Component for vehicle interior

Abstract

A component for a vehicle interior may include a composite structure including a substrate and a cover. The substrate may include a fiber panel. The cover may include a cover layer / skin layer providing an exterior surface. The cover layer / skin layer may include features such as recesses / recesses and / or protrusions / protrusions. The composite structure may include a stitch pattern formed in the skin layer and the substrate. Suture patterns and features may provide an effect such as a simulated seam (e.g., a French seam or a deck seam). The feature may include a groove or an image / mark at the exterior surface. The cover may include a thermoplastic material molded on the substrate. The cover may be softer than the substrate and may include a TPE, TPV, or PU material. The components may include an instrument panel, an instrument panel, a cockpit, a door panel, a steering wheel, a console, a knee bolster, a trim component, and the like.

Description

Cross - Reference to Related Applications

[0001] This application incorporates by reference in its entirety the following patent applications: (a) U.S. Provisional Patent Application No. 63 / 413,800, filed on October 6, 2022, entitled "COMPONENNT FOR VEHICLE INTERIOR"; (b) U.S. Provisional Patent Application No. 63 / 460,371, filed on April 19, 2023, entitled "COMPONENNT FOR VEHICLE INTERIOR". Technical Field

[0002] The present invention relates to a component for a vehicle interior. Background Art

[0003] Vehicle interior components can include trim components provided throughout the interior of a typical passenger vehicle. Interior components can provide visible surfaces that face and define the vehicle interior. Interior components can cover, hide, and protect functional components such as those within doors, behind dashboards, in center consoles, etc. Stitching can be applied to the surfaces of components visible within the vehicle interior; the stitching can indicate hand craftsmanship details and can represent product quality (e.g., in combination with visible cover materials and surfaces). It is known to provide a component for a vehicle interior that includes a cover attached to a substrate. It is known to provide a vehicle interior component that includes a seam configured to join two materials. It is known to provide a vehicle interior component that includes a recess configured to simulate joining two materials using a single material. It is known to provide a vehicle interior component that includes a single material that simulates two materials stitched together. It is known to provide a component for a vehicle interior that includes a cover with an icon or image.

[0004] It would be advantageous to provide improved components for a vehicle interior.

[0005] Advantageously, manufacture a component for a vehicle interior that simulates functional seams / stitches without using multiple cover materials and without the need to join different materials.

[0006] It is advantageous to manufacture a component for a vehicle interior that includes a cover with an icon / mark or image formed integrally. Summary of the Invention

[0007] The present invention relates to a component for use inside a vehicle, the component comprising a composite structure, the composite structure comprising a substrate and a cover member. The substrate may comprise a panel. The cover member may comprise a cover layer. The cover layer may comprise an inner surface and an outer surface. The outer surface of the cover layer may comprise the outer surface of the composite structure. The cover layer may comprise features in the outer surface of the cover layer. The panel may comprise a fiber panel. The substrate may comprise a compressed fiber panel. The features of the cover layer may comprise at least one of (a) a depression in the outer surface of the cover layer and (b) a protrusion in the outer surface of the cover layer. The cover layer may comprise a protrusion in the outer surface of the cover layer. The cover layer may comprise a recess in the outer surface of the cover layer. The features of the cover layer may comprise a recess in the outer surface of the cover layer and a protrusion in the outer surface of the cover layer. The recess may be formed above the outer surface of the cover layer. The protrusion may be formed above the outer surface of the cover layer. The features of the cover layer may comprise a groove in the outer surface of the cover layer. The features of the cover layer may comprise a rib in the outer surface of the cover layer. The features of the cover layer may comprise a depression in the outer surface of the cover layer and a rib in the outer surface of the cover layer. The features of the cover layer may be below the outer surface of the cover layer. The features of the cover layer may comprise a depression below the outer surface of the cover layer. The features of the cover layer may be above the outer surface of the cover layer. The features of the cover layer may comprise a protrusion above the outer surface of the cover layer. The cover member may comprise a resin. The cover layer may comprise a surface layer. The inner surface of the cover layer may be coupled to the substrate. The cover layer may be formed on the substrate. The cover layer may be molded on the substrate. The cover layer may be molded around the substrate. The composite structure may comprise a stitch pattern. The stitch pattern may be formed in the cover layer and the substrate. The features of the cover layer may comprise a stitch pattern provided above the outer surface of the cover layer. The stitch pattern may comprise stitching through the inner surface of the cover layer. The stitch pattern may be within a recess in the outer surface of the substrate. The stitch pattern may be provided through the top surface of the substrate. The stitch pattern may be below the outer surface of the cover layer. The stitch pattern may be above the outer surface of the cover layer. The stitch pattern may be within a groove in the outer surface of the cover layer. Features may be provided in the top surface of the substrate. The features in the top surface of the substrate may comprise at least one of a protrusion or a recess. The substrate may comprise a structural substrate. The structural substrate may comprise a compression molded panel. The compression molded panel of the structural substrate may comprise a rigid compressed fiber panel. The substrate may comprise a semi-rigid compressed fiber panel. The cover layer may comprise a material that is softer than the material of the substrate. The composite structure may be configured to provide a decorative effect; the decorative effect may comprise a stitch pattern. The composite structure may comprise a stitch pattern; the stitch pattern may be formed in the cover layer and the substrate. The stitch pattern may be adjacent to the features of the cover layer. The stitch pattern may be in a groove in the outer surface of the cover layer. The stitch pattern and the features of the cover layer may be configured to provide a decorative effect.The features of the stitch pattern and the cover layer can be configured to provide a visual effect; the visual effect includes at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The features of the cover layer can include protrusions and / or depressions. The composite structure can include a stitch pattern adjacent to the features of the cover layer. The composite structure can include a stitch pattern at the features of the cover layer. The composite structure can include a stitch pattern passing through the features of the cover layer. The features of the cover layer can include at least one of the following: (a) a mark; (b) an image; (c) an icon; (d) an identification. The composite structure can include a cover layer formed on a substrate; the features of the cover layer can be configured to provide a visual effect to the outer surface of the cover layer. The composite structure can include a cover layer (a) formed on or (b) molded on the substrate. The composite structure can include a cover layer (a) molded around a portion of the substrate; (b) molded laterally around the substrate; (c) molded on the substrate and at least partially under the substrate. The cover layer can be molded on the substrate; the cover layer can include a thermoplastic material by injection molding. The cover layer can include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The features of the cover layer can include formed protrusions. The formed protrusions can include at least one of the following: (a) an image; (b) an icon. The features of the cover layer can include formed recesses. The composite structure is configured to provide an opening for deploying an airbag through the opening. The component can include at least one of the following: (a) a dashboard; (b) an instrument panel; (c) a door panel; (d) a steering wheel assembly; (e) a console; (f) a cockpit; (g) a knee pad; (h) a decorative component.

[0008] The present invention relates to a component for a vehicle interior, the component comprising a substrate formed of a fiber panel; and a cover member including a surface layer covering the substrate. The surface layer may include an inner surface coupled to the substrate and an outer surface providing an external surface. The surface layer may include at least one of the following: (a) a recess in the outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer. The recess may be formed as a concave portion in the outer surface of the surface layer. The surface layer may be molded on the substrate. The surface layer may include an injection-molded thermoplastic material. The surface layer may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The surface layer may include a surface layer material; the surface layer material may be softer than the substrate. The component may include a stitch pattern formed in the surface layer and the substrate. The stitch pattern and the recess in the outer surface of the surface layer may be configured to provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The stitch pattern and the protrusion in the outer surface of the surface layer may be configured to provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The protrusion in the outer surface of the surface layer may include at least one of the following: (a) an image; (b) an icon.

[0009] The present invention relates to a component for a vehicle interior formed in a mold, the mold comprising: (a) a substrate including a compression-molded component; and (b) a cover member including a surface layer. The compression-molded component may be formed by compressing a fiber panel between a first surface of the mold and a second surface of the mold. The surface layer may be formed by molding the surface layer on the compression-molded component. The cover member may include features including at least one of the following: (a) a recess in the outer surface of the cover member and (b) a protrusion in the outer surface of the cover member. The component may include a composite structure including the substrate and the cover member; the composite structure may include a stitch pattern adjacent to the features of the cover member.

[0010] The present invention relates to a method of manufacturing a component for a vehicle interior in a mold, the method comprising: (a) providing a preformed substrate; (b) disposing the preformed substrate on a first surface of the mold; (c) compressing the preformed substrate between the first surface of the mold and a second surface of the mold to form the preformed substrate into a compression-molded component having a shape corresponding to a first profile of the first surface and a second profile of the second surface; and (d) molding a skin on the compression-molded component. The step of molding a skin on the compression-molded component may include molding the skin between the compression-molded component and a third surface of the mold; the third surface of the mold may be configured to form at least one of the following: (a) a recess in the outer surface of the skin; (b) a protrusion in the outer surface of the skin. The step of molding a skin on the compression-molded component may include molding the skin on a top surface of the compression-molded component and on an edge of the compression-molded component. The method may include the step of forming a stitch pattern in the skin and the compression-molded component. A component manufactured by the method may include a composite structure including a structural substrate formed from the preformed substrate and a cover including the skin. The outer surface of the skin of the cover may include the outer surface of the composite structure; the composite structure may include a stitch pattern adjacent to features of the cover layer.

[0011] The present invention relates to a component for a vehicle interior, the component comprising a substrate formed of a fiber panel and a cover for the substrate including a surface layer. The surface layer may include an inner surface coupled to the substrate and an outer surface providing the outer surface of the component. The surface layer may include at least one of the following: (a) a depression in the outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer. The depression may be formed as a recess in the surface layer. The surface layer may include a protrusion in the inner surface of the surface layer opposite the depression in the outer surface of the surface layer. The protrusion in the inner surface of the surface layer may be configured to fit within a depression in the top surface of the substrate. The depression in the top surface of the substrate may be formed in the fiber panel. The surface layer may be molded on the substrate. The surface layer may include an injection-molded thermoplastic material. The surface layer may include a generally opaque material. The surface layer may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The surface layer may include a surface layer material; the surface layer material may be softer than the substrate. The fiber panel may include a panel containing fibers. The fiber panel may be configured to provide an opening for deploying an airbag through the opening. The rear side of the fiber panel may be configured to contact the airbag to establish an opening for deploying the airbag. The rear side of the panel may be configured to support an airbag module including the airbag. The substrate may include at least one feature on the rear side of the panel. The at least one feature may include at least one of the following: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The at least one feature may be formed on the rear side of the panel. The at least one feature may include at least one of the following: (a) an airbag chute; (b) a passage for the airbag; (c) a feature configured to facilitate opening; (d) a structure for a safety airbag door; (e) a set of ribs configured to establish a seam for the airbag door; (f) a welding rib configured to couple the airbag chute to the panel. The substrate may include a compression-molded component from the fiber panel. The component may include a stitch pattern. The stitch pattern may be formed in the surface layer and the substrate. The stitch pattern may be adjacent to the protrusion in the outer surface of the surface layer. The stitch pattern and the protrusion in the outer surface of the surface layer may be configured to provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The substrate may include at least one feature formed on the rear side of the panel. The at least one feature may include at least one of the following: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The at least one feature may include at least one of the following: (a) a rib; (b) a set of ribs; (c) a resin-formed feature; (d) a resin-formed feature molded on the substrate. The protrusion in the outer surface of the surface layer may include at least one of the following: (a) an image; (b) an icon. The depression in the outer surface of the surface layer may include a groove.The component may include at least one of the following: (a) an instrument panel; (b) an instrument cluster; (c) a door panel; (d) a steering wheel assembly; (e) a console; (f) a cockpit; (g) a knee pad; (h) a trim component.

[0012] The present invention relates to a component for a vehicle interior formed in a mold, the mold including: a base plate including a compression molded component; and a cover including a surface layer. The compression molded component may be formed by compressing a fiber panel between a first surface and a second surface of the mold. The surface layer may be formed by molding the surface layer on the compression molded component.

[0013] The present invention relates to a method of manufacturing a component for a vehicle interior in a mold, the method including: providing a preformed base plate; disposing the preformed base plate on a first surface of the mold; compressing the preformed base plate between the first surface and a second surface of the mold to form the preformed base plate into a compression molded component having a shape corresponding to a first profile of the first surface and a second profile of the second surface; and molding a surface layer on the compression molded component. The method may include the step of injecting resin into the mold to form features on a rear side of the compression molded component. The method may include the step of injecting resin into the mold to form features on a rear side of the compression molded component. The step of molding the surface layer on the compression molded component may include molding the surface layer between the compression molded component and a third surface of the mold. The third surface of the mold may be configured to form at least one of the following: (a) a recess in an outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer. The step of molding the surface layer on the compression molded component may include molding the surface layer on a top surface and an edge of the compression molded component. The step of compressing the preformed base plate between the first surface and the second surface of the mold may include forming a recess on a top surface of the compression molded 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 showing a vehicle interior according to an exemplary embodiment.

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

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

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

[0019] Figure 3 is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0020] Figure 4 is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0021] Figure 5 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0022] Figure 6 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0023] Figure 7 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0024] Figure 8 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0025] Figure 9 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0026] Figure 10 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0027] Figure 11 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0028] Figure 12 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0029] Figure 13 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0030] Figure 14 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0031] Figure 15 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0032] Figure 16 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0033] Figure 17 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0034] Figure 18 is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0035] Figure 19A and Figure 19B is a schematic perspective view of a fiber mat compressed into a preform according to an exemplary embodiment.

[0036] Figures 19C to 19F is a schematic perspective view of a preform of a compression-molded component according to an exemplary embodiment.

[0037] Figures 20A to 20C is a schematic perspective view of a fiber mat formed into a component for a vehicle interior according to an exemplary embodiment.

[0038] Figure 20D is a schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0039] Figure 21A is a schematic perspective view of a process for forming a component for a vehicle interior according to an exemplary embodiment.

[0040] Figure 21B is a schematic partial cross-sectional perspective view of a process for forming a component for a vehicle interior according to an exemplary embodiment.

[0041] Figure 21C is a schematic partial cross-sectional perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0042] Figures 22A to 22E is a schematic partial cross-sectional view of a process for forming a component for a vehicle interior according to an exemplary embodiment.

[0043] Figure 23A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0044] Figure 23B is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0045] Figures 24A to 24D is a schematic perspective view of a fiber mat formed into a component for a vehicle interior according to an exemplary embodiment.

[0046] Figure 25A and Figure 25Bis a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0047] Figure 26A and Figure 26B is a schematic flow chart of forming a component for a vehicle interior according to an exemplary embodiment.

[0048] Figure 27 is a schematic flow chart of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0049] Figure 28 is a schematic flow chart of a method for forming a component for a vehicle interior according to an exemplary embodiment. DETAILED DESCRIPTION

[0050] Referring Figures 1A - 1B to FIGS. 2A - 2C, a vehicle V having an interior I is shown, the vehicle including components C (and other components such as panels, consoles, seats, etc.) shown as instrument panel IP and door / panel DP and steering wheel SW.

[0051] As schematically shown according to Figures 2A - 2C the exemplary embodiment in, the component C may include a composite structure configured to provide a visual / decorative effect at an outer surface TX, the visual / decorative effect being provided by features FT such as stitching / stitch pattern ST and / or protrusion / bump PN and / or depression / recess ND. As Figures 2A - 2C , Figure 3 , Figure 4 and Figures 23A - 23B schematically shown in, the visual / decorative effect in the outer surface of the component may include a shape / form such as a boundary presented by features FT and / or an image / mark such as an icon, logo, text, etc. presented by features FT.

[0052] As according to Figure 2C , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 9 , Figure 10 , Figure 11 , Figure 12 , Figure 13 , Figure 14 , Figure 15 , Figure 16 , Figure 17 and Figure 18As schematically shown in the exemplary embodiments herein, component C may include a composite structure that includes a base B and a structure shown as a housing CH (such as an airbag chute), and a substrate SB shown as including a panel CF (such as a compression fiber panel), and a cover T configured to provide an external surface TX, the external surface having an arrangement and / or combination of features FT shown as protrusions PN and depressions ND and a stitching / seaming pattern ST. As schematically shown, the composite structure including the substrate SB and the cover T having an arrangement of a plurality of features FT may be configured to provide any one of a variety of shapes / forms and visual / decorative effects for any one of a plurality of components in the vehicle interior; as schematically shown, features such as protrusions / projections and depressions / recesses may be provided in any one of a variety of forms and combinations of forms (e.g., ribs, ridges, chunks, protrusions, connectors, holes, grooves, slots, boundaries, etc.).

[0053] As Figure 2C , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 9 , Figure 10 , Figure 11 , Figure 12 , Figure 13 , Figure 14 , Figure 15 , Figure 16 , Figure 17 and Figure 18 As schematically shown in Figure 2C ), in the arrangement and / or combination of features FT at the cover T that provides the external surface TX on the substrate SB of the composite structure, the stitching pattern ST may be presented adjacent to the depression ND shown as a groove and the protrusion PN shown as a rib / ridge ( Figure 5 and Figure 6 ), or having a depression ND below the level of the external surface of the cover T ( Figure 7 and Figure 8 ), or having a protrusion PN above the level of the external surface of the cover T ( Figure 9 、 Figure 10 ), or having a depression ND that has a stitching pattern ST above the level of the depression NC ( Figure 11 ), or having a depression ND that has a stitching pattern ST at / below the level of the depression ND ( Figure 12 ), or having a set of protrusions PN that have a stitching pattern ST above the level of the external surface of the cover T ( Figure 15 and Figure 17 ), or having a set of protrusions PN that have a stitching pattern ST at / below the level of the external surface of the cover T ( Figure 16 and Figure 18)。As Figure 9 、 Figure 10 、 Figure 17 and Figure 18 schematically shown in Figure 6 、 Figure 8 、 Figure 10 、 Figure 12 、 Figure 14 、 Figure 16 and Figure 18 schematically shown in

[0054] As Figure 25A and Figure 25B schematically shown in Figures 2A - 2C 、 Figure 3 and Figure 4 。

[0055] As Figures 2A - 2C 、 Figure 3 、 Figure 4 、 Figures 22A - 22E and Figures 23A - 23B schematically shown in Figure 5 、 Figure 6 、 Figure 7 、 Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 、 Figure 13 、 Figure 14 、 Figure 15 、 Figure 16 、 Figure 17 and Figure 18 。As Figures 2A - 2C 、Figure 3 , Figure 4 , Figures 21A - 21C and Figures 22A - 22E As schematically shown in Figure 2C and Figure 4 ), the feature FT for a composite structure including a substrate SB (shown as a compressed fiber panel CF) and a cover layer T for a component C (providing a cover layer / external surface) can be arranged and / or combined in any one of a variety of designs / shapes and configurations / arrangements, such as having a set of features FT including protrusions PN, depressions ND, and a stitch pattern (see Figure 3 and Figures 22B - 22C ) or having a set of features FT including protrusions PN and depressions ND (see Figure 22D and Figure 22E ); the feature FT can include a bulge / protrusion PN (see Figure 2C and Figures 21A - 21C ) or a depression / recess ND (see Figures 2A - 2C 、 Figure 3 、 Figure 4 、 Figures 22A - 22E and Figures 25A - 25B ), the feature FT for a composite structure including a substrate SB for a component C and a cover T can be arranged and / or combined in any one of a variety of designs / shapes, configurations / arrangements, and textures / elasticities, such as with a rigid substrate SB (shown as a rigid compressed / treated fiber panel CF) and a compliant cover T (shown as an elastic / compressible material) providing the feature FT (see Figures 22A - 22C and Figures 25A - 25B ).

[0056] As schematically shown in the exemplary embodiments according to Figure 2C 、 Figure 4 、 Figure 11 、 Figure 12 、 Figure 13 、 Figure 14 、 Figure 15 、 Figure 16 、 Figure 17 、 Figure 18 and Figures 21A - Figure 21C , the feature shown as a stitch pattern ST can be formed in / via the substrate SB of the compressed fiber panel CF and the cover T of the composite structure shown as a component in various arrangements; as schematically shown in the exemplary embodiment according to Figures 21A - 21C , a stitch pattern can be applied by using a device shown as a sewing machine MW having a needle NL, and the device applies a stitch shown as a stitch pattern ST including a top stitch TS and a bottom stitch BS. Also see Figure 2C and Figure 4 . As Figures 2A - 2B and Figure 4Schematically shown, component C may include a composite structure that provides an outer surface for the cover member with a visual / decorative effect provided by a stitch pattern ST. Also see Figure 2C and Figure 21C .

[0057] As schematically shown according to the exemplary embodiments in Figures 20A - 20D and Figures 24A - 24D , the composite structure of the component may be formed in a tooling die that includes a die bottom MB and a die top MT to compress and form a substrate SB from a preformed panel PF, and a die top MTX for molding a cover member T into a cover layer formed on the substrate SB (e.g., injection molding with a material shown as resin R); the substrate may include a base layer. Also see Figures 26A - 26B , Figure 27 and Figure 28 . As schematically shown according to the exemplary embodiments in Figures 20A - 20D and Figures 24A - 24D , the composite structure may include a cover layer formed on the substrate; the composite structure may include a cover layer molded on the substrate; the composite structure may include a cover layer molded around the substrate; the composite structure may include a cover layer partially molded around the substrate; the composite structure may include a cover layer molded laterally around the substrate; the composite structure may include a cover layer molded on and at least partially under the substrate. Also see Figures 26A - 26B , Figure 27 and Figure 28 . As schematically shown according to the exemplary embodiments in Figures 20A - 20D and Figures 24A - 24D , the cover member T may include formed features such as a protrusion PN (see Figures 20C - 20D ) and / or a depression (see Figure 24C and 24D ); the cover member T may include an injection-molded thermoplastic material such as resin R; the cover member T may include an injection-molded material formed with the feature. As schematically shown according to the exemplary embodiments in Figures 20A - 20D and Figures 24A - 24D , the tooling die / die top MT may be configured to form features in the substrate; the tooling die / die top MTX may be configured to form features in the cover member. Also see Figures 26A - 26B , Figure 27 and Figure 28 .

[0058] As according to Figures 2A - 2C , Figure 3 , Figure 4 and Figures 23A - 23BAs schematically shown in the exemplary embodiments herein, the component C for the interior of a vehicle may include a composite structure that includes a substrate SB and a cover T; the substrate SB may include a fiber panel CF; the cover layer T may include a cover layer / surface layer that provides an outer surface TX; the cover may include features FT such as recesses / depressions ND and / or protrusions / bulges PN. See Figure 2C , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 9 , Figure 10 , Figure 11 , Figure 12 , Figure 13 , Figure 14 , Figure 15 , Figure 16 , Figure 17 and Figure 18 . The composite structure may include features FT such as a stitch pattern ST formed in the cover T and the substrate SB; the stitch pattern may provide a visual / decorative effect; the decorative effect may include simulating seams (e.g., French seams or deck seams). See Figures 2A - 2C , Figure 4 , Figure 11 , Figure 12 , Figure 13 , Figure 14 , Figure 15 , Figure 16 , Figure 17 and Figure 18 . The feature FT may include an image or a mark at the outer surface. See Figures 2A - 2C , Figure 3 , Figure 4 and Figures 23A - 23B . The feature FT may include grooves and / or ribs. See Figures 2A - 2C , Figure 3 and Figure 4 . The cover may include a thermoplastic material molded onto the substrate; the cover may be generally opaque and may be softer than the substrate; the cover may include TPE, TPV or PU materials.

[0059] The component C may include a dashboard, an instrument panel, a cockpit, a door panel, a steering wheel, a console, a knee pad, a decorative component, etc. Exemplary embodiment A

[0060] According to an exemplary embodiment schematically illustrated in the accompanying drawings, a component for a vehicle interior may include a composite structure that includes a substrate and a cover. The substrate may include a panel. The cover may include a cover layer. The cover layer may include an inner surface and an outer surface. The outer surface of the cover layer may include an outer surface of the composite structure. The cover layer may include features in the outer surface of the cover layer. The panel may include a fiber panel. The substrate may include a compressed fiber panel. The features of the cover layer may include at least one of (a) a depression in the outer surface of the cover layer and (b) a protrusion in the outer surface of the cover layer. The cover layer may include a protrusion in the outer surface of the cover layer. The cover layer may include a recess in the outer surface of the cover layer. The features of the cover layer may include a recess in the outer surface of the cover layer and a protrusion in the outer surface of the cover layer. The recess may be formed above the outer surface of the cover layer. The protrusion may be formed above the outer surface of the cover layer. The features of the cover layer may include a groove in the outer surface of the cover layer. The features of the cover layer may include a rib in the outer surface of the cover layer. The features of the cover layer may include a depression in the outer surface of the cover layer and a rib in the outer surface of the cover layer. The features of the cover layer may be below the outer surface of the cover layer. The features of the cover layer may include a depression below the outer surface of the cover layer. The features of the cover layer may be above the outer surface of the cover layer. The features of the cover layer may include a protrusion above the outer surface of the cover layer. The cover may include a resin. The cover layer may include a surface layer. The inner surface of the cover layer may be coupled to the substrate. The cover layer may be formed on the substrate. The cover layer may be molded on the substrate. The cover layer may be molded around the substrate. The composite structure may include a stitch pattern. The stitch pattern may be formed in the cover layer and the substrate. The features of the cover layer may include a stitch pattern provided above the outer surface of the cover layer. The stitch pattern may include stitching through the inner surface of the cover layer. The stitch pattern may be within a recess in the outer surface of the substrate. The stitch pattern may be provided through the top surface of the substrate. The stitch pattern may be below the outer surface of the cover layer. The stitch pattern may be above the outer surface of the cover layer. The stitch pattern may be within a groove in the outer surface of the cover layer. Features may be provided in the top surface of the substrate. The features in the top surface of the substrate may include at least one of a protrusion or a recess. The substrate may include a structural substrate. The structural substrate may include a compression molded panel. The compression molded panel of the structural substrate may include a rigid compressed fiber panel. The substrate may include a semi-rigid compressed fiber panel. The cover layer may include a material softer than the material of the substrate. The composite structure may be configured to provide a decorative effect; the decorative effect may include a stitch pattern. The composite structure may include a stitch pattern; the stitch pattern may be formed in the cover layer and the substrate. The stitch pattern may be adjacent to the features of the cover layer. The stitch pattern may be in a groove in the outer surface of the cover layer.The features of the stitch pattern and the cover layer can be configured to provide a decorative effect. The features of the stitch pattern and the cover layer can be configured to provide a visual effect; the visual effect includes at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The features of the cover layer can include protrusions and / or depressions. The composite structure can include a stitch pattern adjacent to the features of the cover layer. The composite structure can include a stitch pattern at the features of the cover layer. The composite structure can include a stitch pattern passing through the features of the cover layer. The features of the cover layer can include at least one of the following: (a) markings; (b) images; (c) icons; (d) logos. The composite structure can include a cover layer formed on a substrate; the features of the cover layer can be configured to provide a visual effect to the outer surface of the cover layer. The composite structure can include a cover layer (a) formed on or (b) molded on the substrate. The composite structure can include a cover layer (a) molded around a portion of the substrate; (b) molded laterally around the substrate; (c) molded on the substrate and at least partially under the substrate. The cover layer can be molded on the substrate; the cover layer can include a thermoplastic material by injection molding. The cover layer can include at least one of the following: (a) TPE material; (b) TPV material; (c) PU material. The features of the cover layer can include formed protrusions. The formed protrusions can include at least one of the following: (a) images; (b) icons. The features of the cover layer can include formed recesses. The composite structure is configured to provide an opening for deploying an airbag through the opening. The component can include at least one of the following: (a) instrument panel; (b) dashboard; (c) door panel; (d) steering wheel assembly; (e) console; (f) cockpit; (g) knee pad; (h) decorative component.

[0061] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior may include a substrate formed of a fiber panel; and a cover member including a surface layer covering the substrate. The surface layer may include an inner surface coupled to the substrate and an outer surface providing an external surface. The surface layer may include at least one of the following: (a) a recess in the outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer. The recess may be formed as a concave portion in the outer surface of the surface layer. The surface layer may be molded on the substrate. The surface layer may include an injection-molded thermoplastic material. The surface layer may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The surface layer may include a surface layer material; the surface layer material may be softer than the substrate. The component may include a stitch pattern formed in the surface layer and the substrate. The stitch pattern and the recess in the outer surface of the surface layer may be configured to provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The stitch pattern and the protrusion in the outer surface of the surface layer may be configured to provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The protrusion in the outer surface of the surface layer may include at least one of the following: (a) an image; (b) an icon.

[0062] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior formed in a mold may include (a) a substrate including a compression-molded component; and (b) a cover member including a surface layer. The compression-molded component may be formed by compressing a fiber panel between a first surface of the mold and a second surface of the mold. The surface layer may be formed by molding the surface layer on the compression-molded component. The cover member may include features including at least one of the following: (a) a recess in the outer surface of the cover member and (b) a protrusion in the outer surface of the cover member. The component may include a composite structure including the substrate and the cover member; the composite structure may include a stitch pattern adjacent to the features of the cover member.

[0063] According to an exemplary embodiment schematically shown in the accompanying drawings, a method of manufacturing a component for a vehicle interior in a mold may include: (a) providing a preformed substrate; (b) disposing the preformed substrate on a first surface of the mold; (c) compressing the preformed substrate between the first surface of the mold and a second surface of the mold to form the preformed substrate into a compression-molded component having a shape corresponding to a first profile of the first surface and a second profile of the second surface; and (d) molding a surface layer on the compression-molded component. The step of molding the surface layer on the compression-molded component may include molding the surface layer between the compression-molded component and a third surface of the mold; the third surface of the mold may be configured to form at least one of the following: (a) a recess in an outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer. The step of molding the surface layer on the compression-molded component may include molding the surface layer on a top surface of the compression-molded component and an edge of the compression-molded component. The method may include the step of forming a stitch pattern in the surface layer and the compression-molded component. A component manufactured by this method may include a composite structure including a structural substrate formed from the preformed substrate and a cover including the surface layer. An outer surface of the surface layer of the cover may include an outer surface of the composite structure; the composite structure may include a stitch pattern adjacent to a feature of the cover layer. Exemplary Embodiment B

[0064] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior may include a composite structure that includes a substrate and a cover. The substrate may include a panel. The cover may include a cover layer. The cover layer may include an inner surface and an outer surface. The outer surface of the cover layer may include the outer surface of the composite structure. The cover layer may include features in the outer surface of the cover layer. The panel may include a fiber panel. The substrate may be formed of the fiber panel. The substrate may include a compressed fiber panel. The features of the cover layer may include at least one of (a) a depression in the outer surface of the cover layer and (b) a protrusion in the outer surface of the cover layer. The features of the cover layer may include at least one of (a) a recess in the outer surface of the cover layer and (b) a protrusion in the outer surface of the cover layer. The cover layer may include a protrusion in the outer surface of the cover layer. The cover layer may include a recess in the outer surface of the cover layer. The features of the cover layer may include a recess in the outer surface of the cover layer and a protrusion in the outer surface of the cover layer. The recess may be formed above the outer surface of the cover layer. The protrusion may be formed above the outer surface of the cover layer. The features of the cover layer may include a groove in the outer surface of the cover layer. The groove of the cover layer may include at least one of (a) a recess in the outer surface of the cover layer and (b) a protrusion in the outer surface of the cover layer. The groove of the cover layer may include a recess in the outer surface of the cover layer and a set of protrusions in the outer surface of the cover layer. The features of the cover layer may include a rib in the outer surface of the cover layer. The features of the cover layer may include a depression in the outer surface of the cover layer and a rib in the outer surface of the cover layer. The features of the cover layer may be below the outer surface of the cover layer. The feature may include a depression below the outer surface of the cover layer. The features of the cover layer may be above the outer surface of the composite structure. The feature may include a protrusion above the outer surface of the composite structure. The cover may include a surface layer. The cover may include a resin. The cover layer may include a surface layer. The inner surface of the cover layer may be coupled to the substrate. The cover layer may be formed on the substrate. The cover layer may be molded on the substrate. The cover layer and the substrate may be molded around. The cover layer may be molded around the substrate. The cover layer may be applied to the substrate. The cover layer may be applied to the substrate. The cover layer may be wound around the substrate. The cover layer may be partially wrapped around the substrate. The composite structure may include a stitch pattern. The stitch pattern may be formed in the cover layer and the substrate. The features of the cover layer may include a stitch pattern provided above the outer surface of the cover layer. The stitch pattern may include stitches passing through the inner surface of the cover layer. The stitch pattern may be within a recess in the outer surface of the substrate. The stitch pattern may be provided through the top surface of the substrate. The stitch pattern may be below the outer surface of the cover layer. The stitch pattern may be above the outer surface of the composite structure. The stitch pattern may be below the outer surface of the composite structure. The stitch pattern may be above the outer surface of the cover layer.The stitching pattern can be within a groove in the outer surface of the cover layer. Features can be provided in the top surface of the substrate. The features can be formed in the top surface of the substrate. The features in the top surface of the substrate can include at least one of a protrusion or a recess. The features can be formed in the panel of the substrate. The substrate can include a structural substrate. The structural substrate can include a compression molded panel. The compression molded panel can include a compression molded fiber panel. The panel of the structural substrate can include a rigid compression fiber panel. The panel of the substrate can include a semi-rigid compression fiber panel. The panel of the substrate can include a semi-rigid compression fiber panel; the cover layer can include a material softer than the material of the substrate panel. The cover layer can include a material softer than the material of the substrate. The panel can include a fiber panel. The panel can include a fiber panel containing natural fibers. The composite structure can be configured to provide a decorative effect. The outer surface of the cover can be configured to provide a decorative effect. The outer surface of the composite structure can be configured to provide a decorative effect. The composite structure can be configured to provide a decorative effect; the decorative effect can include a stitching pattern. The composite structure can include a stitching pattern; the stitching pattern can be formed in the cover layer and the substrate. The stitching pattern can be adjacent to the features in the outer surface of the cover layer. The stitching pattern can be in a groove in the outer surface of the cover layer. The stitching pattern and the features in the outer surface of the cover layer can be configured to provide a decorative effect. The features can include protrusions and / or depressions. The decorative effect can include a visual effect. The stitching pattern and the features in the outer surface of the cover layer can be configured to provide a visual effect. The visual effect can include at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The stitching pattern and the features in the outer surface of the cover layer can be configured to provide a visual effect that includes at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The visual effect can include a decorative effect. The composite structure can include a stitching pattern adjacent to the features of the cover layer. The composite structure can include a stitching pattern at the features of the cover layer. The composite structure can include a stitching pattern in the features of the cover layer. The composite structure can include a stitching pattern passing through the features of the cover layer. The substrate can include features at the back side of the panel. The substrate can include features formed at the back side of the panel. The features at the back side of the panel can include at least one of the following: (a) resin; (b) thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The features at the back side of the panel can be molded on the back side of the panel. The substrate can include a set of protrusions formed on the back side of the panel. The set of protrusions formed on the back side of the panel can include at least one of the following: (a) resin; (b) thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate.The set of protrusions formed on the rear side of the panel may include at least one of the following: (a) ribs; (b) a set of ribs; (c) resin-formed features; (d) resin-molded features molded on the substrate. The set of protrusions formed on the rear side of the panel may include at least one protrusion. Features in the outer surface of the cover layer may include markings. The markings may include at least one of the following: (a) images; (b) icons; (c) logos. Protrusions in the outer surface of the cover layer may include at least one of the following: (a) images; (b) icons. Recesses in the outer surface of the cover layer may include grooves. The composite structure may include a cover layer formed on a substrate; the features of the cover layer may be configured to provide a visual effect to the outer surface of the composite structure. The outer surface of the cover may include a decorative effect. The composite structure may include a cover layer formed on a base layer of the substrate; the features of the cover layer of the cover may include a stitch pattern visible above the outer surface of the composite structure. The stitch pattern may include a decorative effect visible above the outer surface of the composite structure. The composite structure may include a cover layer formed on a substrate. The composite structure may include a cover layer molded on a substrate. The composite structure may include a cover layer molded around a substrate. The composite structure may include a cover layer partially molded around a substrate. The composite structure may include a cover layer molded laterally around a substrate. The composite structure may include a cover layer molded on and at least partially under a substrate. The cover layer may be molded on the substrate; the cover layer may include an injection-molded thermoplastic material. The cover layer may include a generally opaque material. The cover layer may include at least one of the following: (a) TPE material; (b) TPV material; (c) PU material. Features of the cover layer may include formed protrusions. Features of the cover layer may include formed recesses. The formed protrusions may include protrusions. The formed recesses may include depressions. Features of the cover layer may include integrally formed protrusions. Features of the cover layer may include integrally formed recesses. Features in the outer surface of the cover layer may include protrusions in the inner surface of the cover layer; the protrusions may be configured to fit within depressions in the top surface of the substrate. The composite structure may be configured to facilitate the formation of an opening for deploying an airbag into the vehicle interior. The composite structure may be configured to facilitate the formation of an airbag door to provide an opening for deploying an airbag into the vehicle interior. The composite structure is configured to provide an opening for deploying an airbag through the opening. The composite structure may be configured to contact an airbag to form an opening for deploying the airbag. The rear side of the fiber panel may be configured to contact an airbag to establish an opening for deploying the airbag. The composite structure may be configured to support an airbag module including an airbag. The panel may be configured to support an airbag module including the airbag.A feature at the rear side of the panel may include at least one of the following: (a) an airbag chute; (b) a passage for the airbag; (c) a feature configured to facilitate opening; (d) a structure for an airbag door; (e) a set of ribs configured to establish a seam for the airbag door; (f) a welding rib configured to couple the airbag chute to the panel. The component may include at least one of the following: (a) an instrument panel; (b) a dashboard; (c) a door panel; (d) a steering wheel assembly; (e) a console; (f) a cockpit; (g) a knee pad; (h) a trim component.

[0065] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior may include a substrate formed of a fiber panel; and a cover member including a surface layer for the substrate. The surface layer may include an inner surface coupled to the substrate and an outer surface providing an external surface. The surface layer may include at least one of the following: (a) a recess in the outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer. The protrusion may include a bulge; the recess may include a concave portion. The substrate and the cover member may include a composite structure configured to provide an external surface. The surface layer may include a cover layer. The recess may be formed as a concave portion in the outer surface of the surface layer. The surface layer may include a protrusion in the inner surface of the surface layer opposite to the recess in the outer surface of the surface layer. The protrusion in the inner surface of the surface layer may be configured to fit within a recess in the top surface of the substrate. The recess in the top surface of the substrate may be formed in the fiber panel. The surface layer may be molded on the substrate. The surface layer may include an injection-molded thermoplastic material. The surface layer may include a generally opaque material. The surface layer may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The surface layer may include a surface layer material; the surface layer material may be softer than the substrate. The fiber panel may include a panel containing fibers. The fiber panel may be configured to provide an opening for deploying an airbag through the opening. The rear side of the fiber panel may be configured to contact the airbag to establish an opening for deploying the airbag. The rear side of the panel may be configured to support an airbag module including the airbag. The substrate may include at least one feature on the rear side of the panel. The at least one feature may include at least one of the following: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The at least one feature may be formed on the rear side of the panel. The at least one feature may include at least one of the following: (a) an airbag chute; (b) a passage for the airbag; (c) a feature configured to facilitate opening; (d) a structure for a safety airbag door; (e) a set of ribs configured to establish a seam for the airbag door; (f) a welding rib configured to couple the airbag chute to the panel. The substrate may include a compression-molded component from the fiber panel. The component may include a stitch pattern. The stitch pattern may be formed in the surface layer and the substrate. The stitch pattern may be adjacent to the protrusion in the outer surface of the surface layer. The stitch pattern and the protrusion in the outer surface of the surface layer may be configured to provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The substrate may include at least one feature formed on the rear side of the panel. The at least one feature may include at least one of the following: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate.The at least one feature may include at least one of the following: (a) ribs; (b) a set of ribs; (c) resin-formed features; (d) resin-formed features molded on the substrate. Protrusions in the outer surface of the surface layer may include at least one of the following: (a) images; (b) icons. Depressions in the outer surface of the surface layer may include grooves. The component may include a composite structure including the substrate and the cover; the outer surface of the cover may include the outer surface of the composite structure. The surface layer may include a cover layer. The component may include at least one of the following: (a) instrument panel; (b) dashboard; (c) door panel; (d) steering wheel assembly; (e) console; (f) cockpit; (g) knee pad; (h) decorative component.

[0066] According to an exemplary embodiment schematically shown in the drawings, a component for a vehicle interior formed in a mold may include (a) a substrate including a compression-molded component; and (b) a cover including a surface layer. The compression-molded component may be formed by compressing a fiber panel between a first surface and a second surface of the mold. The surface layer may be formed by molding the surface layer on the compression-molded component. The component may include a composite structure including the substrate and the cover. The outer surface of the surface layer of the cover may include the outer surface of the composite structure. The surface layer may include a cover layer. The composite structure may include a stitch pattern adjacent to features of the cover layer. The composite structure may include a stitch pattern at features of the cover layer. The features of the cover layer may include at least one of (a) recesses in the outer surface of the cover layer and (b) protrusions in the outer surface of the cover layer. The composite structure may be configured to facilitate the formation of an airbag door to provide an opening for deploying an airbag into the vehicle interior.

[0067] According to an exemplary embodiment schematically shown in the drawings, a method of manufacturing a component for a vehicle interior in a mold may include: (a) providing a preformed substrate; (b) disposing the preformed substrate on a first surface of the mold; (c) compressing the preformed substrate between the first surface of the mold and a second surface of the mold to form the preformed substrate into a compression molded component having a shape corresponding to a first profile of the first surface and a second profile of the second surface; and (d) molding a surface layer on the compression molded component. The method may include the step of injecting resin into the mold to form features on a rear side of the compression molded component. The step of molding a surface layer on the compression molded component may include molding the surface layer between the compression molded component and a third surface of the mold. The third surface of the mold may be configured to form at least one of: (a) a recess in an outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer. The step of molding a surface layer on the compression molded component may include molding the surface layer on a top surface of the compression molded component and on an edge of the compression molded component. The step of compressing the preformed substrate between the first surface of the mold and the second surface of the mold may include forming a recess on a top surface of the compression molded component. A component manufactured by the method may include a composite structure including a structural substrate formed by the preformed substrate and a cover including the surface layer. An outer surface of the surface layer of the cover may include an outer surface of the composite structure. The surface layer may include a cover layer. The composite structure may include a stitch pattern adjacent to features of the cover layer. The composite structure may include a stitch pattern at features of the cover layer. The features of the cover layer may include at least one of: (a) a recess in an outer surface of the cover layer; (b) a protrusion in the outer surface of the cover layer. The composite structure may be configured to facilitate forming an airbag door to provide an opening for deploying an airbag into the vehicle interior. Exemplary Embodiment C

[0068] See Figure 1A and Figure 1B FIGS. and, illustrate a vehicle V including an interior I having an instrument panel IP and a door panel DP. According to an exemplary embodiment, interior components of the vehicle V such as the instrument panel IP and the door panel DP may include trim panels. According to an exemplary embodiment, components such as the instrument panel IP and the door panel DP (and other trim components) may provide a visible surface in the vehicle interior of the vehicle V.

[0069] As schematically shown according to an exemplary embodiment in Figure 2A , a component such as the instrument panel IP or the steering wheel may include a substrate covered by a cover. The cover may include visible stitching. As schematically shown according to an exemplary embodiment in Figure 2B , a component such as the door panel may include a substrate covered by a cover. The cover may include visible stitching.

[0070] According to an exemplary embodiment schematically shown as Figure 3 below, a component C for a vehicle interior may include a substrate SB formed of a compression molded component CF. The component C may include a base B shown as a housing / chute CH (e.g., for an airbag). The base B may be coupled to the substrate SB. The substrate SB may be covered by a cover T. The cover T may include protrusions PN and / or depressions ND.

[0071] According to Figure 4 an exemplary embodiment schematically shown as below, the component C may include a stitching ST shown as a stitching pattern. The stitching pattern may be formed to cover the cover T and the substrate SB. The stitching pattern may be adjacent protrusions PN. The stitching pattern may be adjacent to a recess RS. The stitching pattern and the protrusions PN and / or the recess RS may provide a visual effect that includes at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam.

[0072] According to Figure 19A an exemplary embodiment schematically shown as below, a 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.). According to an exemplary embodiment, the fiber mat FM may have a thickness tM. According to an exemplary embodiment, the fiber mat FM may be heated to cause the thermoplastic resin to liquefy. According to Figure 19B an exemplary embodiment schematically shown as below, the fiber mat FM may be heated and partially compressed into a preform PF. 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 cools, the thermoplastic material within the fiber mat may solidify to establish a substantially rigid composite panel. According to an exemplary embodiment, the preform may have a thickness tP, which may be less than the thickness tM.

[0073] 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 having a desired shape and cause the thermosetting resin to cure. According to an exemplary embodiment, a substantially rigid composite panel may be formed after the thermosetting resin cures.

[0074] According to Figure 19C an exemplary embodiment schematically shown as below, a preform PF including a compressed fiber mat may be heated in an oven VN. As Figure 19DAs schematically shown, the heated preform can be transferred into a mold having a mold top MT and a mold bottom MB. According to an exemplary embodiment, the compression molded part CF shown as the substrate SB can be produced by the process of compression molding the preform PF. The method can further include injection molding. According to an exemplary embodiment, the heated preform can be further compressed into a fiber panel; a plastic resin can be injected into the rear side of the fiber panel to form auxiliary features. According to an exemplary embodiment, the compression molded part CF can provide auxiliary features, such as plastic ribs, on the rear side of the compression molded part CF to improve structural integrity and rigidity. According to an exemplary embodiment, the compression molded part CF can be configured to support an airbag chute (i.e., an airbag module) and / or an airbag. According to an exemplary embodiment, the plastic ribs can be placed at any position on the rear side of the compression molded part CF (e.g., along the edge, in the middle, etc.). According to an exemplary embodiment, multiple plastic ribs can be placed at different positions on the rear side of the compression molded part CF.

[0075] According to Figure 20A the exemplary embodiment schematically shown in, the preform PF is placed in a mold having a mold top MT and a mold bottom MB. According to Figure 20B the exemplary embodiment schematically shown in, the compression molded part CF shown as the substrate SB can be produced by compression molding the preform PF. According to Figure 20C the exemplary embodiment schematically shown, the cover T can be molded on the substrate SB. The cover layer T can include a surface layer. The cover T can be formed by injection molding a thermoplastic material on the substrate SB. The thermoplastic material can include a generally opaque material. The thermoplastic material can include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The cover T can be molded between the substrate SB and the mold top MTX. The mold top MTX can include a surface configured to form at least one of the following: (a) a recess in the outer surface of the cover T; (b) a protrusion in the outer surface of the cover T. The cover T can be molded on the top surface of the substrate SB and on the edge of the substrate SB. According to Figure 20D the exemplary embodiment schematically shown in, the part C can include a substrate SB formed of a fiber panel and a cover T for the substrate SB including a surface layer. The surface layer can include an inner surface connected to the substrate SB and an outer surface providing the outer surface of the part C. The surface layer can include at least one of the following: (a) a depression ND in the outer surface of the surface layer; (b) a protrusion PN in the outer surface of the surface layer.

[0076] Reference Figures 22A to 22E, the construction / formation of component C is schematically shown according to an exemplary embodiment. The compression molded component CF can be formed by compression molding a fiber mat. As Figure 22A schematically shown therein, the compression molded component CF can provide a surface effect including a substantially rigid form. As Figures 22B to 22C schematically shown therein, the compression molded component CF can be covered with a cover T; as Figure 22C schematically shown therein, component C can provide a surface effect including a substantially smooth surface and a substantially soft form (e.g., from cover T).

[0077] According to Figure 13 the exemplary embodiment schematically shown therein, component C can include (a) a compression molded component CF including a substrate SB and (b) a cover T including a surface layer. The surface layer can include an inner surface connected to the substrate SB and an outer surface providing the outer surface of component C. The surface layer can include a recess ND in the outer surface of the surface layer. Component C can include a stitch ST shown as a stitch pattern. The stitch pattern can be formed on the cover T and the substrate SB. The stitch pattern can be adjacent to the recess RS. The stitch pattern and the recess RS can provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam.

[0078] According to Figure 15 the exemplary embodiment schematically shown therein, component C can include (a) a compression molded component CF including a substrate SB and (b) a cover T including a surface layer. The surface layer can include an inner surface connected to the substrate SB and an outer surface providing the outer surface of component C. The surface layer can include a protrusion PN in the outer surface of the surface layer. Component C can include a stitch ST shown as a stitch pattern. The stitch pattern can be formed on the cover T and the substrate SB. The stitch pattern can be adjacent to the protrusion PN. The stitch pattern and the protrusion PN can provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam.

[0079] According to Figure 17In the exemplary embodiment schematically shown, component C may include (a) a compression-molded component CF including a substrate SB and (b) a cover T including a surface layer. The surface layer may include an inner surface connected to the substrate SB and an outer surface providing the outer surface of component C. The surface layer may include protrusions PN in the outer surface of the surface layer. The substrate SB includes protrusions PN in the outer surface of the substrate SB. The protrusions PN in the outer surface of the surface layer may be formed by molding the surface layer over the protrusions PN in the outer surface of the substrate SB. Component C may include a stitch pattern ST shown as a suture pattern. The stitch pattern may be formed to cover the cover T and the substrate SB. The stitch pattern may be adjacent protrusions PN. The stitch pattern and the protrusions PN may provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. Exemplary embodiment D

[0080] According to an exemplary embodiment schematically shown in the accompanying drawings, a component C for a vehicle interior may include a substrate SB formed of a fiber panel; and a cover member including a surface layer covering the substrate. The surface layer may include an inner surface coupled to the substrate and an outer surface providing an outer surface of the component. The surface layer may include at least one of the following: (a) a depression ND in the outer surface of the surface layer; (b) a protrusion PN in the outer surface of the surface layer. The depression may be formed as a recess in the surface layer. The surface layer may include a protrusion in the inner surface of the surface layer opposite to the depression in the outer surface of the surface layer. The protrusion in the inner surface of the surface layer may be configured to fit within a depression ND in the top surface of the substrate. The depression in the top surface of the substrate may be formed in the fiber panel. The surface layer may be molded on the substrate. The surface layer may include an injection-molded thermoplastic material. The surface layer may include a generally opaque material. The surface layer may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The surface layer may include a surface layer material; the surface layer material may be softer than the substrate. The fiber panel may include a panel containing fibers. The fiber panel may be configured to provide an opening for deploying an airbag through the opening. The rear side of the fiber panel may be configured to contact the airbag to establish an opening for deploying the airbag. The rear side of the panel may be configured to support an airbag module including the airbag. The substrate may include at least one feature on the rear side of the panel. The at least one feature may include at least one of the following: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The at least one feature may be formed on the rear side of the panel. The at least one feature may include at least one of the following: (a) an airbag chute; (b) a passage for the airbag; (c) a feature configured to facilitate opening; (d) a structure for a safety airbag door; (e) a set of ribs configured to establish a seam for the airbag door; (f) a welding rib configured to couple the airbag chute to the panel. The substrate may include a compression-molded component CF from the fiber panel. The component may include a stitch pattern ST. The stitch pattern may be formed in the surface layer and the substrate. The stitch pattern may be adjacent to the protrusion in the outer surface of the surface layer. The stitch pattern and the protrusion in the outer surface of the surface layer may be configured to provide a visual effect including at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam. The substrate may include at least one feature formed on the rear side of the panel. The at least one feature may include at least one of the following: (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The at least one feature may include at least one of the following: (a) a rib; (b) a set of ribs; (c) a resin-formed feature; (d) a resin-molded feature molded on the substrate.The protrusions in the outer surface of the surface layer may include at least one of the following: (a) an image; (b) an icon. The depressions in the outer surface of the surface layer may include grooves. The component may include at least one of the following: (a) a dashboard; (b) an instrument panel; (c) a door panel; (d) a steering wheel assembly; (e) a console; (f) a cockpit; (g) a knee pad; (h) a decorative component.

[0081] According to an exemplary embodiment schematically shown in the drawings, a component C for a vehicle interior formed in a mold may include a substrate SB and a cover T, the substrate SB including a compression-molded component CF, and the cover T including a surface layer. The compression-molded component may be formed by compressing a fiber panel between a first surface and a second surface of the mold. The surface layer may be formed by molding the surface layer on the compression-molded component.

[0082] According to an exemplary embodiment schematically shown in the drawings, a method of manufacturing a component for a vehicle interior in a mold may include: providing a preformed substrate PF; disposing the preformed substrate on a first surface MB of the mold; compressing the preformed substrate between the first surface and a second surface MT of the mold to form the preformed substrate into a compression-molded component having a shape corresponding to a first profile of the first surface and a second profile of the second surface; and molding a surface layer on the compression-molded component. The method may include the step of injecting resin into the mold to form features on the rear side of the compression-molded component. The method may include the step of injecting resin into the mold to form features on the rear side of the compression-molded component. The step of molding the surface layer on the compression-molded component may include molding the surface layer between the compression-molded component and a third surface MTx of the mold. The third surface of the mold may be configured to form at least one of the following: (a) a depression ND in the outer surface of the surface layer; (b) a protrusion PN in the outer surface of the surface layer. The step of molding the surface layer on the compression-molded component may include molding the surface layer on the top surface and the edge of the compression-molded component. The step of compressing the preformed substrate between the first surface and the second surface of the mold may include forming a depression on the top surface of the compression-molded component.

[0083] According to as Figure 26A schematically shown in the exemplary embodiment, a method of manufacturing a component for a vehicle interior may include providing a mold including a first surface, a second surface, and a third surface; placing a preform on the first surface of the mold; compressing the preform between the first surface and the second surface of the mold to form the preform into a compression-molded component; molding a cover between the compression-molded component and the third surface of the mold; and removing the component for the vehicle interior from the mold.

[0084] According to asFigure 26B In the exemplary embodiments schematically shown, a method of manufacturing a component for a vehicle interior may include: providing a mold including a first surface and a second surface; placing a preform on the first surface of the mold; compressing the preform between the first surface of the mold and the second surface of the mold to form the preform into a compression molded component; and molding a cover on a top surface and an edge of the compression molded component to form a component for the vehicle interior.

[0085] It is important to note that the present invention (e.g., inventive concept, etc.) has been described in the specification and / or shown in the drawings of this patent document according to the exemplary embodiments; the embodiments of the present invention are given only by way of example and are not intended to limit the scope of the present invention. The construction and / or arrangement of the elements of the inventive concept implemented in the present invention as described in the specification and / or shown in the drawings are merely illustrative. Although the exemplary embodiments of the present invention have been described in detail in this patent document, those of ordinary skill in the art will readily understand 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.) is intended to be included within the scope of the present invention. It should also be noted that various / other modifications, variations, substitutions, equivalents, changes, omissions, etc. can 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, order of process / method steps, operating conditions, performance, materials, compositions, combinations, etc.) without departing from the scope of the present invention; all such subject matter (e.g., modifications, variations, embodiments, combinations, equivalents, etc.) is 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 subject matter described in the specification and / or shown in the drawings of this patent document (e.g., details, structures, functions, materials, actions, steps, sequences, systems, results, etc.). It is expected that the claims of this patent document will be properly construed to cover the full scope of the subject matter of the present invention (e.g., including any and all such modifications, variations, embodiments, combinations, equivalents, etc.); it should be understood that the terms used in this patent document are for the purpose of providing a description of the subject matter of the exemplary embodiments and are not a limitation on the scope of the present invention.

[0086] Equally importantly, it is noted that according to an exemplary embodiment, the present invention may include conventional techniques (e.g., those implemented and / or integrated, modified, varied, combined, equivalents, etc. in the exemplary embodiment) or may include any other applicable techniques (current and / or future) having applicability and / or ability to perform the functions and processes / operations described in the specification and / or illustrated in the drawings. All such techniques (e.g., as implemented, modified, varied, combined, equivalents, etc. in the embodiment) are considered to be within the scope of the present invention of this patent document.

Claims

1. A component for use inside a vehicle, comprising: a composite structure including a substrate and a cover member; wherein the substrate includes a panel; wherein the cover member includes a cover layer; wherein the cover layer includes an inner surface and an outer surface; wherein the outer surface of the cover layer includes the outer surface of the composite structure; wherein the cover layer includes features in the outer surface of the cover layer.

2. The component according to claim 1, wherein the panel includes a fiber panel.

3. The component according to claim 1, wherein the substrate includes a compressed fiber panel.

4. The component according to claim 1, wherein the features of the cover layer include at least one of the following: (a) depressions in the outer surface of the cover layer and (b) protrusions in the outer surface of the cover layer.

5. The component according to claim 1, wherein the cover layer includes protrusions in the outer surface of the cover layer.

6. The component according to claim 1, wherein the cover layer includes recesses in the outer surface of the cover layer.

7. The component according to claim 1, wherein the features of the cover layer include recesses in the outer surface of the cover layer and protrusions in the outer surface of the cover layer.

8. The component according to claim 7, wherein the recesses are formed in the outer surface of the cover layer.

9. The component according to claim 7, wherein the protrusions are formed in the outer surface of the cover layer.

10. The component according to claim 1, wherein the features of the cover layer include grooves in the outer surface of the cover layer.

11. The component according to claim 1, wherein the features of the cover layer include ribs in the outer surface of the cover layer.

12. The component according to claim 1, wherein the features of the cover layer include depressions in the outer surface of the cover layer and ribs in the outer surface of the cover layer.

13. The component according to claim 1, wherein the features of the cover layer are below the outer surface of the cover layer.

14. The component according to claim 1, wherein the features of the cover layer include depressions below the outer surface of the cover layer.

15. The component according to claim 1, wherein the features of the cover layer are above the outer surface of the cover layer.

16. The component according to claim 1, wherein the features of the cover layer include protrusions above the outer surface of the cover layer.

17. The component according to claim 1, wherein the cover member includes resin.

18. The component according to claim 1, wherein the cover layer includes a surface layer.

19. The component according to claim 1, wherein the inner surface of the cover layer is coupled to the substrate.

20. The component according to claim 1, wherein the cover layer is formed on the substrate.

21. The component according to claim 1, wherein the cover layer is molded on the substrate.

22. The component according to claim 1, wherein the cover layer is molded around the substrate.

23. The component according to claim 1, wherein the composite structure includes a stitch pattern.

24. The component according to claim 23, wherein the stitch pattern is formed in the cover layer and the substrate.

25. The component according to claim 1, wherein the feature of the cover layer includes a stitch pattern at the outer surface of the cover layer.

26. The component according to claim 25, wherein the stitch pattern includes stitches passing through the inner surface of the cover layer.

27. The component according to claim 25, wherein the stitch pattern is located within a recess at the outer surface of the substrate.

28. The component according to claim 25, wherein the stitch pattern passes through the top surface of the substrate.

29. The component according to claim 25, wherein the stitch pattern is located below the outer surface of the cover layer.

30. The component according to claim 25, wherein the stitch pattern is located above the outer surface of the cover layer.

31. The component according to claim 25, wherein the stitch pattern is located within a groove in the outer surface of the cover layer.

32. The component according to claim 1, wherein the feature is located on the top surface of the substrate.

33. The component according to claim 32, wherein the feature on the top surface of the substrate includes at least one of a protrusion or a recess.

34. The component according to claim 1, wherein the substrate includes a structural substrate.

35. The component according to claim 34, wherein the structural substrate includes a compression molded panel.

36. The component according to claim 35, wherein the compression molded panel of the structural substrate includes a rigid compressed fiber panel.

37. The component according to claim 1, wherein the substrate includes a semi-rigid compressed fiber panel.

38. The component according to claim 1, wherein the cover layer includes a material softer than the material of the substrate.

39. The component according to claim 1, wherein the composite structure is configured to provide a decorative effect; wherein the decorative effect includes a stitch pattern.

40. The component according to claim 1, wherein the composite structure includes a stitch pattern; wherein the stitch pattern is formed in the cover layer and the substrate.

41. The component according to claim 40, wherein the stitch pattern is adjacent to the feature of the cover layer.

42. The component according to claim 40, wherein the stitch pattern is located within a groove in the outer surface of the cover layer.

43. The component according to claim 40, wherein the stitch pattern and the feature of the cover layer are configured to provide a decorative effect.

44. The component according to claim 40, wherein the suture pattern and the feature of the cover layer are configured to provide a visual effect; wherein the visual effect includes at least one of the following: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam.

45. The component according to claim 1, wherein the feature of the cover layer includes protrusions and / or depressions.

46. The component according to claim 1, wherein the composite structure includes a suture pattern adjacent to the feature of the cover layer.

47. The component according to claim 1, wherein the composite structure includes a suture pattern at the feature of the cover layer.

48. The component according to claim 1, wherein the composite structure includes a suture pattern passing through the feature of the cover layer.

49. The component according to claim 1, wherein the feature of the cover layer includes at least one of the following: (a) a mark; (b) an image; (c) an icon; (d) a logo (of a company or organization).

50. The component according to claim 1, wherein the composite structure includes the cover layer formed on the substrate; wherein the feature of the cover layer is configured to provide a visual effect for the outer surface of the cover layer.

51. The component according to claim 1, wherein the composite structure includes the cover layer (a) formed on or (b) molded on the substrate.

52. The component according to claim 1, wherein the composite structure includes the cover layer (a) molded partially around the substrate; (b) molded on the side of the substrate; (c) molded on the substrate and at least partially molded under the substrate.

53. The component according to claim 1, wherein the cover layer is molded on the substrate; wherein the cover layer includes a thermoplastic material by injection molding.

54. The component according to claim 1, wherein the cover layer includes at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material.

55. The component according to claim 1, wherein the feature of the cover layer includes a formed protrusion.

56. The component according to claim 55, wherein the formed protrusion includes at least one of the following: (a) an image; (b) an icon.

57. The component according to claim 1, wherein the feature of the cover layer includes a formed recess.

58. The component according to claim 1, wherein the composite structure is configured to provide an opening for deploying an airbag through the opening.

59. The component according to claim 1, includes at least one of the following: (a) an instrument panel; (b) a dashboard; (c) a door panel; (d) a steering wheel assembly; (e) a console; (f) a cockpit; (g) a knee pad; (h) a decorative component.

60. A component for a vehicle interior, comprising: a substrate formed of a fiber panel; and A covering member for use with the substrate, the covering member including a surface layer; wherein the surface layer includes an inner surface coupled to the substrate and an outer surface providing an external surface; wherein the surface layer includes at least one of: (a) a recess in the outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer.

61. The component according to claim 60, wherein the recess is formed as a concave portion in the outer surface of the surface layer.

62. The component according to claim 60, wherein the surface layer is molded onto the substrate.

63. The component according to claim 60, wherein the surface layer includes an injection-molded thermoplastic material.

64. The component according to claim 60, wherein the surface layer includes at least one of: (a) a TPE material; (b) a TPV material; (c) a PU material.

65. The component according to claim 60, wherein the surface layer includes a surface layer material; wherein the surface layer material is softer than the substrate.

66. The component according to claim 60, further including a stitch pattern formed in the surface layer and the substrate.

67. The component according to claim 66, wherein the stitch pattern and the recess in the outer surface of the surface layer are configured to provide a visual effect including at least one of: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam.

68. The component according to claim 66, wherein the stitch pattern and the protrusion in the outer surface of the surface layer are configured to provide a visual effect including at least one of: (a) simulating a seam; (b) simulating a French seam; (c) simulating a deck seam.

69. The component according to claim 60, wherein the protrusion in the outer surface of the surface layer includes at least one of: (a) an image; (b) an icon.

70. A component formed in a mold for use in a vehicle interior, comprising: (a) a substrate including a compression-molded component; and (b) a covering member including a surface layer; wherein the compression-molded component is formed by pressing a fiber panel between a first surface of the mold and a second surface of the mold; wherein the surface layer is formed by molding the surface layer onto the compression-molded component.

71. The component according to claim 70, wherein the covering member includes features including at least one of: (a) a concave portion in the outer surface of the covering member and (b) a protrusion in the outer surface of the covering member.

72. The component according to claim 71, including a composite structure including the substrate and the covering member; wherein the composite structure includes a stitch pattern adjacent to the features of the covering member.

73. A method of manufacturing a component for use in a vehicle interior in a mold, comprising: (a) providing a preformed substrate; (b) disposing the preformed substrate on a first surface of the mold; (c) Compress the preformed substrate between a first surface and a second surface of the mold to form the preformed substrate into a compression-molded part having a shape corresponding to a first profile of the first surface and a second profile of the second surface; and (d) Mold a surface layer on the compression-molded part.

74. The method according to claim 73, wherein the step of molding the surface layer on the compression-molded part includes molding the surface layer between the compression-molded part and a third surface of the mold; wherein the third surface of the mold is configured to form at least one of the following: (a) a recess in the outer surface of the surface layer; (b) a protrusion in the outer surface of the surface layer.

75. The method according to claim 73, wherein the step of molding a surface layer on the compression-molded part includes molding the surface layer on the top surface and the edge of the compression-molded part.

76. The method according to claim 73, wherein the method includes the step of forming a stitch pattern in the surface layer and the compression-molded part.

77. A part prepared by the method according to claim 73, comprising a composite structure, the composite structure including a structural substrate formed from the preformed substrate and a covering including the surface layer.

78. A part prepared by the method according to claim 73, wherein the outer surface of the surface layer of the covering includes the outer surface of the composite structure; wherein the composite structure includes a stitch pattern adjacent to the features of the covering layer.

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