of a resin RN. See also Figures 5B-5D , 10G, 17, 18A-18B, 19, 20A-20B, 21 and 34B. Fig.19 , 20A -20B and 21, the material of the structure SR / RB and the material of the panel FP / PL may form an interface including a mixture of materials. The features of such a structure SR / RB formed on the fiber panel FP / PL may include desired shapes / sizes (e.g., nominal width, height, angle, curvature, etc.) and variations. See also Figures 5B-5D , 10G, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 19, 20A-20B, 21 and 34AB.

[0122] like Fig.19 , 20A- 20B, 21, the formation of the panel PL having the structure SR may result in irregularities in shape / form due to processing and material properties.

[0123] like Figures 6A-6C As schematically shown in FIGS. 20A-20B , a cover T may be applied to the panel PL to form the component C; the cover T may be provided in a form / configuration to provide an outer surface of the component C. Figure 2A and 6A As shown in FIG. 6C , the cover T may be configured to provide a desired visual effect on the outer surface of the component C (eg, to ensure that the separation area provided by the recess RS is not easily visible on the exterior of the component). Example Embodiment-A

[0124] like Figure 1A-1B As schematically shown in FIG. 1 , a vehicle V is shown to include an interior I having components C, such as instruments, doors / door panels, and an underbody console; components of the vehicle, such as the instrument panel and door panels, may include decorative components / panels composed of fibers and plastics; the instrument panel and door panels may provide visible surfaces in the vehicle interior of the vehicle; vehicle interior / decorative components, such as the instrument panel and / or door panels, may provide at least one airbag behind the visible surface; the instrument panel and / or door panels may provide a weakened area to assist the airbag in breaking through the decorative components / panels during airbag deployment. See FIG. Figure 2A-2C , 3 and 4A-4L.

[0125] according to Figures 5A-5D , 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may include a structural substrate, the structural substrate including a fiber panel FP / PL; the fiber panel FP / PL may include a base area and a weakened area; the weakened area may include a recess RS, the recess RS including a profile; the profile of the recess may include a bottom and a set of walls; the fiber panel has a reduced thickness in the recess at the bottom of the profile; the profile of the recess may be configured to guide the formation of an airbag door at the weakened area of ​​the fiber panel during airbag deployment. See also Figures 22A-22B, 23A-23B, 24A-24D, 25A-25C, 26A-26C, 27A-27C, 28A-28B and 29A-29F (schematic diagrams of variations in weakened areas of segments along recesses RS in panel PL, including at center / main segments and connection interfaces and lateral / side segments). The weakened area may include a generally H-shaped area. The weakened area may include a generally U-shaped area. The fiber panel FP / PL may include an inner surface and an outer surface; a recess RS including a profile may be formed in the inner surface of the fiber panel FP / PL. The recess may be configured to form a seam for an opening through the weakened area of ​​the fiber panel of the airbag door.

[0126] according to Figures 5A-5D , 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, the profile may include a multi-sided form; the multi-sided form may include a bottom and a set of side walls; the multi-sided form may include a generally trapezoidal form; the profile may include a variable depth; the profile may include a transition section / region; the transition region may include a transition into the profile; the transition region may include a transition into a generally trapezoidal cross-section of the profile; the transition region may include a generally curved form; the transition region may include a feature formed adjacent to the recess; the feature may include a ridge segment; the transition region may include a thickness less than the nominal thickness of the base region of the fiber panel; the transition region may include a thickness greater than the nominal thickness of the base region of the fiber panel. See also Figures 22A-22B , 23A-23B, 24A-24D, 25A-25C, 26A-26C, 27A-27C, 28A-28B and 29A-29F (schematic diagrams of variations in weakened areas of segments along recess RS in panel PL, including central / main segments as well as connecting interfaces and lateral / side segments).

[0127] like Figures 9A-9B As schematically shown in , the fiber panel FP / PL may have a nominal average thickness in the base region and a reduced thickness in the weakened region. See also Table A.

[0128] according to Figures 5A-5D , 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and Figures 34A-34BIn the exemplary embodiment schematically shown in , the recess RS for the weakened area may include a central recess and a set of lateral recesses; the weakened area may include a set of lateral recesses connected by a central recess; the central recess may include a connecting segment; the weakened area may include a set of segments; the set of segments may include a set of lateral segments connected by a center line; the recess RS may include a formed recess; the recess RS may include a notch; the recess RS may include a groove; the groove may be formed in the fiber panel FP / PL; the groove may include a central groove and a set of lateral grooves; the weakened area may include a set of lateral grooves connected by a central groove; the central groove may include a connecting segment; the profile may include a transition area into the groove; the groove may include a wavy line; the bottom may include a generally flat bottom; the set of walls may include a set of flat tapered walls adjacent to the bottom; the profile may include a generally curved form; the profile may include a circular form including the bottom and a set of walls adjacent to the bottom; the profile may include a multi-segment form; the profile may include a transition area from the base area to the weakened area; the profile may be formed to provide a weakened area in the fiber panel FP / PL. See also Figures 22A-22B , 23A-23B, 24A-24D, 25A-25C, 26A-26C, 27A-27C, 28A-28B and 29A-29F (schematic diagrams of the variation of the weakened areas of the segments along the recess RS in the panel PL, including at the central / main segment and the connecting interface and at the lateral / side segments).

[0129] like Figures 5B-5D , 10G, 17, 18A-18B, 19 and 34B, the component may include a structure formed on the fiber panel FP / PL; the structure may include an injection molded resin; the structure may include a set of ribs at a weakened area of ​​the fiber panel FP / PL; the set of ribs may be configured to guide the formation of the airbag door. The fibers of the fiber panel FP / PL may be at least partially fused with the resin of the structure.

[0130] The fiber panel FP / PL may include a compression formed fiber panel. The component may include a panel, the panel including the fiber panel; the panel may include at least one of the following: (a) resin; (b) thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate.

[0131] according to Figures 5A-5D, 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, the recess RS may include at least one of: (a) a tear line configured to establish an opening for deployment of the airbag; (b) a weakening / weakening line configured to establish an opening for deployment of the airbag. The component may include a cover on the fiber panel; the weakened area is generally not visible at the cover. See also Figure 2A-2C .

[0132] according to Figures 5A-5D , 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, the profile of the recess may have a shape / form provided by segments / segments having sizes / dimensions (e.g., width, thickness, reduced width, reduced thickness, etc.). See also Figures 22A-22B, 23A-23B, 24A-24D, 25A-25C, 26A-26C, 27A-27C, 28A-28B and 29A-29F. The reduced thickness at the bottom of the profile of the recess may be between 0.4 mm and 0.85 mm. The nominal width of the bottom of the profile of the recess may include between about 0.4 mm and 0.6 mm. The nominal width of the bottom of the profile of the recess may include between about 0.2 mm and 2.0 mm. The recess may include a width across the profile; the width across the profile may be between about 5 mm and about 6 mm. The recess may include a width across the profile; the width across the profile may be greater than 2 mm. The nominal thickness of the fiber panel at the base area may be between about 1.5 mm and 1.7 mm. The component may include a structure formed on the fiber panel; the structure may include at least one rib; the at least one rib may include a set of ribs at a weakened area of ​​the fiber panel. At least one rib may include a nominal height between about 2.5 mm and about 3.5 mm. The at least one rib may include a nominal width between about 1.5 mm and about 2.0 mm. The distance between the set of ribs may include a nominal width between about 5 mm and about 7 mm. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal width on the profile may be in the range between about 5 and about 12. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal thickness at the base area may be in the range between about 1.5 and 4. The ratio between the nominal width at the bottom of the profile of the recess and the nominal width on the profile of the recess may be in the range between about 1.5 and about 12. The ratio between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be in the range between about 1 and 5. The ratio between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be greater than 2. The ratio between the nominal reduced thickness at the bottom of the profile of the recess divided by the nominal thickness at the base area may be in the range between about 1.5 and 4. The ratio relationship between the nominal width at the bottom of the profile of the recess and the nominal width on the profile of the recess may be in the range between about 1.5 and about 12. The ratio relationship between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be in the range between about 1 and 5. The ratio relationship between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be greater than 2. The ratio relationship between the nominal width at the bottom of the profile of the recess and the nominal thickness at the bottom of the recess may be in the range of about 1 to 2. The ratio relationship between the nominal width at the bottom of the profile of the recess and the nominal thickness at the bottom of the recess may be in the range of about 0.5 to 3. The nominal width at the bottom of the profile of the recess may be in the range between about 0.5 and 3 times the nominal thickness at the bottom of the recess. The nominal width across the recess profile may be about 1 to 5 times greater than the nominal thickness of the base area of ​​the fiber panel.The nominal thickness of the base area of ​​the fiber panel may be in the range of about 1.5 to 3.5 times greater than the nominal thickness of the bottom of the recess. The nominal thickness of the base area of ​​the fiber panel may be in the range of about 2 to 4 times greater than the nominal width of the bottom of the recess. The nominal width across the recess profile may be in the range of about 1 to 12 times greater than the nominal thickness of the bottom of the recess. The nominal width of the bottom of the profile of the recess may include between about 0.2 mm and 2.0 mm. The component may include at least one of the following: (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.

[0133] according to Figures 5A-5D , 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B schematically illustrate exemplary embodiments, a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may include a fiber panel, the fiber panel including a base area and a weakened area; the weakened area may include a recess, the recess including a multi-sided profile; the multi-sided profile of the recess may include a bottom and a set of walls; the fiber panel may have a reduced thickness in the recess at the bottom of the profile; the profile of the recess may be configured to guide the formation of the airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel; the component may include a cover on the fiber panel. Figures 5B-5D , 10G, 17, 18A-18B, 19 and 34B, the component may include a structure formed on the fiber panel; the structure may include injection molded resin; the structure may include a group of ribs at a weakened area of ​​the fiber panel; the group of ribs may be configured to guide the formation of an airbag door.

[0134] According to Figures 5A-5D, 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, the exemplary embodiments schematically shown in Figures 1-6, 10, 20A-20B, 21 and 34A-34B, a component for a vehicle interior configured to facilitate airbag deployment may include a panel including a fiber; the panel may include a front side and a rear side, the The front side provides a surface, the rear side is configured to contact the airbag to establish an opening for deploying the airbag; the panel may include a recess in the rear side of the panel to establish an opening for deploying the airbag and directly deploying the airbag through the panel; the front side of the panel may include a substantially planar surface opposite the recess; the panel including fibers may include a compressed fiber panel; the recess may be formed as a depression in the rear side of the panel or a notch in the rear side of the panel. Figures 30A-30E , 31A-31E and 33A-33F, a recess may be formed in the mold by: (a) compressing at least a first portion of a fiber panel between a first surface and a second surface of the mold; (b) penetrating the material of the fiber panel at the rear side with a protrusion of the mold to push the material of the fiber panel aside, thereby forming a recess in the rear side and maintaining a continuous surface at the front side. The recess may include a path including at least one of: (a) a continuous wave portion including a periodic function; (b) a sinusoidal shape. The panel may include at least one of: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate.

[0135] like Figures 5B-5D , 10G, 17, 18A-18B, 19 and 34B, the panel may include a resin rib formed on the panel adjacent to a recess at the rear side of the panel; the resin rib may be configured to guide the airbag to deploy through the panel. The resin rib may extend from the recess below the rear side of the panel.

[0136] according to Figures 5A-5D , 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and Figures 34A-34BIn the exemplary embodiment schematically shown in , the recess may include a path including a connecting segment between substantially parallel segments; the connecting segment may include a substantially sinusoidal shape; the panel may include a rib adjacent to the connecting segment of the recess at the rear side of the panel; the rib may include a substantially sinusoidal shape; the rib may include a first rib on one side of the connecting segment and a second rib on an opposite side of the connecting segment; the recess may include a cavity including a cross-sectional profile; the cross-sectional profile of the cavity may include a depth within the panel; the cross-sectional profile of the cavity may include a set of facets; the set of facets may include a first set of connected facets opposite to a second set of connected facets; the set of facets may include a bottom facet connecting the first set of connected facets and the second set of connected facets; the bottom facet may include a surface; the cross-sectional profile of the cavity may include at least one of the following: (a) a slope; (b) a fillet; (c) a chamfer; the cross-sectional profile of the cavity may include a wall and a bottom surface; the bottom surface may be substantially parallel to the surface of the front side of the panel; the cross-sectional profile of the cavity may include at least one inclined surface connecting the wall and the bottom surface; the wall may include at least two substantially planar surfaces; the wall may include a first surface and a second surface; the second surface may extend from the bottom surface to the first surface; the first surface may extend from the second surface to the rear side of the panel; the wall may include a first substantially planar wall connected to the second substantially planar wall at a radius; the recess may include a width at the rear side of the panel; the bottom surface may include a width that may be less than the width of the recess at the rear side of the panel. See also Figures 22A-22B , 23A-23B, 24A-24D, 25A-25C, 26A-26C, 27A-27C, 28A-28B and 29A-29F (schematic diagrams of the variation of the weakened areas of the segments along the recess RS in the panel PL, including at the central / main segment and the connecting interface and at the lateral / side segments).

[0137] According to Figures 5A-5D, 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, the exemplary embodiments schematically shown in Figures 1 and 3, a component for a vehicle interior configured to facilitate deployment of an airbag may include a panel including a fiber; the panel may include a front side and a rear side, the front side providing a surface, the rear side configured to contact the airbag to establish an opening for deploying the airbag; the panel may to include a recess formed as a depression in the rear side of the panel to establish an opening for deploying the airbag and directly deploying the airbag through the panel; the front side of the panel may include a substantially planar surface opposite the recess; the recess may be formed as a notch in the rear side of the panel; the recess may include a depth within the panel; the recess may include a set of facets; the set of facets may include a bottom facet connecting a first set of connected facets and a second set of connected facets; the bottom facet may include a surface substantially parallel to the front side of the panel; the recess may include a wall and a bottom surface and at least one inclined surface connecting the wall and the bottom surface. See also Figures 22A-22B , 23A-23B, 24A-24D, 25A-25C, 26A-26C, 27A-27C, 28A-28B and 29A-29F (schematic diagrams of the variation of weakened areas along segments of recesses in panels, including at the center / main segments and connection interfaces and lateral / side segments).

[0138] according to Figures 30A-30E , 31A-31E and 33A-33F, a vehicle interior component formed in a mold and configured to facilitate deployment of an airbag from an airbag module may include a panel including a fiber panel. See also Figures 5A-5D, 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B. The fiber panel may include a base area and a weakened area; the weakened area may include a recess; the recess may include a multi-sided profile; the multi-sided profile of the recess may include a bottom and a set of walls; the fiber panel has a reduced thickness in the recess at the bottom of the profile; the profile of the recess may be configured to guide the formation of an airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel. The recess may be formed by: (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of a mold; (b) penetrating the material of the fiber panel at the rear side with a protrusion of the mold to push the material of the fiber panel aside, thereby forming a recess in the rear side and maintaining a continuous surface at the front side; and (c) filling the recess of the mold with material of the fiber panel to form a protrusion at the rear side. The panel may include at least one of: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The recess may include a notch configured to guide the deployment of the airbag through the panel. The feature may include a protrusion configured to provide a protrusion to the notch.

[0139] According to Figures 30A-30E , 31A-31E and 33A-33F, a method for manufacturing a vehicle interior component may include (a) providing a mold comprising a first surface and a second surface, the second surface comprising protrusions and recesses; (b) setting a fiber panel comprising a first side and a second side on the first surface of the mold; (c) compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; (d) penetrating the material of the fiber panel at the first side of the panel, wherein the protrusions of the second surface of the mold push the material of the fiber panel aside to form a recess in the first side of the fiber panel and maintain a continuous surface at the second side of the fiber panel; and (e) filling the recesses of the second surface of the mold with the material of the fiber panel to form protrusions on the first side of the fiber panel. The fiber panel may include a base region and a weakened region; the weakened region may include the notch; the notch may include a recess; the recess may include a multi-sided profile; the multi-sided profile of the recess may include a bottom and a set of walls; the fiber panel has a reduced thickness in the recess at the bottom of the profile; the profile of the recess may be configured to guide the formation of an airbag door at the weakened region of the fiber panel during deployment of an airbag through the fiber panel. See also Figures 5A-5D , 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B. The method may include the step of injecting a resin into the mold at a recess on the second surface of the mold to form a rib. Example Embodiment-B

[0140] like Figure 1A-1B As schematically shown in , a vehicle may include an interior, wherein vehicle interior components are shown as an instrument panel, a door / door panel, and an underbody console. According to an exemplary embodiment, vehicle components such as the instrument panel and door panel may include a decorative component / panel constructed of fiber and plastic. According to an exemplary embodiment, the instrument panel and door panel may provide a visible surface in the vehicle interior of the vehicle. According to an exemplary embodiment, the vehicle interior / decorative component such as the instrument panel and / or door panel may provide at least one airbag behind the visible surface; the instrument panel and / or door panel may provide a weakened area to assist the airbag in breaching the decorative component / panel during airbag deployment. See Figure 2A-2C , 3 and 4A-4L.

[0141] According to exemplary embodiments as schematically illustrated in 5A-5D, 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21, and 34A-34B, a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may include a structural substrate comprising a fiber panel. The fiber panel may include a base region and a weakened region. The weakened region may include a recess having a profile. The profile of the recess may include a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide the formation of the airbag door at the weakened region of the fiber panel during deployment of the airbag. The weakened region may include a generally H-shaped region. The weakened region may include a generally U-shaped region. The fiber panel may include an inner surface and an outer surface. A recess may be formed in the inner surface of the fiber panel. A recess including a profile may be formed in the inner surface of the fiber panel. The recess may be configured to form a seam for an opening for an airbag door. The seam may be formed as a tear line for the opening of the airbag door. The recess may be configured to form a seam for an opening through a weakened area of ​​the fiber panel for the airbag door. The profile may include a generally trapezoidal form. The profile may include a multi-featured form. The profile may include a multi-faceted form. The profile may include a multi-sided form. The multi-sided form may include a bottom and a set of sidewalls. The multi-sided form may include a generally trapezoidal form. The multi-sided form may include a generally symmetrical shape. The profile may include a variable profile. The profile may include a variable depth. The weakened area may include a transition area. The weakened area may include a transition section. The profile may include a transition section. The profile may include a transition area. The transition area may include a transition into the profile. The transition area may include a transition to a generally trapezoidal cross-section of the profile. The transition area may include a generally curved form. The transition area may include features formed adjacent to the recess. The transition region may include a thickness less than the nominal thickness of the base region of the fiber panel. The transition region may include a thickness greater than the nominal thickness of the base region of the fiber panel. The transition region may include a reduced thickness segment. The transition region may include a ridge segment. The transition region may include a ridge adjacent to the profile of the recess. The recess may include a width. The recess may include a width across the profile. The fiber panel may have a nominal average thickness in the base region and a reduced thickness in the weakened region. The recess for the weakened region may include a central recess and a set of lateral recesses. The weakened region may include a set of lateral recesses connected by the central recess. The central recess may include a connecting segment. The weakened region may include a set of segments. The set of segments may include a set of lateral segments. The set of segments may include a central segment. The set of segments may include a set of lateral segments connected by segment lines. The set of segments may include a set of lines. The weakened region may include a set of lines. The set of lines may include a set of lateral lines.The set of lines may include a center line. The set of lines may include a set of lateral lines connected by the center line. The recess may include a formed recess. The recess may include a notch. The notch may include a groove. The recess may include a cavity. The recess may include a notch. The recess may include a groove. The groove may include a line. The groove may include a wavy line. The groove may include a set of grooves. The groove may include a set of lateral grooves. The groove may include a center groove. The groove may include a center groove and a set of lateral grooves. The weakened area may include a set of lateral grooves connected by the center groove. The center groove may include a connecting section. The bottom may include a generally flat bottom. The bottom may include a generally curved bottom. The set of walls may include a set of inclined walls. The set of walls may include a set of flat walls. The set of walls may include a set of flat inclined walls. The set of walls may include a set of flat tapered walls. The set of walls may include a set of flat tapered walls adjacent to the bottom. The profile may include a generally curved form. The profile may include a circular form. The profile may include a circular form including the bottom and a set of walls adjacent to the bottom. The profile may include a segmented form. The profile may include a multi-segmented form. The profile may include a generally continuous form. The profile may include a transition area into the groove. The profile may include a transition area from the base area to the weakened area. The groove may be formed in the fiber panel. The profile may be formed in the fiber panel. The profile may be formed to provide a weakened area in the fiber panel. The component may include a structure formed on the fiber panel. The structure may include a resin. The resin may include an injection molding resin. The structure may include a set of ribs at the weakened area of ​​the fiber panel. The set of ribs may be configured to guide the formation of the airbag door. The set of ribs may include a resin material; the fiber panel may include fibers. The set of ribs may include a resin material; the fiber panel may include fibers; the set of ribs may be formed on the fiber panel. The set of ribs may include a resin material; the fiber panel may include fibers; the set of ribs may be formed on the fiber panel; the resin material of the set of ribs may be at least partially mixed with the fibers of the fiber panel. The set of ribs may include a resin material; the fiber panel may include fibers; the set of ribs may be formed on the fiber panel; the fibers of the fiber panel may be at least partially mixed into the resin material of the set of ribs. The set of ribs may include a resin material; the fiber panel may include fibers; the set of ribs may be formed on the fiber panel; the fibers of the fiber panel may be at least partially fused with the resin material of the set of ribs. The component may include an airbag chute for deploying an airbag. The airbag chute may be separate from the structure. The fiber panel may include a compression-formed fiber panel. The component may include a panel, the panel including a fiber panel; the panel may include at least one of the following: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate.The recess may include at least one of: (a) a tear line configured to establish an opening for deploying the airbag; (b) a weakening / weakening line configured to form an opening for deploying the airbag. The airbag door may be formed as an opening in the fiber panel. The component may include a cover on the fiber panel. The weakened area is generally not visible at the cover. The airbag may be configured to be deployed through an airbag door formed at the front of the decorative panel. The airbag may be configured to be deployed through an airbag door formed at the bottom of the decorative panel. The nominal reduced thickness at the bottom of the profile of the recess may include between 0.4 mm and 0.8 mm. The reduced thickness at the bottom of the profile of the recess may include between 0.4 mm and 0.85 mm. The reduced thickness at the bottom of the profile of the recess may include between 0.45 mm and 0.65 mm. The reduced thickness at the bottom of the profile of the recess may be between about 0.45 mm and 0.65 mm. The reduced thickness at the bottom of the profile of the recess may be between about 0.45 mm and about 0.75 mm. The nominal reduced thickness at the bottom of the profile of the recess may include about 0.5 mm. The nominal reduced thickness at the bottom of the profile of the recess may include about 0.55 mm. The nominal width of the bottom of the profile of the recess may include between about 0.4 mm and 0.6 mm. The nominal width of the bottom of the profile of the recess may include between about 0.2 mm and 2.0 mm. The recess may include a width. The recess may include a width across the profile; the width across the profile may be between about 5 mm and about 6 mm. The recess may include a width across the profile; the width across the profile may be greater than 2 mm. The recess may include a width across the profile; the width across the profile may be greater than 3 mm. The fiber panel may have a nominal thickness of at least about 1.5 mm in the base area. The fiber panel may include an effective nominal thickness of at least about 1.5 mm at the base area. The fiber panel may include a nominal thickness of between about 1.5 mm and 1.7 mm at the base area. The fiber panel may include a nominal thickness of about 1.7 mm at the base area. The fiber panel may include a nominal thickness of about 1.5 mm at the base area. The fiber panel may include a nominal thickness of less than about 2.0 mm at the base area. The component may include a structure formed on the fiber panel; the structure may include at least one rib. The at least one rib may include an injection molded resin. The at least one rib may include a group of ribs at a weakened area of ​​the fiber panel. The at least one rib may include a nominal height between about 2.5 mm and about 3.5 mm. The at least one rib may include a nominal width between about 1.5 mm and about 2.0 mm. The distance between the group of ribs may include a nominal width between about 5 mm and about 7 mm. The distance across the group of ribs may include a nominal width between about 8 mm and about 9 mm. The distance across the group of ribs may include a nominal width that varies between about 8 mm and about 9 mm.The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal width on the profile may be in the range of between about 5 and about 12. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal width on the profile may be in the range of between about 8 and about 12. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal width on the profile may be about 10. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal thickness at the base area may be in the range of between about 2 and 3. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal thickness at the base area may be in the range of between about 1.5 and 4. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal thickness at the base area may be about 2. The ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal thickness at the base area may be about 3. The ratio between the nominal width at the bottom of the profile of the recess and the nominal width on the profile of the recess may be in the range of between about 1.5 and about 12. The ratio between the nominal width at the bottom of the profile of the recess and the nominal width on the profile of the recess may be about 10. The ratio between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be in the range between about 1 and 5. The ratio between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be in the range between about 3 and 4. The ratio between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be greater than 2. The ratio between the nominal reduced thickness at the bottom of the profile of the recess divided by the nominal thickness at the base area may be in the range between about 1.5 and 4. The ratio between the nominal reduced thickness at the bottom of the profile of the recess divided by the nominal thickness at the base area may be about 2. The ratio between the nominal reduced thickness at the bottom of the profile of the recess divided by the nominal thickness at the base area may be about 3. The ratio between the nominal width at the bottom of the profile of the recess and the nominal width on the profile of the recess may be in the range between about 1.5 and about 12. The ratio relationship between the nominal width at the bottom of the profile of the recess and the nominal width on the profile of the recess may be about 10. The ratio relationship between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be in the range between about 1 and 5. The ratio relationship between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be in the range between about 3 and 4. The ratio relationship between the nominal thickness of the base area of ​​the fiber panel and the nominal width on the profile of the recess may be greater than 2. The ratio relationship between the nominal width at the bottom of the profile of the recess and the nominal thickness at the bottom of the recess may be in the range of about 1 to 2. The ratio relationship between the nominal width at the bottom of the profile of the recess and the nominal thickness at the bottom of the recess may be in the range of about 0.5 to 3. The ratio relationship between the nominal width at the bottom of the profile of the recess and the nominal thickness at the bottom of the recess may be about 1.The nominal width at the bottom of the recess profile may be in the range between about 0.5 and 3 times the nominal thickness at the bottom of the recess. The nominal width at the bottom of the recess profile may be substantially equal to the nominal thickness at the bottom of the recess. The nominal width at the bottom of the recess profile may be greater than the nominal thickness at the bottom of the recess. The nominal width at the bottom of the recess profile may be less than the nominal thickness at the bottom of the recess. The nominal width at the bottom of the recess profile may be no less than 0.5 mm less than the nominal thickness at the bottom of the recess. The nominal width across the recess profile may be about 1 to 5 times greater than the nominal thickness of the base area of ​​the fiber panel. The nominal width across the recess profile may be about 1 to 5 times greater than the nominal thickness of the base area of ​​the fiber panel. The nominal width across the recess profile may be less than the nominal thickness of the base area of ​​the fiber panel. The nominal width across the recess profile may be greater than the nominal thickness of the base area of ​​the fiber panel. The nominal thickness of the base area of ​​the fiber panel may be in the range of about 1.5 to 3.5 times greater than the nominal thickness of the recess bottom. The nominal thickness of the base region of the fiber panel may be in the range of about 2 to 3 times greater than the nominal thickness of the bottom of the recess. The nominal thickness of the base region of the fiber panel may be greater than the nominal thickness of the bottom of the recess. The nominal thickness of the base region of the fiber panel may be at least 1 mm greater than the nominal thickness of the bottom of the recess. The nominal thickness of the base region of the fiber panel may be in the range of about 1 to 3 times greater than the nominal width of the bottom of the recess. The nominal thickness of the base region of the fiber panel may be in the range of about 2 to 4 times greater than the nominal width of the bottom of the recess. The nominal thickness of the base region of the fiber panel may be greater than the nominal width of the bottom of the recess. The nominal thickness of the base region of the fiber panel may be at least 1 mm greater than the nominal width of the bottom of the recess. The nominal width across the recess profile may be in the range of about 1 to 12 times greater than the nominal thickness of the bottom of the recess. The nominal width across the recess profile may be in the range of about 2 to 10 times greater than the nominal thickness of the bottom of the recess. The nominal width across the recess profile may be less than the nominal thickness of the bottom of the recess. The nominal width across the recess profile may be greater than the nominal thickness of the bottom of the recess. The nominal width across the recess profile may be in the range of approximately 1.5 to 12 times greater than the nominal width of the bottom of the recess. The nominal width across the recess profile may be in the range of approximately 2 to 10 times greater than the nominal width of the bottom of the recess. The nominal width across the recess profile may be at least 1 mm greater than the nominal width of the bottom of the recess. The nominal width of the bottom of the recess profile may include between approximately 0.2 mm and 2.0 mm. The component may include an airbag chute; the airbag chute may be separate from the structure. The component may include at least one of the following: (a) a decorative panel; (b) an instrument panel; (c) a door panel; (d) a pillar.

[0142] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may include a fiber panel including a base area and a weakened area. The weakened area may include a recess having a multi-sided profile. The multi-sided profile of the recess may include a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide the formation of the airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel. The component may include a cover on the fiber panel. The component may include a structure formed on the fiber panel. The structure may include an injection molded resin. The structure may include a set of ribs at the weakened area of ​​the fiber panel. The set of ribs may be configured to guide the formation of the airbag door.

[0143] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior configured to facilitate airbag deployment may include a panel including fibers. The panel may include a front side providing a surface and a rear side configured to contact an airbag to form an opening for airbag deployment. The panel may include a recess in the rear side of the panel to establish an opening for deploying the airbag and directly deploying the airbag through the panel. The front side of the panel may include a substantially planar surface opposite the recess. The panel including fibers may include a compressed fiber panel. The recess may be formed as a depression in the rear side of the panel. The recess may be formed as a notch in the rear side of the panel. The recess may be formed in a mold by: (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) penetrating the material of the fiber panel at the rear side with a protrusion of the mold to push the material of the fiber panel aside, thereby forming a recess in the rear side and maintaining a continuous surface at the front side. The recess may include a generally H-shaped arrangement including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape. The recess may include a generally U-shaped arrangement including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape. The recess may include a path including a continuous wave portion, the continuous wave portion including a periodic function. The recess may include a path having a sinusoidal shape. The panel may include at least one of: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The panel may include a rib adjacent to the recess at a rear side of the panel. The rib may be configured to guide the airbag to deploy through the panel. The rib may be formed on the panel. The rib may include a resin material. The rib may extend from the recess. The rib may include a height below the rear side of the panel; the recess may include a cavity in the panel, the cavity including a depth. The recess may include a path including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape; the panel may include a rib adjacent to the connecting segment of the recess at a rear side of the panel; the rib may include a generally sinusoidal shape. The rib may include a first rib on one side of the connecting section and a second rib on an opposite side of the connecting section. The rib may include a resin material, and the rib may extend from the recess. The recess may include a cavity having a cross-sectional profile. The profile of the cavity may include a depth within the panel. The profile of the cavity may include a set of facets. The set of facets may include a first set of connected facets opposite to a second set of connected facets. The set of facets may include a bottom facet connecting the first set of connected facets and the second set of connected facets. The bottom facet may include a surface substantially parallel to the front side of the panel. The profile of the cavity may include an inclined surface. The profile of the cavity may include a multi-faceted shape. The profile of the cavity may include at least one of: (a) a bevel; (b) a fillet; (c) a chamfer. The profile of the cavity may include a wall and a bottom surface.The contour of the cavity may include at least one inclined surface connecting the wall and the bottom surface. The bottom surface may be substantially parallel to the surface of the front side of the panel. The wall may include at least two substantially planar surfaces. The wall may include a first surface and a second surface; the second surface may extend from the bottom surface to the first surface. The first surface may extend from the second surface to the rear side of the panel. The wall may include a first substantially planar wall connected to a second substantially planar wall. The recess may include a width at the rear side of the panel; the bottom surface includes a width that is less than the width of the recess at the rear side of the panel. The recess may include at least one of the following: (a) a tear line configured to establish an opening for deploying the airbag; (b) a weakening line configured to form an opening for deploying the airbag. The component may include at least one of the following: (a) a decorative panel; (b) an instrument panel; (c) a door panel; (d) a pillar.

[0144] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior configured to facilitate airbag deployment may include a panel including a fiber. The panel may include a front side providing a surface and a rear side configured to contact an airbag to form an opening for airbag deployment. The panel may include a recess formed as a depression in the rear side of the panel to establish an opening for deploying the airbag and directly deploying the airbag through the panel. The front side of the panel may include a substantially planar surface opposite the recess. The recess may be formed as a notch in the rear side of the panel. The recess may be formed in a mold by: (a) compressing at least a first portion of a fiber panel between a first surface and a second surface of the mold; (b) penetrating the material of the fiber panel at the rear side with a protrusion of the mold to push the material of the fiber panel aside, thereby forming a recess in the rear side and maintaining a continuous surface at the front side. The recess may include a generally H-shaped arrangement including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape. The recess may include a generally U-shaped arrangement including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape. The recess may include a path including a continuous wave portion, the continuous wave portion including a periodic function. The recess may include a path having a sinusoidal shape. The panel may include at least one of: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The panel may include a rib adjacent to the recess at a rear side of the panel. The rib may be configured to guide the airbag to deploy through the panel. The rib may be formed on the panel. The rib may include a resin material. The rib may extend from the recess. The rib may include a height below the rear side of the panel; the recess may include a cavity in the panel, the cavity including a depth. The recess may include a path including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape; the panel may include a rib adjacent to the connecting segment of the recess at a rear side of the panel; the rib may include a generally sinusoidal shape. The rib may include a first rib on one side of the connecting section and a second rib on an opposite side of the connecting section. The rib may include a resin material. The rib may extend from a recess. The recess may include a cavity having a cross-sectional profile. The profile of the cavity may include a depth within the panel. The profile of the cavity may include a set of facets. The set of facets may include a first set of connected facets opposite to a second set of connected facets. The set of facets may include a bottom facet connecting the first set of connected facets and the second set of connected facets. The bottom facet may include a surface substantially parallel to the front side of the panel. The profile of the cavity may include an inclined surface. The profile of the cavity may include a multi-faceted shape. The profile of the cavity may include at least one of: (a) a bevel; (b) a fillet; (c) a chamfer. The profile of the cavity may include a wall and a bottom surface. The profile of the cavity may include at least one inclined surface connecting the wall and the bottom surface.The bottom surface may be substantially parallel to a surface on the front side of the panel. The wall may include at least two substantially planar surfaces. The wall may include a first surface and a second surface; the second surface may extend from the bottom surface to the first surface. The first surface may extend from the second surface to the rear side of the panel. The wall may include a first substantially planar wall connected to a second substantially planar wall. The recess may include a width at the rear side of the panel; the bottom surface includes a width that is less than the width of the recess at the rear side of the panel. The recess may include at least one of: (a) a tear line configured to establish an opening for deploying the airbag; (b) a weakening line configured to form an opening for deploying the airbag. The component may include at least one of: (a) a decorative panel; (b) an instrument panel; (c) a door panel; (d) a pillar.

[0145] According to an exemplary embodiment schematically shown in the accompanying drawings, a method of manufacturing a component for a vehicle interior, the component being configured to facilitate deployment of an airbag through an airbag door, may include (a) providing a mold including a first surface and a second surface including a protrusion; (b) placing a fiber panel including a first side and a second side on the first surface of the mold; (c) compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; (d) using the protrusion of the second surface of the mold to penetrate the material of the fiber panel at the first side of the panel to push the material of the fiber panel aside, thereby forming a recess in the first side of the fiber panel and maintaining a continuous surface at the second side of the fiber panel. The fiber panel may include a base area and a weakened area. The weakened area may include a recess. The recess may include a multi-sided profile. The multi-sided profile of the recess may include a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide the formation of the airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel. The method may include the step of injecting resin into the mold at the recess of the second surface of the mold to form a rib. The recess may be configured to create an opening in the vehicle interior component for deploying an airbag through the vehicle interior component.

[0146] According to an exemplary embodiment schematically shown in the accompanying drawings, a vehicle interior component formed in a mold and configured to facilitate deployment of an airbag from an airbag module may include a panel including a fiber panel. The fiber panel may include a base area and a weakened area. The weakened area may include a recess. The recess may include a multi-sided profile. The multi-sided profile of the recess may include a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide the formation of an airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel. The recess may be formed by: (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) using a protrusion of the mold to penetrate the material of the fiber panel at the rear side to push the material of the fiber panel aside, thereby forming a recess in the rear side and maintaining a continuous surface at the front side; and (c) filling the recess of the mold with the material of the fiber panel to form a protrusion at the rear side. The fiber panel may include at least one of: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The recess may include a notch configured to guide the airbag to deploy through the panel. The feature may include a protrusion configured to provide a convexity to the notch. The component may include a rib adjacent to the notch. The rib may be configured to guide the airbag to deploy through the panel. The front side of the panel may include a substantially non-planar surface. The feature may include a rib configured to guide the airbag to deploy through the panel. The rib may be formed on the panel. The rib may include a resin portion and a fiber portion, the resin portion including the resin and the fiber portion including fibers of the panel.

[0147] According to an exemplary embodiment schematically shown in the accompanying drawings, a vehicle interior component formed in a mold and configured to facilitate deployment of an airbag from an airbag module may include a panel including fibers. The panel may include a front side and a rear side. The panel may include a first portion including a first thickness, a second portion including a second thickness less than the first thickness, and a third portion including a third thickness greater than the first thickness. The rear side of the structural substrate may be configured to support the airbag module. The front side of the panel may be configured to provide a surface. The first portion of the panel may be separated from the second portion of the panel by a third portion of the panel. The second portion of the panel may include a notch formed as a recess in the rear side of the panel, the notch being configured to guide the airbag to deploy through the panel. The third portion of the panel may include at least one feature at the rear side of the panel adjacent to the notch: the panel including fibers may include a fiber panel. The recess may be formed by: (a) compressing the fiber panel in a mold; (b) penetrating the material of the fiber panel at the rear side with a protrusion of the mold to push the material of the fiber panel aside, thereby forming a recess in the rear side and maintaining a continuous surface at the front side; and (c) filling the recess of the mold with the material of the fiber panel to form a protrusion at the rear side. The fiber panel may include a base area and a weakened area. The recess may include a recess. The weakened area may include a recess. The recess may include a multi-sided profile. The multi-sided profile of the recess may include a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide the formation of an airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel. The first portion, the second portion, and the third portion include a substantially constant density. The first portion, the second portion, and the third portion include a substantially continuous surface at the front side of the panel. The third portion may extend from the second portion and / or may be adjacent to the second portion. The second portion and the third portion may be formed simultaneously; the third portion may be formed in response to the formation of the second portion. The member may include a rib formed on the panel adjacent the recess.

[0148] According to an exemplary embodiment schematically shown in the accompanying drawings, a method of manufacturing a vehicle interior component may include (a) providing a mold including a first surface and a second surface, the second surface including protrusions and recesses; (b) placing a fiber panel including a first side and a second side on the first surface of the mold; (c) compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; (d) penetrating the material of the fiber panel at the first side of the panel, wherein the protrusions of the second surface of the mold push the material of the fiber panel aside to form a recess in the first side of the fiber panel and maintain a continuous surface at the second side of the fiber panel; and (e) filling the recess of the second surface of the mold with the material of the fiber panel to form a protrusion on the first side of the fiber panel. The fiber panel may include a base area and a weakened area. The weakened area may include a recess. The recess may include a recess. The recess may include a multi-sided profile. The multi-sided profile of the recess may include a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to guide the formation of an airbag door at a weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel. The method may include the step of injecting resin into the mold at the recess of the second surface of the mold to form the rib. The step of injecting resin into the mold may include moving material of the fiber panel toward the second surface of the fiber panel. The recess may be configured to establish an opening in the vehicle interior component for deploying the airbag through the vehicle interior component.

[0149] like Figure 2A-2C , 3, 4A-4L, 5A-5D, 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, the exemplary embodiments schematically shown, a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may include a structural substrate comprising a fiber panel; the fiber panel may include a base area having a nominal thickness and a weakened area including a recess formed in the fiber panel; the weakened area may include a reduced thickness; the profile of the weakened area / recess may include, for example, a shape / form having a bottom and a set of walls; the profile may include parameters such as the width and thickness of the material; the recess may be configured to guide the formation of the airbag door at the weakened area and reduce visibility of the component from the outside. Structures such as molded resin components may be disposed adjacent the recess; the profile may include variable shapes / forms (e.g., depth, width, etc.). Figures 22A-22B, 23A-23B, 24A-24D, 25A-25C, 26A-26C, 27A-27C, 28A-28B and 29A-29F. The component may include a trim panel, an instrument panel, a door panel or a pillar. Example Embodiment-C

[0150] according to Figure 2B-2C In an exemplary embodiment schematically shown in FIG. 1 , a component C shown as an instrument panel IP may provide a weakened shape / area shown as a recess RS (e.g., a line, a score line, a cut, a notch, a groove, a discontinuity, an interruption, etc.) to facilitate the deployment of the airbag AB through the airbag door ABD. According to an exemplary embodiment, the weakened shape / area may include at least one of a recess or a score line behind the visible surface of the component C shown as the instrument panel IP; as schematically shown, the weakened shape / area may include an "H" shaped pattern (e.g., corresponding to a door, a double door, etc., so that the airbag includes an airbag door in the panel). According to an exemplary embodiment, the weakened shape / area may include a "U" shaped pattern, a "bow tie" shaped pattern, or any pattern suitable for airbag deployment.

[0151] According to an exemplary embodiment schematically shown in the accompanying drawings, a component C for a vehicle interior configured to facilitate airbag deployment may include a panel PL including fibers. The panel PL may include a front side providing a surface SF and a rear side configured to contact the airbag to form an opening for airbag deployment. The panel PL may include a recess RS formed as a depression in the rear side of the panel PL to establish an opening for deploying the airbag and directly deploying the airbag through the panel PL. The front side of the panel PL may include a substantially continuous surface opposite to the recess RS. The recess RS may be formed as a notch in the rear side of the panel PL. The recess RS is formed in the mold by compressing at least a first portion of the panel PL between the first and second surfaces of the mold and penetrating the material of the panel PL at the rear side with a protrusion PN of the mold to push the material of the panel PL aside, thereby forming the recess RS in the rear side and maintaining a continuous surface at the front side. The recess RS may include a generally H-shaped arrangement including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape. The recess RS may include a generally U-shaped arrangement including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape. The recess RS may include a path including a continuous wave portion having a periodic function. The recess RS may include a path having a sinusoidal shape. The panel PL may include at least one of: a resin; a thermoplastic resin; polypropylene; acrylonitrile butadiene styrene; polycarbonate. The panel PL may include a rib RB adjacent to the recess RS at the rear side of the panel PL. The rib RB may be configured to guide the airbag to deploy through the panel PL. The rib RB may be formed on the panel PL. The rib RB may include a resin material. The rib RB may extend from the recess RS. The rib RB may include a height below the rear side of the panel PL; the recess RS may include a cavity in the panel PL including a depth. The recess RS may include a path including a connecting segment between generally parallel segments; the connecting segment may include a generally sinusoidal shape; the panel PL may include a rib RB adjacent to the connecting segment at the rear side of the panel PL; the rib RB may include a generally sinusoidal shape. The component may include a first rib on one side of the connecting section and a second rib on the opposite side of the connecting section. The rib RB may include a resin material, and the rib RB may extend from the recess RS. The recess RS may include a cavity having a cross-sectional profile. The profile of the cavity may include a depth within the panel PL. The profile of the cavity may include a set of facets. The set of facets may include a first set of connected facets opposite to a second set of connected facets. The set of facets may include a bottom facet connecting the first set of connected facets and the second set of connected facets. The bottom facet may include a surface substantially parallel to the front side of the panel PL. The profile of the cavity may include a wall and a bottom surface. The profile of the cavity may include at least one inclined surface connecting the wall and the bottom surface. The bottom surface may be substantially parallel to the surface of the front side of the panel PL. The wall may include at least two substantially planar surfaces.The wall may include a first surface and a second surface; the second surface may extend from the bottom surface to the first surface. The first surface may extend from the second surface to the rear side of the panel PL. The wall may include a first substantially planar wall connected to a second substantially planar wall. The recess RS may include a width at the rear side of the panel PL; the bottom surface may include a width less than the width of the recess RS at the rear side of the panel PL. The recess RS may include at least one of the following: (a) a tear line configured to establish an opening for deploying the airbag; (b) a weakening line configured to form an opening for deploying the airbag. The component may include at least one of the following: (a) a decorative panel; (b) an instrument panel; (c) a door panel; (d) a pillar.

[0152] According to an exemplary embodiment schematically shown in the accompanying drawings, a vehicle interior component C configured to facilitate deployment of an airbag from an airbag module may include a panel PL including fibers. The panel PL may include a structural substrate for the component. Component C may include a panel PL including a recess RS; the panel PL may include a recess RS and a rib RB. The panel may include a rear side and a front / facing side and a recess RS formed as a depression, notch or indentation in the rear side; the front / facing side of the panel may include a substantially planar surface opposite to the recess on the rear side of the panel. The panel may include at least one of: a resin, a thermoplastic resin, polypropylene, acrylonitrile butadiene styrene, polycarbonate. As Figure 3 and 4A -4L, the recess RS may be configured to guide the deployment of the airbag through the panel. The panel may include a rib RB adjacent to the recess RS, the rib RB being configured to facilitate / guide the deployment of the airbag through the panel (e.g., through an opening established by the recess in the panel). The rib RB may include a resin.

[0153] according to Fig. 7A In the exemplary embodiment schematically shown, the fiber mat FM may include a combination of fibers (e.g. natural and / or synthetic fibers) and a thermoplastic resin (e.g. polypropylene (PP), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), etc.). Figure 8 In the schematically illustrated exemplary embodiment, the fiber mat FM may be trimmed. According to an exemplary embodiment, the fiber mat FM may have a thickness tFM. According to an exemplary embodiment, the fiber mat MA may be heated to cause the thermoplastic resin to liquefy. According to Fig.9AAccording to an exemplary embodiment schematically shown in FIG, the fiber mat FM may be heated and partially compressed into a compressed fiber mat FP having a thickness tFP, which may be less than the thickness tFM. According to an exemplary embodiment, the fiber mat FM may be placed in a low temperature mold and compression molded into a desired shape. According to an exemplary embodiment, when the compressed fiber mat FM cools, the thermoplastic material within the fiber mat FM may solidify to form a substantially rigid composite panel.

[0154] According to an exemplary embodiment, the fiber mat FM may include a combination of structural fibers and a thermosetting resin (e.g., epoxy resin, polyester, etc.). According to an exemplary embodiment, the fiber mat FM may be compressed in a heated mold to form a partially compressed fiber mat FM having a desired shape and cause curing of the thermosetting resin. According to an exemplary embodiment, a substantially rigid composite panel may be formed after the thermosetting resin is cured.

[0155] according to Fig. 10A In the schematically shown exemplary embodiment, the compressed fiber mat FM can be heated in an oven OV. Fig. 10B As schematically shown in FIG. 1 , the hot compressed fiber mat FM can be transferred into a mold having a mold top MT and a mold bottom MB. Figure 5C According to an exemplary embodiment schematically shown in FIG, the panel PL can be produced by a compression forming or a simultaneous compression forming and injection molding process. According to an exemplary embodiment, the heated compressed fiber mat FM can be further compressed into a fiber panel PL; plastic resin can be injected into the back of the fiber panel PL to form auxiliary features such as the airbag chute ABH. According to Fig. 10D According to an exemplary embodiment schematically shown in FIG. 1 , the panel PL may include an airbag chute ABH configured to facilitate deployment of an airbag. According to an exemplary embodiment, the airbag chute ABH may be welded to the panel PL. According to an exemplary embodiment, the airbag chute ABH may be injection molded onto the panel PL in a process that includes compression forming the cushion FM into the panel PL and injection molding the airbag chute ABH onto the panel PL in a single tool. According to an exemplary embodiment, the airbag chute ABH may be injection molded onto the panel PL in a process that includes compression forming the cushion FM into the panel PL and injection molding the airbag chute ABH onto the panel PL in a single tool. Figures 10D to 10G According to an exemplary embodiment schematically shown in FIG, the panel PL may provide an auxiliary feature shown as a plastic reinforcement SR on the back side of the panel PL to improve structural integrity and rigidity. According to an exemplary embodiment, the panel PL may include an airbag chute ABH and / or an airbag module and / or an airbag. Figures 10D to 10GAs schematically shown in FIG. 1 , a plastic reinforcement SR may be placed on the back side of the panel PL to provide structural support for the panel PL. According to an exemplary embodiment, the plastic reinforcement SR may be placed at any position on the back side of the panel PL (e.g., along the edge of the panel PL, in the middle of the panel PL, etc.). According to an exemplary embodiment, a plurality of reinforcements SR may be provided at various different positions on the back side of the panel PL.

[0156] According to an exemplary embodiment, the reinforcement SR can improve the structural integrity of the panel PL. According to an exemplary embodiment, the panel PL is able to maintain structural integrity during airbag deployment; the location / placement of the reinforcement SR can be used to create strength differences between different areas of the panel PL; the energy required for the airbag to break through the panel PL can be directed to the recess RS of the panel PL; during the airbag deployment process, the reinforcement SR on the back side of the panel PL can help prevent or minimize the panel PL from splitting or tearing at any location other than the recess RS (i.e., the score line). According to Fig.10F In the exemplary embodiment schematically shown in FIG. 1 , the reinforcement SR on the back side of the panel PL may form a honeycomb pattern to improve structural integrity and rigidity. According to exemplary embodiments, the reinforcement SR may be formed in any configuration depending on the specific application (e.g., auxiliary features for attaching vents, speakers, or infotainment systems, etc.).

[0157] According to an exemplary embodiment, the panel PL may include a compressed fiber mat FM and a visible surface. According to an exemplary embodiment, the visible surface may include a cover, such as leather or other aesthetic material.

[0158] According to an exemplary embodiment, the panel PL may include a recess RS. According to an exemplary embodiment, the recess RS may be configured to provide a weakened area within the panel PL; the weakened area at the recess RS may facilitate deployment of the airbag. Figure 5D As schematically shown in FIG. 1 , the thickness of the panel PL at the recess RS may be less than the thickness of the panel PL at locations other than the recess RS. According to an exemplary embodiment, the smaller thickness at the recess RS may reduce the strength of the local area at the recess RS; the strength difference between the recess RS and the adjacent area may help guide the airbag to penetrate toward the recess RS during airbag deployment.

[0159] According to an exemplary embodiment, the recess RS may include a cross-sectional profile. The profile of the recess RS may include a depth within the panel PL. The profile of the recess RS may include a set of facets. The set of facets may include a first set of connected facets opposite to a second set of connected facets. The set of facets may include a bottom facet connecting the first set of connected facets and the second set of connected facets. The bottom facet may include a surface substantially parallel to the visible surface of the panel PL. The profile of the recess RS may include an inclined surface. The profile of the recess RS may include a multi-faceted shape. The profile of the recess RS may include at least one of the following: (a) a chamfer; (b) a rounded corner; (c) a chamfer. The recess RS may include a wall and a bottom surface. The profile of the recess RS may include at least one inclined surface connecting the wall and the bottom surface. The bottom surface may be substantially parallel to the visible surface of the panel PL. The wall may include at least two substantially planar surfaces. The wall may include a first surface and a second surface; the second surface may extend from the bottom surface to the first surface. The first surface may extend from the second surface to the rear surface / rear side of the panel PL.

[0160] According to an exemplary embodiment, the recess RS may include at least one of: (a) a notch, (b) a recess, (c) a notch, (d) a depression, (e) a cavity.

[0161] According to example embodiments, the panel PL may provide a smooth visible surface; additional material may not be required to cover the visible surface of the panel PL.

[0162] According to an exemplary embodiment, the panel PL may include a rib RB formed on the panel PL, behind the visible surface of the panel PL and adjacent to the recess RS. According to an exemplary embodiment, a resin may be injection molded onto the back of the panel PL to form the rib RB. According to an exemplary embodiment, the thickness of the panel PL at the recess RS may be less than the thickness at a position on the panel PL other than the recess RS. The height of the rib RB may be greater than the thickness of the panel PL.

[0163] according to Fig. 30A In the exemplary embodiment schematically shown in FIG. 1 , the mold apparatus may include a mold top MT and a mold bottom MB; a compressed fiber mat FM may be placed between the mold top MT and the mold bottom MB. See also Fig. 30B .

[0164] according to Figures 30B to 30D In the exemplary embodiment schematically shown, the compressed fiber mat FM can be placed between the mold top MT and the mold bottom MB; at least one of the mold top MT and the mold bottom MB can be moved between an open position and a closed position; the compressed fiber mat FM can be further compressed and formed between the mold top MT and the mold bottom MB. According to an exemplary embodiment, the compressed fiber mat FM can be heated before being compressed and formed. According to Figures 30A to 30DIn the exemplary embodiment schematically shown, the mold top MT may include protrusions. When the compressed fiber mat FM is further compressed, the protrusions may push material of the compressed fiber mat FM aside to form a recess RS in the panel PL. Fig.30E .according to Fig.30E In the exemplary embodiment schematically shown in FIG. 1 , the panel PL may be formed with a recess RS.

[0165] like Fig.33A As schematically shown in , the mold apparatus may include a mold top MT and a mold bottom MB; the mold top MT may include at least one nozzle NZ to inject plastic resin into the mold cavity; a compressed fiber mat FM may be placed between the mold top MT and the mold bottom MB.

[0166] according to Figures 33A to 33C In the exemplary embodiment schematically shown, the compressed fiber mat MF can be placed between the mold top MT and the mold bottom MB; at least one of the mold top MT and the mold bottom MB can be moved between an open position and a closed position; the compressed fiber mat FM can be further compressed between the mold top MT and the mold bottom MB. According to an exemplary embodiment, the compressed fiber mat FM can be heated before compression and forming. According to Figures 33A to 33F In the exemplary embodiment schematically shown, the mold top MT may include a protrusion PN and at least one depression DP adjacent to the protrusion PN. When the compressed fiber mat FM is further compressed in the mold cavity, the protrusion PN may push the material of the compressed fiber mat FM aside. See also Fig.33C .according to Fig.33D In the exemplary embodiment schematically shown in FIG. 1 , the resin RN can be sprayed onto the back side of the panel PL through the nozzle NZ. Fig.33E In the exemplary embodiment schematically shown in FIG. , the resin RN can be cured and hardened. Fig.33F As schematically shown in FIG. 1 , the panel PL may be formed with a recess RS and two ribs RB adjacent to the recess RS. Fig.33C According to an exemplary embodiment, the smaller thickness at the recess RS can reduce the strength of the local area at the recess RS; the rib RB can increase the strength of the local area adjacent to the recess RS; the strength difference between the recess RS and the adjacent rib RB can help guide the penetration energy of the airbag toward the recess RS (i.e., the score line) during the deployment of the airbag. Fig.33F In the exemplary embodiment schematically shown in FIG. 4 , the panel PL may provide a smooth visible surface; additional material may not be required to cover the visible surface of the panel PL.

[0167] According to the conventional embodiment, the conventional decorative panel PLx is Fig.35A It is schematically shown as a conventional dashboard Cx / IPx. Fig.35BIn the schematically shown conventional embodiment, a conventional instrument panel provides a conventional recess RSx. Fig.35B As schematically shown in , the conventional instrument panel also provides a protrusion PRx on the visible surface of the conventional instrument panel opposite the conventional recess. According to conventional embodiments, for aesthetic reasons, an additional material layer is required to cover and hide the protrusion on the visible surface of the conventional instrument panel (e.g., to provide a smooth visible surface in the vehicle interior). ***

[0168] It is important to note that the present invention (e.g., inventive concepts, etc.) is described in the specification of this patent document and / or shown in the drawings according to exemplary embodiments; these embodiments of the present invention are given by way of example only and are not intended to be limiting on the scope of the present invention. The construction and / or arrangement of the elements of the inventive concepts embodied in the present invention as described in the specification and / or shown in the drawings is merely illustrative. Although exemplary embodiments of the present invention have been described in detail in this patent document, it will be readily understood by those of ordinary skill in the art that equivalents, modifications, variations, etc. of the subject matter of the exemplary embodiments and alternative embodiments are possible and are considered to be within the scope of the present invention; all such subject matter (e.g., modifications, variations, embodiments, combinations, equivalents, etc.) are intended to be included within the scope of the present invention. It should also be noted that various / other modifications, changes, substitutions, equivalents, alterations, omissions, etc. may be made to the configuration and / or arrangement of the exemplary embodiments (e.g., in concepts, designs, structures, devices, forms, components, constructions, means, functions, systems, processes / methods, steps, the order of process / method steps, operations, operating conditions, performance, materials, compositions, combinations, etc.) without departing from the scope of the present invention; all of these subjects (e.g., modifications, changes, embodiments, combinations, equivalents, etc.) are intended to be included within the scope of the present invention. The scope of the present invention is not intended to be limited to the subjects (e.g., details, structures, functions, materials, actions, steps, sequences, systems, results, etc.) described in the specification of this patent document and / or shown in the drawings. It is expected that the claims of this patent document will be appropriately interpreted to cover the full scope of the subject matter of the present invention (e.g., including any and all such modifications, changes, embodiments, combinations, equivalents, etc.); it should be understood that the terms used in this patent document are intended to provide a description of the subject matter of the exemplary embodiments, rather than as a limitation on the scope of the present invention.

[0169] It is also important to note that, depending on the exemplary embodiments, the present invention may include conventional technologies (e.g., implemented and / or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or may include any other applicable technologies (current and / or future) having the applicability and / or ability to perform the functions and methods / operations described in the specification and / or shown in the drawings. All such technologies (e.g., as implemented in embodiments, modifications, variations, combinations, equivalents, etc.) are considered to be within the scope of the present invention of this patent document.

Claims

1. A component for use in a vehicle interior, configured to facilitate deployment of an airbag through an airbag door, the component comprising: a structural substrate comprising a fiber panel; wherein the fiber panel comprises a base region and a weakened region; wherein the weakened region comprises a recess, the recess comprising a profile; wherein the recess has a profile including a bottom and a set of walls; wherein the fiber panel has a reduced thickness in a recess at the bottom of the profile; Wherein the profile of the recess is configured to guide formation of the airbag door at the weakened area of ​​the fiber panel during deployment of the airbag.

2. The component of claim 1, wherein the weakened area comprises an H-shaped area.

3. The component of claim 1, wherein the weakened area comprises a U-shaped area.

4. The component of claim 1, wherein the fiber panel comprises an inner surface and an outer surface; wherein the recess including the contour is formed into the inner surface of the fiber panel. 5 . The component of claim 1 , wherein the recess is configured to form a seam for an opening through the weakened area of ​​the fiber panel of the airbag door.

6. The component of claim 1, wherein the profile comprises a multi-sided form.

7. The component of claim 6, wherein the multi-sided form includes a base and a set of side walls.

8. The component of claim 6, wherein the multi-sided form comprises a trapezoidal form.

9. The component of claim 1, wherein the profile comprises a variable depth.

10. The component of claim 1, wherein the profile includes a transition region. The component of claim 10 , wherein the transition region comprises a transition to the contour.

12. The component of claim 10, wherein the transition region comprises a transition to a trapezoidal cross-section of the profile.

13. The component of claim 10, wherein the transition region comprises a curved form.

14. The component of claim 10, wherein the transition region comprises a feature formed adjacent the recess; wherein the feature comprises a ridge segment.

15. The component of claim 10, wherein the transition region comprises a thickness that is less than a nominal thickness of the base region of the fiber panel.

16. The component of claim 10, wherein the transition region comprises a thickness greater than a nominal thickness of the base region of the fiber panel.

17. The component of claim 1 wherein the fiber panel has a nominal average thickness in the base region and a reduced thickness in the weakened region.

18. The component of claim 1, wherein the recess for the weakened area includes a central recess and a set of lateral recesses; wherein the weakened area includes the set of lateral recesses connected by the central recess; wherein the central recess includes a connecting section.

19. The component of claim 1, wherein the weakened area comprises a group of segments.

20. The component of claim 19, wherein the set of segments comprises a set of lateral segments connected by a centerline.

21. The component of claim 1, wherein the recess comprises a formed recess.

22. The component of claim 1, wherein the recess comprises a notch.

23. The component of claim 1, wherein the recess comprises a groove; wherein the groove is formed in the fiber panel.

24. The component of claim 23, wherein the groove comprises a central groove and a set of lateral grooves; wherein the weakened area comprises the set of lateral grooves connected by the central groove; wherein the central groove comprises a connecting section.

25. The component of claim 24, wherein the profile includes a transition region into the groove.

26. The component of claim 23, wherein the grooves comprise wavy lines.

27. The component of claim 1, wherein the bottom comprises a flat bottom.

28. The component of claim 1 wherein the set of walls comprises a set of flat tapered walls adjacent a base.

29. The component of claim 1, said profile comprising a curved form.

30. The component of claim 1, wherein the profile comprises a circular form including the base and a set of walls adjacent the base.

31. The component of claim 1, wherein the profile comprises a multi-segment form.

32. The component of claim 1, wherein the profile includes a transition region from the base region to the weakened region.

33. The component of claim 1 wherein the profile is formed to provide the weakened area in the fiber panel.

34. The component of claim 1 further comprising a structure formed on the fiber panel; wherein the structure comprises an injection molded resin; wherein the structure comprises a set of ribs at the weakened area of ​​the fiber panel; wherein the set of ribs is configured to guide the formation of the airbag door.

35. The component of claim 34, wherein the fibers of the fiber panel are at least partially fused with the resin of the structure.

36. The component of claim 1, wherein the fiber panel comprises a compression formed fiber panel.

37. The component of claim 1 further comprising a panel, the panel comprising the fiber panel; wherein the panel comprises at least one of: (a) a resin; (b) polypropylene; (c) acrylonitrile butadiene styrene; (d) polycarbonate.

38. The component of claim 1, wherein the recess comprises at least one of: (a) a tear line configured to establish an opening for deploying the airbag; (b) a weakening line configured to form an opening for deploying the airbag.

39. The component of claim 1, further comprising a cover on the fiber panel; wherein the weakened area is not visible at the cover.

40. The component of claim 1 wherein the reduced thickness at the bottom of the profile of the recess is between 0.4 mm and 0.85 mm.

41. The component of claim 1 wherein the nominal width of the recess at the bottom of the profile is between about 0.4 mm and 0.6 mm.

42. The component of claim 1 wherein the nominal width of the recess at the bottom of the profile is between about 0.2 mm and 2.0 mm.

43. The component of claim 1, wherein the recess comprises a width across the profile; wherein the width across the profile is comprised between about 5 mm and about 6 mm.

44. The component of claim 1, wherein the recess comprises a width across the profile; wherein the width across the profile comprises greater than 2 mm.

45. The component of claim 1, wherein the fiber panel comprises a nominal thickness at the base region of between about 1.5 mm and 1.7 mm.

46. ​​The component of claim 1, further comprising a structure formed on the fiber panel; wherein the structure comprises at least one rib; wherein the at least one rib comprises a set of ribs at the weakened area of ​​the fiber panel.

47. The component of claim 46, wherein the at least one rib comprises a nominal height of between about 2.5 mm and about 3.5 mm.

48. The component of claim 46, wherein the at least one rib comprises a nominal width of between about 1.5 mm and about 2.0 mm.

49. The component of claim 46, wherein the distance between the set of ribs comprises a nominal width of between about 5 mm and about 7 mm.

50. The component of claim 1, wherein the ratio between the nominal reduced thickness at the bottom of the profile of the recess and the nominal width across the profile is in a range between about 5 and about 12.

51. The component of claim 1, wherein the ratio between the nominal reduced thickness at the bottom of the recessed profile and the nominal thickness at the base region is in the range of between about 1.5 and 4.

52. The component of claim 1, wherein the ratio between the nominal width at the bottom of the recess profile and the nominal width across the recess profile is in a range between about 1.5 and about 12.

53. The component of claim 1, wherein the ratio between the nominal thickness of the base region of the fiber panel and the nominal width of the contour of the recess is in the range of between about 1 and 5.

54. The component of claim 1, wherein the ratio between the nominal thickness of the base region of the fiber panel and the nominal width of the contour of the recess is greater than 2.

55. The component of claim 1, wherein the ratio of the nominal reduced thickness at the bottom of the profile of the recess to the nominal thickness at the base region is in the range of between about 1.5 and 4.

56. The component of claim 1, wherein the ratio between the nominal width at the bottom of the recess profile and the nominal width across the recess profile is in a range between about 1.5 and about 12.

57. The component of claim 1, wherein the ratio between the nominal thickness of the base region of the fiber panel and the nominal width of the contour of the recess is in the range of between about 1 and 5.

58. The component of claim 1, wherein the ratio between the nominal thickness of the base region of the fiber panel and the nominal width of the contour of the recess is greater than 2.

59. The component of claim 1, wherein the ratio between the nominal width of the recess at the bottom of the profile and the nominal thickness at the bottom of the recess is in the range of about 1 to 2.

60. The component of claim 1, wherein a ratio relationship between a nominal width of the recess at the bottom of the profile and a nominal thickness at the bottom of the recess is in the range of about 0.5 to 3.

61. The component of claim 1, wherein a nominal width of the recess at the bottom of the profile is in the range of about 0.5 to 3 times the nominal thickness at the bottom of the recess.

62. The component of claim 1, wherein a nominal width across the recess profile is in the range of about 1 to 5 times the nominal thickness of a base region of the fiber panel.

63. The component of claim 1, wherein the nominal thickness of the base region of the fiber panel is in the range of about 1.5 to 3.5 times the nominal thickness of the bottom of the recess.

64. The component of claim 1, wherein the nominal thickness of the base region of the fiber panel is in the range of about 2 to 4 times the nominal width of the recess bottom.

65. The component of claim 1, wherein a nominal width across the contour of the recess is in the range of about 1 to 12 times the nominal thickness of the recess bottom.

66. The component of claim 1, wherein the nominal width of the recess at the bottom of the profile is between about 0.2 mm and 2.0 mm.

67. The component of claim 1, comprising at least one of: (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.

68. A component for use in a vehicle interior, configured to facilitate deployment of an airbag through an airbag door, the component comprising: a fiber panel including a base region and a weakened region; wherein the weakened region comprises a recess comprising a multi-sided profile; wherein said multi-sided profile of said recess comprises a base and a set of walls; wherein the fiber panel has a reduced thickness in a recess at the bottom of the profile; Wherein the profile of the recess is configured to guide formation of the airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel.

69. The component of claim 68, further comprising a cover on the fiber panel.

70. The component of claim 68, further comprising a structure formed on the fiber panel; wherein the structure comprises an injection molded resin.

71. The component of claim 70, wherein the structure includes a set of ribs at the weakened area of ​​the fiber panel; wherein the set of ribs is configured to guide the formation of the airbag door.

72. A component for a vehicle interior, configured to facilitate air bag deployment, comprising: Panels including fibers; wherein the panel includes a front side and a rear side, the front side providing a surface, the rear side being configured to contact the airbag to establish an opening for deploying the airbag; wherein the panel includes a recess in a rear side of the panel to create an opening for deploying the airbag and directly deploying the airbag through the panel; Wherein the front side of the panel includes a substantially planar surface opposite the recess.

73. The component of claim 72, wherein the panel comprising fibers comprises a compressed fiber panel; wherein the recess is formed as a depression in the rear side of the panel or as an indentation in the rear side of the panel.

74. A component according to claim 72, wherein the recess is formed in the mold by: (a) compressing at least a first portion of the panel between a first surface and a second surface of the mold; (b) using a protrusion of the mold to penetrate the material of the panel at the rear side to push the material of the panel aside, thereby forming the recess in the rear side and maintaining a continuous surface at the front side.

75. A component according to claim 72, wherein the recess comprises a path, the path comprising at least one of: (a) a continuous wave portion including a periodic function; (b) a sinusoidal shape.

76. The component of claim 72, wherein the panel further comprises at least one of: (a) a resin; (b) polypropylene; (c) acrylonitrile butadiene styrene; (d) polycarbonate.

77. The component of claim 72, wherein the panel includes a resin rib formed on the panel adjacent the recess at the rear side of the panel; wherein the resin rib is configured to guide deployment of the airbag through the panel.

78. A component as claimed in claim 77, wherein the resin rib extends from the recess below the rear side of the panel.

79. A component according to claim 72, wherein the recess includes a path, the path includes a connecting segment between parallel segments; wherein the connecting segment includes a sinusoidal shape; wherein the panel includes a rib adjacent to the connecting segment of the recess at the rear side of the panel; wherein the rib includes a sinusoidal shape.

80. The component of claim 79, wherein the ribs include a first rib on one side of the connecting segment and a second rib on an opposite side of the connecting segment.

81. The component of claim 72, wherein the recess comprises a cavity, the cavity comprising a cross-sectional profile; wherein the cross-sectional profile of the cavity comprises a depth within the panel.

82. A component according to claim 81, wherein the cross-sectional profile of the cavity includes a group of facets; wherein the group of facets includes a first group of connected facets opposite to a second group of connected facets.

83. A component according to claim 82, wherein the set of facets includes a bottom facet connecting the first set of connected facets and the second set of connected facets; wherein the bottom facet includes a surface parallel to the front side of the panel.

84. The component of claim 81, wherein the cross-sectional profile of the cavity comprises at least one of: (a) a bevel; (b) a fillet; (c) a chamfer.

85. The component of claim 81, wherein the cross-sectional profile of the cavity comprises a wall and a bottom surface; wherein the bottom surface is substantially parallel to a surface of a front side of the panel.

86. The component of claim 85, wherein the cross-sectional profile of the cavity includes at least one inclined surface connecting the wall and the floor.

87. The component of claim 85, wherein the wall comprises at least two planar surfaces.

88. A component according to claim 85, wherein the wall includes a first surface and a second surface; wherein the second surface extends from the bottom surface to the first surface; and wherein the first surface extends from the second surface to the back side of the panel.

89. The component of claim 85, wherein the wall comprises a first planar wall connected to a second planar wall at a radius.

90. The component of claim 85, wherein the recess comprises a width at the rear side of the panel; wherein the bottom surface comprises a width that is less than the width of the recess at the rear side of the panel.

91. A component for a vehicle interior configured to facilitate air bag deployment and comprising a panel, the panel comprising a fiber; wherein the panel includes a front side and a rear side, the front side providing a surface, the rear side being configured to contact the airbag to establish an opening for deploying the airbag; wherein the panel includes a recess formed as a depression in a rear side of the panel to establish an opening for deploying the airbag and directly deploying the airbag through the panel; Wherein the front side of the panel includes a planar surface opposite the recess.

92. The component of claim 91, wherein the recess is formed as a notch in the rear side of the panel; wherein the recess comprises a depth within the panel.

93. A component according to claim 91, wherein the recess includes a group of facets; wherein the group of facets includes a bottom facet connecting a first group of connected facets and a second group of connected facets; wherein the bottom facet includes a surface substantially parallel to the front side of the panel.

94. The component of claim 91, wherein the recess comprises a wall and a bottom surface and at least one inclined surface connecting the wall and the bottom surface.

95. A vehicle interior component formed in a mold and configured to facilitate deployment of an airbag from an airbag module, the vehicle interior component comprising: Panels including fiber panels; wherein the fiber panel comprises a base region and a weakened region; wherein the weakened region comprises a recess; wherein the recess comprises a multi-sided profile; wherein said multi-sided profile of said recess comprises a base and a set of walls; wherein the fiber panel has a reduced thickness in a recess at the bottom of the profile; wherein the profile of the recess is configured to guide formation of the airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel; Wherein the recess is formed by: (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) penetrating the material of the fiber panel at the rear side with the protrusions of the mold to push the material of the fiber panel aside, thereby forming the recess in the rear side and maintaining a continuous surface at the front side; as well as (c) filling the recess of the mould with material of the fibre panel to form a protrusion at the rear side.

96. The vehicle interior component of claim 95, wherein the panel further comprises at least one of: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate.

97. The vehicle interior component of claim 95, wherein the recess includes a notch configured to guide deployment of the airbag through the panel.

98. The vehicle interior component of claim 95, wherein the feature comprises a protrusion configured to provide a relief to the recess.

99. A method of manufacturing a vehicle interior component, comprising: (a) providing a mold comprising a first surface and a second surface, wherein the second surface comprises protrusions and recesses; (b) placing a fiber panel including a first side and a second side onto a first surface of a mold; (c) compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; (d) penetrating material of the fiber panel at the first side of the panel, wherein the protrusions of the second surface of the mold push material of the fiber panel aside to form a recess in the first side of the fiber panel and maintain a continuous surface at the second side of the fiber panel; as well as (e) filling the recess of the second surface of the mold with material of the fiber panel to form a protrusion at the first side of the fiber panel; wherein the fiber panel comprises a base region and a weakened region; wherein said weakened region comprises said notch; wherein the notch comprises a recess; wherein the recess comprises a multi-sided profile; wherein said multi-sided profile of said recess comprises a base and a set of walls; wherein the fiber panel has a reduced thickness in a recess at the bottom of the profile; Wherein the profile of the recess is configured to guide formation of the airbag door at the weakened area of ​​the fiber panel during deployment of the airbag through the fiber panel.

100. The method of claim 99, further comprising the step of injecting resin into the mold at the recesses of the second surface of the mold to form ribs.

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