Component for vehicle interior

Abstract

A component for a vehicle interior may include a composite structure including a substrate and a cover including a cover layer / skin layer. The substrate may include features, such as protrusions / protrusions displayed as tiles, ribs, ridges, connections in an arrangement; features such as recesses may be provided in the inner surface of the cover. The recesses and protrusions may be fitted / formed to facilitate a configuration of forming an opening in the composite structure during deployment of the airbag. The substrate may include a fiber panel / compressed panel. A cover may be molded on the substrate. Recesses in the cover may be formed by protrusions of the substrate. The cover may include an injection molded thermoplastic material. The component may include a panel, such as an instrument panel, a cab, a dashboard, 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 claims priority to the following patent applications and incorporates them herein by reference in their entirety: U.S. Provisional Patent Application No. 63 / 413,782, filed on October 6, 2022, entitled "COMPONENT FOR VEHICLE INTERIOR".

[0002] This application incorporates the following patent applications by reference in their entirety: (a) PCT / CN2021 / 088929, filed on April 22, 2021, entitled "VEHICLE INTERIOR COMPONENT"; (b) U.S. Patent Application No. 17 / 941,579, filed on September 9, 2022, entitled "COMPONENT FOR VEHICLE INTERIOR". Technical Field

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

[0004] It is known to provide a component (e.g., a decorative panel) for a vehicle interior. Interior trim components are typically provided as a headliner, door panel, instrument panel, center console, and various other components in a vehicle. It is also known in vehicles to provide an airbag behind a trim component. It is also known to provide a weakened area, such as a score line, in the trim component to guide the airbag during airbag deployment. It is also known to form the trim component by a compression molding process.

[0005] It is advantageous to provide an improved trim component (e.g., a decorative panel, instrument panel, or door panel) for a vehicle interior that provides an outlet for airbag deployment.

[0006] It is also advantageous to provide an improved trim component for a vehicle interior that has an outlet for airbag deployment that is not readily perceptible from the vehicle interior (e.g., has a smooth visible surface).

[0007] It is also advantageous to provide an improved trim component having reduced penetration energy to facilitate effective airbag deployment. It is further advantageous to manufacture the improved trim component in a single mold apparatus. Summary of the Invention

[0008] The present invention relates to a component for a vehicle interior, the component being configured to facilitate the formation of an opening for deploying an airbag into the vehicle interior, the component comprising a composite structure, the composite structure comprising a substrate and a cover. The substrate may comprise a base layer and features configured to facilitate the formation of an opening through the cover layer. The cover layer may comprise a cover having an inner surface. The cover may be disposed on the substrate. The features of the substrate may be configured to initiate the formation of the opening. The cover layer may be provided on the base layer of the substrate. The substrate may comprise a structural substrate. The features of the substrate may include a raised arrangement. The raised arrangement may include at least one protrusion. The raised arrangement may include a set of protrusions. The set of protrusions may include a set of small pieces. The set of protrusions may include a set of ribs. The set of protrusions may include a set of connecting portions connecting a set of small pieces. The base layer may comprise a material; the raised arrangement may include a set of raised portions formed of the material. The raised arrangement may include a set of protrusions integrally formed with the base layer. The raised arrangement may include a tear line. The raised arrangement may include a plurality of raised portions configured to protrude from the base layer towards the cover layer. The raised arrangement may include a plurality of raised portions configured to protrude from the base layer into the cover. The cover may include a set of cavities aligned with a set of raised portions of the substrate. The set of raised portions of the substrate may be configured to fit within the cavities of the cover. The inner surface of the cover layer may include cavities aligned with the features of the substrate. The features of the substrate may be configured to fit within the cavities of the inner surface of the cover layer. The features of the substrate may include a tear initiation portion for forming an opening for deploying the airbag; the tear initiation portion may include a central section configured to initiate the opening and a set of lateral sections configured to complete the opening. The cover may include features including a tear initiation portion configured to form an opening for deploying the airbag. The features of the substrate and the features of the cover may together facilitate the formation of an opening for airbag deployment. The cover may be formed on the substrate. The cover may be molded onto the substrate. The features of the substrate may include raised portions within the features of the inner surface of the cover layer; the features of the inner surface of the cover layer may include recesses configured to facilitate the formation of an opening through the cover layer. The raised portions may include a raised arrangement. The raised arrangement may include a pattern of raised portions. The pattern of raised portions may include a central section and a set of lateral sections. The pattern of raised portions may include a set of small pieces and a set of connecting portions. When the cover layer is formed on the substrate, the features of the inner surface of the cover layer may be formed by the features of the substrate. The cover may include features configured to initiate the formation of an opening through the cover layer to deploy the airbag into the vehicle interior. The base layer of the substrate may comprise a generally rigid fiber panel. The features of the substrate may include generally rigid raised portions. The base layer of the substrate may comprise a compressed fiber panel having substrate features. The features of the substrate may include generally rigid raised portions formed in the compressed fiber panel. The features of the substrate may include generally rigid raised portions formed on the compressed fiber panel.The features of the substrate may include protrusions formed on a compressed fiber panel. The features of the substrate may include protrusions integrally formed on the compressed fiber panel. The features of the substrate may include protrusions molded on the compressed fiber panel. The features of the substrate may include a protrusion that includes a set of small pieces molded on the compressed fiber panel. The features of the substrate may include a protrusion that includes a set of small pieces injection molded on the compressed fiber panel. The features of the substrate may include a protrusion that includes a set of small pieces formed of resin on the compressed fiber panel. The substrate may include a front side and a rear side opposite the front side; the rear side of the substrate may be configured to contact the airbag to establish an opening for deploying the airbag; the front side of the substrate may include the features of the substrate. The base layer may include an upper surface providing the substrate features and a lower surface including a recess. The recess may be offset from the features of the substrate; the recess may be configured to facilitate forming an opening for airbag deployment. The composite structure may be configured to facilitate forming an opening for the airbag to facilitate airbag deployment. The composite structure may include a cover layer formed on the base layer of the substrate; the cover layer may be configured to provide an outer surface; the features of the substrate are generally not visible on the outer surface of the cover. The composite structure may include a cover layer molded on the base layer of the substrate. The cover layer may include a recess configured to facilitate forming an opening through the cover layer. The recess may be formed as a depression in the inner surface of the cover layer. The protrusion of the substrate may be in the recess of the cover layer. The protrusion of the substrate may penetrate the inner surface of the cover layer to form the recess of the cover layer. The recess may be formed by molding the cover layer on the protrusion of the substrate. The substrate may include at least one feature adjacent to the recess on the rear side of the substrate. The at least one feature may include (a) resin; (b) thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The cover layer may include an injection molded thermoplastic material. The cover layer may include at least one of the following: (a) TPE material; (b) TPV material; (c) PU material. The inner surface of the cover layer may include features configured to facilitate forming an opening through the cover layer. The features of the inner surface of the cover layer may include a recess. The recess in the cover layer may have a nominal depth in the range between 0.3 mm and 1.5 mm. The nominal remaining thickness at the recess of the cover layer may include the nominal thickness of the cover layer minus the nominal depth of the recess in the cover layer; the nominal remaining thickness at the recess of the cover layer may be in the range between 0.3 mm and 1.5 mm. The cover layer may have a nominal thickness in the range between about 0.7 mm and about 3 mm. The substrate may include a fiber panel with a nominal thickness in the range between about 1.0 mm and 2.5 mm. 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) trim component.

[0009] The present invention relates to a component for a vehicle interior that is configured to provide an opening for deploying an airbag through an opening. The component includes: (a) a substrate including a base layer; and (b) a cover including a cover layer. The cover layer may include an inner surface coupled to the substrate. The cover layer may include a recess in the inner surface of the cover layer. The substrate may include a protrusion aligned with the recess in the cover layer. The recess in the inner surface of the cover layer and the protrusion of the substrate may be configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the cover layer. The recess may be formed as a depression in the inner surface of the cover layer. The protrusion of the substrate may be in the recess of the cover layer. The protrusion of the substrate may penetrate the inner surface of the cover layer to form the recess of the cover layer. The cover layer may include a molded thermoplastic material; the substrate may include a fiber panel. The cover layer may include a molded thermoplastic material; the substrate may include an injection molded component. The cover layer may include a surface material; the substrate may include a composite material; the surface material may be softer than the composite material. The cover layer may include a surface; the protrusion may include a projection. The cover layer may be molded on the substrate. The recess may be formed by molding the cover layer on the protrusion of the substrate. The cover layer may include an outer surface opposite the inner surface of the cover layer; the outer surface may include a substantially flat surface opposite the recess in the inner surface of the cover layer.

[0010] The present invention relates to a component for a vehicle interior that is formed in a mold and is configured to facilitate deployment of an airbag. The component includes: (a) a substrate including a fiber panel; and (b) a cover including a surface layer. The surface layer may include an inner surface coupled to the substrate. The surface layer may include a recess in the inner surface of the surface layer. The substrate may include a projection aligned with the recess in the surface layer. The substrate may include a rear side configured to contact the airbag to establish an opening for deploying the airbag. The projection of the substrate may be formed by: (a) compressing a first portion of the fiber panel between a first surface and a second surface of the mold to a first thickness; and (b) compressing a second portion of the fiber panel between the first surface and the second surface of the mold to a second thickness. The recess of the surface layer may be formed by molding the surface layer on the projection of the substrate.

[0011] The present invention relates to a method of manufacturing a component for a vehicle interior, the component being configured to provide an opening in a mold for deploying an airbag through the opening, the method comprising: (a) providing a preformed substrate; (b) disposing the preformed substrate on a first surface of the mold; (c) compressing a first portion of 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; (d) forming a second portion of the preformed substrate between the first surface of the mold and the second surface of the mold to form a protrusion in the compression-molded component; and (e) molding a skin on the compression-molded component. The inner surface of the skin may include a recess formed by molding the skin over a protrusion of the compression-molded component. The recess in the inner surface of the skin and the protrusion of the compression-molded component may be configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the skin. The method may include a step of injecting resin into the mold to form features on a rear side of the compression-molded component. The step of molding the skin on the compression-molded component may include molding the skin between the compression-molded component and a third surface of the mold. The step of molding the skin on the compression-molded component may include molding the skin on a top surface and an edge of the compression-molded component.

[0012] The present invention relates to a method of manufacturing a component for a vehicle interior, the component being configured to provide an opening in a mold for deploying an airbag through the opening, the method comprising: (a) forming a substrate in the mold; and (b) molding a skin on the substrate. The substrate may include protrusions. The inner surface of the skin may include a recess formed by molding the skin over a protrusion of the substrate. The step of forming the substrate in the mold may include injection molding the substrate. The step of molding the skin on the substrate may include injection molding a thermoplastic material on the substrate. The thermoplastic material may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material.

[0013] The present invention relates to a component for a vehicle interior, which is configured to provide an opening for deploying an airbag through an opening. The component includes a substrate and a cover member including a surface layer. The surface layer may include an inner surface coupled to the substrate. The surface layer may include a recess in the inner surface of the surface layer. The substrate may include a protrusion aligned with the recess in the surface layer. The recess in the inner surface of the surface layer and the protrusion of the substrate may be configured to facilitate the deployment of the airbag through the opening by facilitating the formation of the opening through the surface layer. The recess may be formed as a depression in the inner surface of the surface layer. The recess may include a notch. The protrusion of the substrate may be in the recess of the surface layer. The protrusion of the substrate may penetrate the inner surface of the surface layer to form the recess of the surface layer. The protrusion may include an inclined surface. The surface layer may be molded on the substrate. The recess may be formed by molding the surface layer on the protrusion of 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) TPE material; (b) TPV material; (c) PU material. The surface layer may include a surface layer material; the substrate may include a composite material; the surface layer material may be softer than the composite material. The surface layer may be configured to provide the outer surface of the component. The surface layer may include an outer surface opposite the inner surface of the surface layer; the outer surface may include a substantially flat surface opposite the recess in the inner surface of the surface layer. The substrate may include a fiber-containing panel. The substrate may include a fiber panel. The rear side of the substrate may be configured to contact the airbag to establish an opening for deploying the airbag. The rear side of the substrate may be configured to support an airbag module including the airbag. The substrate may include at least one feature adjacent the recess of the surface layer at the rear side of the substrate. The at least one feature may include (a) resin; (b) thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The at least one feature may be formed on the rear side of the substrate. The substrate may include a recess adjacent the recess of the surface layer at the rear side of the substrate. The recess of the substrate may be configured to facilitate the deployment of the airbag through the opening by facilitating the formation of the opening through the surface layer. The surface layer may include a thermoplastic material; the substrate may include a fiber panel; the substrate may include at least one feature formed by the thermoplastic material of the surface layer at the rear side of the substrate. The substrate may include an injection-molded component. 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) trim component.

[0014] The present invention relates to a component for a vehicle interior, the component being formed in a mold and configured to facilitate the deployment of an airbag. The component includes a substrate and a cover. The substrate includes a fiber panel, and the cover includes a surface layer. The surface layer may include an inner surface coupled to the substrate. The surface layer may include a recess in the inner surface of the surface layer. The substrate may include a protrusion aligned with the recess in the surface layer. The substrate may include a rear side configured to contact the airbag to establish an opening for deploying the airbag. The protrusion of the substrate may be formed by: (a) compressing a first portion of the fiber panel between a first surface and a second surface of the mold to a first thickness; and (b) compressing a second portion of the fiber panel between the first surface and the second surface of the mold to a second thickness. The recess in the surface layer may be formed by molding the surface layer over the protrusion of the substrate.

[0015] The present invention relates to a method of manufacturing a component for a vehicle interior, the component being configured to provide an opening for deploying an airbag through an opening in a mold. The method includes: (a) providing a preformed substrate; (b) disposing the preformed substrate on a first surface of the mold; (c) compressing a first portion of 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; (d) forming a second portion of the preformed substrate between the first surface of the mold and the second surface of the mold to form a protrusion in the compression molded component; and (e) molding a surface layer over the compression molded component. The inner surface of the surface layer may include a recess formed by molding the surface layer over the protrusion of the compression molded component. The recess in the inner surface of the surface layer and the protrusion of the compression molded component may be configured to facilitate the deployment of the airbag through the opening by facilitating the formation of an opening through the surface layer. 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 over the compression molded component may include molding the surface layer between the compression molded component and a third surface of the mold. The step of molding the surface layer over 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.

[0016] The present invention relates to a method of manufacturing a component for a vehicle interior, the component being configured to provide an opening for deploying an airbag through an opening in a mold, the method comprising: forming a substrate in the mold; and molding a surface layer on the substrate. The substrate may include protrusions. The inner surface of the surface layer may include recesses formed by molding the surface layer on the protrusions of the substrate. The step of forming the substrate in the mold may include injection molding the substrate. The step of molding the surface layer on the substrate may include injection molding a thermoplastic material on the substrate. The thermoplastic material may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0018] Figure 1B is a schematic perspective cross-sectional view of a vehicle showing the interior of a vehicle according to an exemplary embodiment.

[0019] Figure 2A is a schematic perspective view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0020] Figures 2B to 2D is a schematic perspective view of an airbag deploying from a vehicle interior component according to an exemplary embodiment.

[0021] Figures 2E to 2G is a schematic perspective view of an airbag deploying from a vehicle interior component according to an exemplary embodiment.

[0022] Figures 3A to 3F is a schematic perspective view of an airbag deploying from a vehicle interior component according to an exemplary embodiment.

[0023] Figures 4A to 4F is a schematic perspective view of an airbag deploying from a vehicle interior component according to an exemplary embodiment.

[0024] Figures 5A to 5G is a schematic perspective view of an airbag deploying from a vehicle interior component according to an exemplary embodiment.

[0025] Figure 6A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0026] Figure 6B is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0027] Figure 7A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0028] Figure 7B is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0029] Figure 8 is a schematic perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0030] Figure 9 is a schematic perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0031] Figure 10 is a schematic perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0032] Figures 11A to 11B is a schematic partial cross-sectional perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0033] Figures 12A to 12B is a schematic partial cross-sectional perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0034] Figures 13A to 13B is a schematic partial cross-sectional perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0035] Figure 14 is a schematic partial cross-sectional perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0036] Figure 15 is a schematic partial cross-sectional perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0037] Figure 16 is a schematic partial cross-sectional perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0038] Figure 17 is a schematic plan view of a tear line of an opening for deploying an airbag from a vehicle interior component according to an exemplary embodiment.

[0039] Figure 18 is a schematic plan view of a tear line of an opening for deploying an airbag from a vehicle interior component according to an exemplary embodiment.

[0040] Figure 19 is a schematic plan view of a tear line of an opening for deploying an airbag from a vehicle interior component according to an exemplary embodiment.

[0041] Figures 20A to 20BIs a schematic cross-sectional view of an airbag deployed from a vehicle interior component according to an exemplary embodiment.

[0042] Figure 21A And Figure 21B Is a schematic perspective view of a fiber mat compressed into a preform according to an exemplary embodiment.

[0043] Figures 21C to 21F Is a schematic perspective view of a preform formed into a component for a vehicle interior according to an exemplary embodiment.

[0044] Figures 22A to 22E Is a schematic cross-sectional view of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0045] Figures 23A to 23C Is a schematic perspective view of a fiber mat cut and compressed into a preform according to an exemplary embodiment.

[0046] Figures 23D to 23F Is a schematic perspective view of a preform formed into a component for a vehicle interior according to an exemplary embodiment.

[0047] Figure 23G Is a schematic partial cross-sectional perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0048] Figure 23H Is a schematic cross-sectional perspective view of a substrate of a component for a vehicle interior according to an exemplary embodiment.

[0049] Figures 24A to 24B Is a schematic perspective view of a process of forming a component for a vehicle interior according to an exemplary embodiment.

[0050] Figure 24C Is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0051] Figures 25A to 25C Is a schematic perspective view of a process of forming a component for a vehicle interior according to an exemplary embodiment.

[0052] Figures 26A to 26D Is a schematic partial cross-sectional view of a process of forming a component for a vehicle interior according to an exemplary embodiment.

[0053] Figures 27A to 27B Is a schematic perspective view of a process of forming a component for a vehicle interior according to an exemplary embodiment.

[0054] Figures 28A to 28B Is a schematic partial cross-sectional view of a process of forming a component for a vehicle interior according to an exemplary embodiment.

[0055] Figure 29 It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0056] Figure 30 It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0057] Figure 31 It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0058] Figures 32A to 32C It is a partial schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0059] Figures 33A to 33C It is a partial schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0060] Figure 34A It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0061] Figure 34B It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0062] Figure 34C It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0063] Figure 34D It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0064] Figure 34E It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0065] Figure 34F It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0066] Figures 35A to 35E It is a schematic cross-sectional view of a method for manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0067] Figure 35F It is a schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0068] Figure 36A It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0069] Figure 36B It is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0070] Figure 36C is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0071] Figure 36D is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0072] Figure 36E is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0073] Figure 36F is a schematic partial cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0074] Figures 37A to 37C is a schematic perspective view of a process for forming a component for a vehicle interior according to an exemplary embodiment.

[0075] Figures 38A to 38D is a schematic partial cross-sectional view of a process for forming a component for a vehicle interior according to an exemplary embodiment.

[0076] Figures 39A to 39C is a partial schematic cross-sectional view of a component for a vehicle interior according to an exemplary embodiment.

[0077] Figure 40A and Figure 40B is a schematic flow chart for forming a component for a vehicle interior according to an exemplary embodiment. DETAILED DESCRIPTION

[0078] Referring to Figures 1A - 1B and Figures 2A - 2G , 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 an instrument panel IP and a door / panel DL and a steering wheel SW; as schematically shown according to an exemplary embodiment, the components shown as a steering wheel C / SW and an instrument panel C / IP can be configured to deploy an airbag AB from an opening at an airbag door ABD formed during deployment at an airbag exit area ABX.

[0079] As according to Figures 2B - 2G , Figures 3A - 3F , Figures 4A - 4F and Figures 5A - 5GAs schematically shown in the exemplary embodiments herein, an opening in a panel for deploying an airbag AB through an opening at an airbag door ABD provided by a component C may be provided at a seam shown as a tear line TR, the seam being configured to form the opening; as shown, the tear line TR for forming an opening for deploying the airbag AB at the airbag door ABD may be provided in various shapes / forms, including an H-shaped form ( Figures 3A - 3F and Figures 24A - 24C ) or a U-shaped form ( Figures 4A - 4F ) or a line shown as a curve ( Figures 5A - 5G , Figure 17 , Figure 18 and Figure 19 ). See also Figures 20A - 20B .

[0080] As schematically shown in the exemplary embodiments according to Figures 6A - 6B , Figures 7A - 7B , Figure 8 , Figure 9 , Figure 10 , Figures 20A - 20B and Figures 24A - 24C , the component may include a composite structure, the composite structure including a panel / substrate shown as a compressed fiber panel CF / SB and a cover T of a cover layer configured to provide a structure / casing shown as an airbag chute CH (e.g., a casing of a casing configured as an airbag module); the panel / substrate CF / SB may include a feature FT shown as a protrusion PN, the protrusion being configured to facilitate the formation of a seam shown as a tear line TR (for deploying the airbag). See also Figures 3A - 3F , Figures 4A - 4F and Figures 5A - 5G .

[0081] As schematically shown in the exemplary embodiments according to Figure 8 , Figure 9 , Figure 10 , Figures 11A - 11B , Figures 12A - 12B , Figures 13A - 13B , Figure 14 , Figure 15 and Figure 16 , the feature FT of the protrusion PN shown as a base layer BL of the panel / substrate CF / SB is configured to facilitate the formation of a seam shown as a tear line TR to provide an opening for deploying an airbag from the component, and the feature may be provided in various arrangements, the arrangements including a set of protrusions NB and ribs RB and protrusions NB connected by ribs RB ( Figures 11A - 11B ), a set of protrusions PN having a circular and / or polyhedral profile ( Figures 12A - 12B and Figures 13A - 13B ), and protrusions PN shown as ribs / strips having a straight profile ( Figure 14) The raised PN shown as a rib / band with an angular profile Figure 15 ) and the raised PN shown as a rib / band with a circular / bent profile Figure 16 )

[0082] As schematically shown in the exemplary embodiments according to Figures 11A - 11B 、 Figures 12A - 12B 、 Figures 13A - 13B 、 Figure 14 、 Figure 15 、 Figure 16 、 Figure 17 、 Figure 18 and Figure 19 The features shown as raised / arranged PN can be configured in various shapes / forms and sections / arrangements, such as sections of multiple sets of small pieces and multiple sets of small pieces (see Figure 17 ) connected by multiple sets of ribs, and sections of multiple sets of ribs (see Figure 18 ). Also see Figure 19 ) Figures 3A - 3F 、 Figures 4A - 4F and Figures 5A - 5G )

[0083] As schematically shown in the exemplary embodiments according to Figures 20A - 20B and Figures 32A - 32C The features shown as raised PN in the panel / substrate SB can be configured to fit into the recesses in the cover T to facilitate the formation of an opening at the seam / tear line for deploying the airbag. Also see Figures 2B - 2G 、 Figures 3A - 3F 、 Figures 4A - 4F 、 Figures 5A - 5G 、 Figures 25A - 25C 、 Figures 26A - 26D 、 Figures 27A - 27B and Figures 28A - 28B As schematically shown in the exemplary embodiments according to Figure 29 、 Figure 30 、 Figure 31 and 33A -33C, the features shown as raised PN in the panel / substrate SB can be configured to fit into the recesses in the cover T, and the recesses RS can be provided in the bottom surface / sides of the panel / substrate SB to facilitate the formation of an opening for deploying the airbag at the seam / tear line; the features FT shown as molded ribs / forms can be provided at or along the recesses RS at the bottom surface / sides of the panel / substrate SB (see Figure 29 、 Figure 30 and Figure 31 ). Also see Figures 2B - 2G 、 Figures 3A - 3F 、 Figures 4A - 4F 、 Figures 5A - 5G 、 Figures 25A - 25C 、 Figures 26A - 26D, Figures 27A - 27B and 28A - 28B.

[0084] As schematically shown in the exemplary embodiments according to Figures 2A - 2G , Figures 3A - 3F , Figures 4A - 4F , Figures 5A - 5G and 24A - 24C, the composite structure of component C for airbag deployment can be configured to provide an outer surface with an airbag exit region ABX, where the seam / tear line for the opening may not be easily visible (until the airbag is deployed through the formation of the opening). See also Figures 20A - 20B , Figures 32A - 32C , Figures 33A - 33C and 39A - 39C. As schematically shown in the exemplary embodiments according to Figures 2A - 2G , Figures 3A - 3F , Figures 4A - 4F , Figures 5A - 5G , Figures 20A - 20B and 24A - 24C, the feature FT / RS in the cover T and the feature FT / PN in the substrate SB of the composite structure of component C for airbag deployment can be configured to have the size / thickness of the material and the arrangement of the features in a manner that facilitates the effective formation of an opening at the seam / tear line for airbag deployment through the cover T and the substrate SB of the composite structure. See also Figures 2B - 2G , Figures 3A - 3F , Figures 4A - 4F , Figures 5A - 5G , Figures 25A - 25C , Figures 26A - 26D , Figures 27A - 27B , Figures 28A - 28B , Figures 32A - 32C , Figures 33A - 33C and Figures 39A - 39C .

[0085] As schematically shown in the exemplary embodiments according to Figures 25A - 25C , Figures 26A - 26C , Figures 27A - 27B , Figures 28A - 28B , Figures 34A - 34F , Figures 36A - 36F , Figures 37A - 37C and Figures 38A - 38D , the feature of the protrusion PN shown in the base layer of the panel / substrate CF / SB and the feature of the recess RS shown in the cover layer of the cover T for the composite structure of the component can be configured in various shapes and sizes / thicknesses and materials. As according to Figures 21A - 21F , Figures 22A - 22E , Figures 23A - 23H , Figures 35A - 35F and Figures 40A - 40BThe exemplary embodiments shown schematically include that a composite structure including a panel / substrate can be formed from a fiber mat FM having a thickness tM into a preform panel PF having a thickness tP and processed / heated in an oven VN; the preform panel PF can be formed into a compression molded fiber panel CF / SB, which provides a substrate for the composite structure; the panel / substrate SB can be formed in a tool having a tool bottom MB and a tool top MT to include features FT such as bosses PN; a cover T having components / recesses can be formed by molding on a substrate having components / bosses in the tool, the tool including a tool bottom MB and a tool top MTx for forming a composite structure having a substrate and a cover as components C and components. As schematically shown according to Figures 21A - 21F 、 Figures 22A - 22E 、 Figures 25A - 25C 、 Figures 26A - 26C 、 Figures 27A - 27B 、 Figures 28A - 28B and Figures 34A - 34F in the exemplary embodiments, the feature / boss FT / PN can be integrally formed with the panel / substrate including the compression fiber panel CF / SB; the cover T can include a molded cover layer formed on the panel / substrate CF / SB for the composite structure of the components. See also Figures 11A - 11B 、 Figures 12A - 12B 、 Figures 13A - 13B and Figures 40A - 40B . As schematically shown according to Figures 35A - 35F and Figures 36A - 36F in the exemplary embodiments, the feature / boss FT / PN can include a resin / plastic material molded onto the panel / substrate including the compression fiber panel CF / SB; the cover T can include a molded cover layer formed on the panel / substrate CF / SB for the composite structure of the components. As schematically shown according to Figures 37A - 37C and Figures 38A - 38D in the exemplary embodiments, the feature / boss FT / PN can be integrally formed with the panel / substrate including the molded / injection molded panel PL / SB; the cover T can include a molded cover layer formed on the panel / substrate PL / SB for the composite structure of the components. See also Figures 39A - 39C . Exemplary Embodiment A

[0086] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior may include a composite structure, the component being configured to facilitate the formation of an opening for deploying an airbag into the vehicle interior, the composite structure including a substrate and a cover. The substrate may include a base layer and features configured to facilitate the formation of an opening through the cover layer. The cover layer may include a cover having an inner surface. The cover may be disposed on the substrate. The features of the substrate may be configured to initiate the formation of the opening. The cover layer may be provided on the base layer of the substrate. The substrate may include a structural substrate. The features of the substrate may include a raised arrangement. The raised arrangement may include at least one protrusion. The raised arrangement may include a set of protrusions. The set of protrusions may include a set of small pieces. The set of protrusions may include a set of ribs. The set of protrusions may include a set of connecting portions connecting a set of small pieces. The base layer may include a material; the raised arrangement may include a set of raised portions formed of the material. The raised arrangement may include a set of protrusions integrally formed with the base layer. The raised arrangement may include a tear line. The raised arrangement may include a plurality of raised portions configured to protrude from the base layer toward the cover layer. The raised arrangement may include a plurality of raised portions configured to protrude from the base layer into the cover. The cover may include a set of cavities aligned with a set of raised portions of the substrate. The set of raised portions of the substrate may be configured to fit within the cavities of the cover. The inner surface of the cover layer may include cavities aligned with the features of the substrate. The features of the substrate may be configured to fit within the cavities of the inner surface of the cover layer. The features of the substrate may include a tear initiation portion for forming an opening for deploying the airbag; the tear initiation portion may include a central section configured to initiate the opening and a set of transverse sections configured to complete the opening. The cover may include features including a tear initiation portion configured to form an opening for deploying the airbag. The features of the substrate and the features of the cover may together facilitate the formation of an opening for airbag deployment. The cover may be formed on the substrate. The cover may be molded onto the substrate. The features of the substrate may include raised portions within the features of the inner surface of the cover layer; the features of the inner surface of the cover layer may include recesses configured to facilitate the formation of an opening through the cover layer. The raised portions may include a raised arrangement. The raised arrangement may include a pattern of raised portions. The pattern of raised portions may include a central section and a set of transverse sections. The pattern of raised portions may include a set of small pieces and a set of connecting portions. When the cover layer is formed on the substrate, the features of the inner surface of the cover layer may be formed by the features of the substrate. The cover may include features configured to initiate the formation of an opening through the cover layer to deploy the airbag into the vehicle interior. The base layer of the substrate may include a generally rigid fiber panel. The features of the substrate may include generally rigid raised portions. The base layer of the substrate may include a compressed fiber panel having substrate features. The features of the substrate may include generally rigid raised portions formed in the compressed fiber panel.The features of the substrate may include a generally rigid protrusion formed on a compressed fiber panel. The features of the substrate may include a protrusion formed on a compressed fiber panel. The features of the substrate may include a protrusion integrally formed on a compressed fiber panel. The features of the substrate may include a protrusion molded on a compressed fiber panel. The features of the substrate may include a protrusion that includes a set of small pieces molded on a compressed fiber panel. The features of the substrate may include a protrusion that includes a set of small pieces injection molded on a compressed fiber panel. The features of the substrate may include a protrusion that includes a set of small pieces formed of resin on a compressed fiber panel. The substrate may include a front side and a rear side opposite the front side; the rear side of the substrate may be configured to contact the airbag to establish an opening for deploying the airbag; the front side of the substrate may include the features of the substrate. The base layer may include an upper surface providing the substrate features and a lower surface including a recess. The recess may be offset from the features of the substrate; the recess may be configured to facilitate the formation of an opening for airbag deployment. The composite structure may be configured to facilitate the formation of an opening for the airbag to facilitate airbag deployment. The composite structure may include a cover layer formed on the base layer of the substrate; the cover layer may be configured to provide an outer surface; the features of the substrate are generally not visible on the outer surface of the cover. The composite structure may include a cover layer molded on the base layer of the substrate. The cover layer may include a recess configured to facilitate the formation of an opening through the cover layer. The recess may be formed as a depression in the inner surface of the cover layer. The protrusion of the substrate may be in the recess of the cover layer. The protrusion of the substrate may penetrate the inner surface of the cover layer to form the recess of the cover layer. The recess may be formed by molding the cover layer on the protrusion of the substrate. The substrate may include at least one feature adjacent to the recess at the rear side of the substrate. The at least one feature may include (a) resin; (b) thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The cover layer may include an injection molded thermoplastic material. The cover layer may include at least one of the following: (a) TPE material; (b) TPV material; (c) PU material. The inner surface of the cover layer may include features configured to facilitate the formation of an opening through the cover layer. The features of the inner surface of the cover layer may include a recess. The recess in the cover layer may have a nominal depth in the range between 0.3 mm and 1.5 mm. The nominal remaining thickness at the recess of the cover layer may include the nominal thickness of the cover layer minus the nominal depth of the recess in the cover layer; the nominal remaining thickness at the recess of the cover layer may be in the range between 0.3 mm and 1.5 mm. The cover layer may have a nominal thickness in the range between about 0.7 mm and about 3 mm. The substrate may include a fiber panel with a nominal thickness in the range between about 1.0 mm and 2.5 mm.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 trim component.

[0087] According to an exemplary embodiment schematically shown in the drawings, a component for a vehicle interior configured to provide an opening for deploying an airbag through the opening may include (a) a substrate including a base layer; and (b) a cover including a cover layer. The cover layer may include being coupled to an inner surface of the substrate. The cover layer may include a recess in an inner surface of the cover layer. The substrate may include a protrusion aligned with the recess in the cover layer. The recess in the inner surface of the cover layer and the protrusion of the substrate may be configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the cover layer. The recess may be formed as a depression in the inner surface of the cover layer. The protrusion of the substrate may be in the recess of the cover layer. The protrusion of the substrate may penetrate the inner surface of the cover layer to form the recess of the cover layer. The cover layer may include a molded thermoplastic material; the substrate may include a fiber panel. The cover layer may include a molded thermoplastic material; the substrate may include an injection molded component. The cover layer may include a surface material; the substrate may include a composite material; the surface material may be softer than the composite material. The cover layer may include a surface layer; the protrusion may include a projection. The cover layer may be molded on the substrate. The recess may be formed by molding the cover layer on the protrusion of the substrate. The cover layer may include an outer surface opposite the inner surface of the cover layer; the outer surface may include a substantially flat surface opposite the recess in the inner surface of the cover layer.

[0088] According to an exemplary embodiment schematically shown in the drawings, a component for a vehicle interior formed in a mold and configured to facilitate airbag deployment may include (a) a substrate including a fiber panel; and (b) a cover including a surface layer. The surface layer may include being coupled to an inner surface of the substrate. The surface layer may include a recess in an inner surface of the surface layer. The substrate may include a projection aligned with the recess in the surface layer. The substrate may include a rear side configured to contact the airbag to establish an opening for deploying the airbag. The projection of the substrate may be formed by: (a) compressing a first portion of the fiber panel between a first surface and a second surface of the mold to a first thickness; and (b) compressing a second portion of the fiber panel between the first surface and the second surface of the mold to a second thickness. The recess of the surface layer may be formed by molding the surface layer on the projection of the substrate.

[0089] A method of manufacturing a component for a vehicle interior, the component being configured to provide an opening for deploying an airbag through an opening in a mold, as schematically shown in the accompanying drawings, the method may include: (a) providing a preformed substrate; (b) disposing the preformed substrate on a first surface of the mold; (c) compressing a first portion of 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; (d) forming a second portion of the preformed substrate between the first surface of the mold and the second surface of the mold to form a protrusion in the compression-molded component; and (e) molding a surface layer on the compression-molded component. The inner surface of the surface layer may include a recess formed by molding the surface layer on the protrusion of the compression-molded component. The recess in the inner surface of the surface layer and the protrusion of the compression-molded component may be configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the surface layer. 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 of the mold. 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.

[0090] A method of manufacturing a component for a vehicle interior, the component being configured to provide an opening for deploying an airbag through an opening in a mold, as schematically shown in the accompanying drawings, the method may include: (a) forming a substrate in the mold; and (b) molding a surface layer on the substrate. The substrate may include a protrusion. The inner surface of the surface layer may include a recess formed by molding the surface layer on the protrusion of the substrate. The step of forming the substrate in the mold may include injection molding the substrate. The step of molding the surface layer on the substrate may include injection molding a thermoplastic material on the substrate. The thermoplastic material may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. Exemplary Embodiment B

[0091] According to an exemplary embodiment schematically shown in the drawings, a component for a vehicle interior may include a composite structure configured to facilitate forming an opening for deploying an airbag into the vehicle interior, the composite structure including a substrate and a cover. The substrate may include a base layer and features configured to facilitate forming the opening through the cover layer. The cover layer may include a cover having an inner surface. The cover may be disposed on the substrate. The features of the substrate may be configured to initiate the formation of the opening. The inner surface of the cover layer may include features. The features of the inner surface of the cover layer may be configured to facilitate forming the opening through the cover layer. The cover layer may be provided on the base layer of the substrate. The substrate may include a structural substrate. The features of the substrate may be configured to initiate the formation of an opening in the cover. The features of the substrate may be configured to start forming an opening in the cover at the features of the cover layer of the cover. The features of the substrate may include a raised arrangement. The features of the substrate including the raised arrangement may be configured to initiate the formation of the opening. The features of the substrate including the raised arrangement may be configured to initiate the formation of the opening. The raised arrangement may include protrusions. The raised arrangement may include projections. The raised arrangement may include at least one protrusion. The raised arrangement may include at least one projection. The raised arrangement may include a set of projections. The set of projections may include a set of projections. The set of projections may include a set of small pieces. The set of projections may include a set of ribs. The set of projections may include a set of ridges. The set of projections may include a set of connections. The set of projections may include a set of connections and a set of small pieces. The set of projections may include a set of connections connecting a set of small pieces. The base layer may include a material; the raised arrangement may include a set of protrusions formed of the material. The raised arrangement may include a set of projections integrally formed with the base layer. The raised arrangement may include a tear line. The raised arrangement may include a seam; the seam may include a tear line. The raised arrangement may include a plurality of protrusions configured to protrude from the base layer towards the cover layer. The raised arrangement may include a plurality of protrusions configured to protrude from the base layer into the cover. The cover may include a set of cavities aligned with a set of protrusions of the substrate. The set of protrusions of the substrate may be configured to fit within the cavities of the cover. The inner surface of the cover layer may include a set of cavities aligned with a set of protrusions of the base layer of the substrate. The set of protrusions of the base layer of the substrate may be configured to fit within the set of cavities of the inner surface of the cover layer. The set of projections may include a set of segments. The set of segments may include a set of small pieces. The set of segments may include a set of small pieces and a set of connections. The set of segments may include a set of small pieces and a set of ribs. The set of ribs may include a set of connections. The set of connections may be configured to connect the set of small pieces. The set of ribs may be configured to connect the set of small pieces. The set of segments may include a set of seams. The features of the substrate may include a tear initiation portion for forming an airbag deployment opening. The tear initiation portion may include a central segment. The tear initiation portion may include a central segment and may be configured to form a set of lateral segments.The tear initiation portion may include a central section configured to initiate an opening. The tear initiation portion may include a central section configured to initiate an opening and a set of lateral sections configured to complete the opening. The tear initiation portion may be configured to facilitate the formation of an opening within a composite structure. The tear initiation portion may be configured to facilitate the formation of an opening by forming a set of airbag doors within the composite structure. The tear initiation portion may be configured to facilitate the formation of an opening in the composite structure from the central section. The tear initiation portion may be configured to facilitate the formation of a set of airbag doors in the composite structure from the central section through a set of lateral sections. The tear initiation portion may include a seam that provides a tear line through the cover of the composite structure. The tear initiation portion may include a seam that provides a tear line through the cover. The seam may include an H-shaped line. The seam may include a U-shaped line. The seam may include a central section. The central section may include a line containing a curve. The central section may include a line having a curved section. The central section may include a line containing a curved section. The cover may include a feature that includes the tear initiation portion configured to form an opening for deploying the airbag. The features of the substrate and the features of the cover may together facilitate the formation of an opening for airbag deployment. The features of the substrate and the features of the cover may together facilitate the formation of an opening for deploying the airbag; the feature may include the tear initiation portion that forms an opening at the cover. The features of the substrate may include a set of small blocks. The cover may be formed on the substrate. The cover may be molded onto the substrate. The cover may be formed on the base layer of the substrate. The cover may be molded onto the base layer of the substrate. The features of the cover including the tear initiation portion may include a recess. The features of the cover including the tear initiation portion may include at least one recess. When the cover is formed onto the substrate, the features of the cover including the tear initiation portion may be formed by the features of the substrate. The features of the substrate may include a raised arrangement in the base layer. The features of the cover layer including the tear initiation portion may include a recess in the cover layer. The features of the substrate including the raised arrangement in the base layer may be configured to initiate the formation of an opening in the cover at the features of the recess in the cover layer including the cover. The features of the substrate may include a protrusion within the features of the inner surface of the cover layer of the cover. The protrusion may include a raised arrangement. The raised arrangement may include a pattern. The pattern may include a set of sections. The pattern may include lines. The pattern may include curves. The pattern may include straight lines. The pattern may include a set of lines. The pattern may include an H-shaped pattern. The pattern may include a U-shaped pattern. The pattern may include a dotted pattern. The pattern may include a dotted pattern formed by a set of protrusions. The pattern may include a dotted pattern formed by a set of small blocks. The pattern may include a central section. The pattern may include a central section and a set of lateral sections. The pattern may be configured to form an airbag door. The pattern may be configured to form a set of airbag doors. The raised arrangement may include a raised pattern. The raised pattern may include a set of small blocks.The raised pattern can include a set of small pieces and a set of connecting parts. The raised pattern can include a set of small pieces and a set of connecting parts between each small piece in a selected set of small pieces. The raised pattern can include a set of small pieces and a set of connecting parts between each small piece in a set of small pieces. The set of connecting parts can include a set of ribs. The inner surface of the cover layer of the cover can include recesses configured to facilitate the formation of an opening through the cover layer. The inner surface of the cover can include recesses configured as features of a substrate, and the features of the substrate are configured to facilitate the formation of an opening. The inner surface of the cover can include recesses configured to initiate the formation of an opening through the cover layer. The cover can include features configured to initiate the formation of an opening through the cover layer to deploy an airbag into the vehicle interior. The features can include a raised portion having a profile. The profile can include a curved shape. The base layer of the substrate can include a fiber panel. The fiber panel can include a substantially rigid fiber panel. The features of the substrate can include substantially rigid raised portions. The base layer of the substrate can include a compressed fiber panel having such features. The features can include substantially rigid raised portions. The features can include substantially rigid raised portions formed in the compressed fiber panel. The features can include substantially rigid raised portions formed on the compressed fiber panel. The panel can include a compressed fiber panel. The features can include raised portions formed on the compressed fiber panel. The features can include raised portions integrally formed on the compressed fiber panel. The features can include raised portions molded on the compressed fiber panel. The features can include raised portions injection molded on the compressed fiber panel. The features can include raised portions that include a set of small pieces molded on the compressed fiber panel. The features can include raised portions that include a set of small pieces injection molded on the compressed fiber panel. The features can include protrusions that include a set of small pieces formed of resin on the compressed fiber panel. The base layer can include an upper surface providing the features and a lower surface including recesses. The base layer can include recesses offset from the substrate features. The recesses can be configured to facilitate the formation of an opening for airbag deployment. The cover layer can include an interior coupled to the substrate. The cover layer can include recesses in the inner surface of the cover layer. The substrate can include raised portions aligned with the recesses in the cover layer. The recesses in the inner surface of the cover layer and the raised portions of the substrate can be configured to facilitate the deployment of the airbag through the opening by facilitating the formation of an opening through the cover layer. The composite structure can be configured to facilitate the formation of an opening for the airbag to facilitate the deployment of the airbag. The cover layer can have a nominal thickness in the range between about 0.7 mm and about 3 mm. The recesses in the cover layer can have a nominal depth in the range between 0.3 mm and 1.5 mm. The nominal remaining thickness at the recesses of the cover layer can include the nominal thickness of the cover layer minus the nominal depth of the recesses in the cover layer. The nominal remaining thickness at the recesses of the cover layer can be in the range between 0.3 mm and 1.5 mm.The ratio of the nominal thickness of the cover layer to the nominal residual thickness of the depression of the cover layer can be between about 1.5 and 4. The panel can include a fiber panel with a nominal thickness between about 1.0 mm and 2.5 mm. The composite structure can include a cover layer formed on the base layer of the substrate. The cover layer of the cover of the composite structure can be configured to provide an external surface. The external surface of the cover can include a decorative effect. The composite structure can include a cover layer formed on the base layer of the substrate; the features of the cover layer of the cover are generally not visible at the external surface of the cover. The composite structure can include a cover layer formed on the base layer of the substrate; the features of the cover layer of the cover can include a pattern; the pattern is generally not visible on the external surface of the cover. The composite structure can include a cover layer formed on the base layer of the substrate. The composite structure can include a cover layer molded on the base layer of the substrate. The recess can be formed as a depression in the inner surface of the cover layer. The recess can include a notch. The protrusion of the substrate can be in the recess of the cover layer. The protrusion of the substrate can penetrate the inner surface of the cover layer to form the recess of the cover layer. The protrusion can include an inclined surface. The cover layer can be molded on the substrate. The recess can be formed by molding the cover layer on the protrusion of the substrate. The cover layer can include an injection-molded thermoplastic material. The cover layer can include a generally opaque material. The cover layer can include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The substrate can include at least one feature adjacent to the recess in the surface layer at the rear side of the substrate. The at least one feature can include (a) a resin; (b) a thermoplastic resin; (c) a polypropylene; (d) an acrylonitrile butadiene styrene; (e) a polycarbonate. The component can 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 decorative component.

[0092] According to an exemplary embodiment schematically shown in the drawings, a component for a vehicle interior configured to provide an opening for deploying an airbag through an opening may include (a) a substrate including a base layer; and (b) a cover including a cover layer. The cover layer may include being coupled to an inner surface of the substrate. The cover layer may include a recess in an inner surface of the cover layer. The substrate may include a protrusion aligned with the recess in the cover layer. The recess in the inner surface of the cover layer and the protrusion of the substrate may be configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the cover layer. The recess may be formed as a depression in the inner surface of the cover layer. The recess may include a notch. The protrusion of the substrate may be in the recess of the cover layer. The protrusion of the substrate may penetrate the inner surface of the cover layer to form the recess of the cover layer. The protrusion may include an inclined surface. The cover layer may be molded on the substrate. The recess may be formed by molding the cover layer on the protrusion of 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) a TPE material; (b) a TPV material; (c) a PU material. The cover layer may include a surface layer material; the substrate may include a composite material; the surface layer material may be softer than the composite material. The cover layer may be configured to provide an outer surface of the component. The cover layer may include an outer surface opposite the inner surface of the cover layer; the outer surface may include a substantially flat surface opposite the recess in the inner surface of the cover layer. The substrate may include a panel containing fibers. The substrate may include a fiber panel. A rear side of the substrate may be configured to contact the airbag to establish an opening for deploying the airbag. A rear side of the substrate may be configured to support an airbag module including the airbag. The substrate may include at least one feature adjacent the recess of the cover layer at the rear side of the substrate. The at least one feature may include (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 substrate. The substrate may include a recess adjacent the recess of the cover layer at the rear side of the substrate. The recess of the substrate may be configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the cover layer. The cover layer may include a thermoplastic material; the substrate may include a fiber panel; the substrate may include at least one feature formed of the thermoplastic material of the cover layer at the rear side of the substrate. The substrate may include an injection-molded component. 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.

[0093] According to an exemplary embodiment schematically shown in the accompanying drawings, a component for a vehicle interior configured to provide an opening for deploying an airbag through the opening may include (a) a substrate; and (b) a cover including a surface layer. The surface layer may include an inner surface coupled to the substrate. The surface layer may include a recess in the inner surface of the surface layer. The substrate may include a protrusion aligned with the recess in the surface layer. The recess in the inner surface of the surface layer and the protrusion of the substrate may be configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the surface layer. The recess may be formed as a depression in the inner surface of the surface layer. The recess may include a notch. The protrusion of the substrate may be in the recess of the surface layer. The protrusion of the substrate may penetrate the inner surface of the surface layer to form the recess of the surface layer. The protrusion may include an inclined surface. The surface layer may be molded on the substrate. The recess may be formed by molding the surface layer on the protrusion of 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 substrate may include a composite material; the surface layer material may be softer than the composite material. The surface layer may be configured to provide an outer surface of the component. The surface layer may include an outer surface opposite the inner surface of the surface layer; the outer surface may include a substantially flat surface opposite the recess in the inner surface of the surface layer. The substrate may include a fiber-containing panel. The substrate may include a fiber panel. The rear side of the substrate may be configured to contact the airbag to establish an opening for deploying the airbag. The rear side of the substrate may be configured to support an airbag module including the airbag. The substrate may include at least one feature adjacent the recess of the surface layer at the rear side of the substrate. The at least one feature may include (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 substrate. The substrate may include a recess adjacent the recess of the surface layer at the rear side of the substrate. The recess of the substrate may be configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the surface layer. The surface layer may include a thermoplastic material; the substrate may include a fiber panel; the substrate may include at least one feature formed of the thermoplastic material of the surface layer at the rear side of the substrate. The substrate may include an injection-molded component. 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 decorative component.

[0094] According to an exemplary embodiment schematically shown in the drawings, a component for a vehicle interior formed in a mold and configured to facilitate airbag deployment may include (a) a substrate including a fiber panel; and (b) a cover including a surface layer. The surface layer may include an inner surface coupled to the substrate. The surface layer may include a recess in the inner surface of the surface layer. The substrate may include a protrusion aligned with the recess in the surface layer. The substrate may include a rear side configured to contact an airbag to establish an opening for deploying the airbag. The protrusion of the substrate may be formed by: (a) compressing a first portion of the fiber panel between a first surface and a second surface of the mold to a first thickness; and (b) compressing a second portion of the fiber panel between the first surface and the second surface of the mold to a second thickness. The recess in the surface layer may be formed by molding the surface layer over the protrusion of the substrate.

[0095] According to an exemplary embodiment schematically shown in the drawings, a method of manufacturing a component for a vehicle interior configured to provide an opening for deploying an airbag through an opening in a mold may include: (a) providing a preformed substrate; (b) disposing the preformed substrate on a first surface of the mold; (c) compressing a first portion of the preformed substrate between a 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; (d) forming a second portion of the preformed substrate between the first surface of the mold and the second surface of the mold to form a protrusion in the compression-molded component; and (e) molding a surface layer over the compression-molded component. The inner surface of the surface layer may include a recess formed by molding the surface layer over the protrusion of the compression-molded component. The recess in the inner surface of the surface layer and the protrusion of the compression-molded component may be configured to facilitate airbag deployment through the opening by facilitating the formation of an opening through the surface layer. 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 over the compression-molded component may include molding the surface layer between the compression-molded component and a third surface of the mold. The step of molding the surface layer over 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.

[0096] A method of manufacturing a component for a vehicle interior, the component being configured to provide an opening for deploying an airbag through an opening in a mold, the method may include: (a) forming a substrate in the mold; (b) molding a surface layer on the substrate. The substrate may include protrusions. The inner surface of the surface layer may include recesses formed by molding the surface layer on the protrusions of the substrate. The step of forming the substrate in the mold may include injection molding the substrate. The step of molding the surface layer on the substrate may include injection molding a thermoplastic material on the substrate. The thermoplastic material may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. Exemplary Embodiment C

[0097] As schematically shown according to Figures 21A - 21F , Figures 23A - 23H , Figures 25A - 25C , Figures 26A - 26D , Figures 27A - 27B , Figures 28A - 28B , Figures 34A - 34F , Figures 36A - 36F , Figures 37A - 37C and Figures 38A - 38D in the exemplary embodiments schematically shown, the features of the protrusions PN in the base layer of the panel / substrate CF / SB and the features of the recesses RS in the cover layer of the cover T may be configured in various shapes and dimensions / thicknesses.

[0098] As schematically shown according to the exemplary embodiments, the cover layer of the composite structure cover may include a surface layer and may have a nominal thickness tT in the range between about 0.7 mm and about 3 mm; the recesses in the cover layer may have a nominal depth in the range between 0.3 mm and 1.5 mm; the nominal remaining thickness tR at the recesses of the cover layer may include the nominal thickness of the cover layer minus the nominal depth of the recesses in the cover layer; the nominal remaining thickness at the recesses of the cover layer may be in the range between 0.3 mm and 1.5 mm; the ratio of the nominal thickness of the cover layer to the nominal remaining thickness of the recesses in the cover layer may be in the range between about 1.5 and 4.

[0099] As schematically shown according to an exemplary embodiment, the cover layer of the composite structure may include a surface layer and may have a nominal thickness tT in the range between 0.7 mm and 1.5 mm; the recess in the cover layer may have a nominal depth in the range between 0.3 mm and 1.0 mm; the nominal remaining thickness tR at the recess of the cover layer may include the nominal thickness of the cover layer minus the nominal depth of the recess in the cover layer; the nominal remaining thickness at the recess of the cover layer may be in the range between 0.4 mm and 1.2 mm; the ratio of the nominal thickness of the cover layer to the nominal remaining thickness of the recess of the cover layer may be between about 1.5 and 3.5. As schematically shown according to an exemplary embodiment, the cover layer of the composite structure may include a surface layer and may have a nominal thickness tT in the range between about 1.0 mm and 1.2 mm; the recess in the cover layer may have a nominal depth in the range between 0.4 mm and 0.7 mm; the nominal remaining thickness tR at the recess of the cover layer may include the nominal thickness of the cover layer minus the nominal depth of the recess in the cover layer; the nominal remaining thickness at the recess of the cover layer may be in the range between 0.4 mm and 0.7 mm; the ratio of the nominal thickness of the cover layer to the nominal remaining thickness of the recess of the cover layer may be between about 1.5 and 2.5.

[0100] As schematically shown according to an exemplary embodiment, the cover layer of the composite structure may include a foam material having a nominal thickness tT in the range between 1.5 mm and 4.0 mm; the recess in the cover layer may have a nominal depth in the range between 0.3 mm and 1.5 mm; the nominal remaining thickness tR at the recess of the cover layer may include the nominal thickness of the cover layer minus the nominal depth of the recess in the cover layer; the nominal remaining thickness at the recess of the cover layer may be in the range between 0.6 mm and 2.5 mm; the ratio of the nominal thickness of the cover layer to the nominal remaining thickness of the recess of the cover layer may be between about 1.5 and 5.0. As schematically shown according to an exemplary embodiment, the cover layer of the composite structure may include a foam material having a nominal thickness tT in the range between about 2.7 mm and 3.3 mm; the recess in the cover layer may have a nominal depth in the range between 0.4 mm and 1.0 mm; the nominal remaining thickness tR at the recess of the cover layer may include the nominal thickness of the cover layer minus the nominal depth of the recess in the cover layer; the nominal remaining thickness at the recess of the cover layer may be in the range between 0.4 mm and 2.5 mm.

[0101] As schematically shown according to an exemplary embodiment, the panel / substrate of the composite structure may include a fiber panel having a nominal thickness between about 1.5 mm and 1.7 mm; the fiber panel may have a nominal thickness between about 1.5 mm and 1.7 mm. The panel may include a fiber panel having a nominal thickness between about 1.0 mm and 2.5 mm. The panel / substrate may include a fiber mat of a preformed panel compressed to a thickness tP of a thickness tM of the preformed panel; the preformed panel may be processed / compressed into a substantially rigid compressed fiber panel, thereby providing a board / substrate with a nominal thickness for the composite structure.

[0102] As according to Figures 2A - 2G , Figures 3A - 3F , Figures 4A - 4F , Figures 5A - 5G , Figures 20A - 20B and Figures 24A - 24C schematically shown according to the exemplary embodiments in Figures 2B - 2G , Figures 3A - 3F , Figures 4A - 4F and 5A-5G, Figures 25A - 25C , Figures 26A - 26D , Figures 27A - 27B , Figures 28A - 28B , Figures 32A - 32C , Figures 33A - 33C and Figures 39A - 39C . Exemplary embodiment D

[0103] See Figure 1A and Figure 1B which shows a vehicle V including an interior I having an instrument panel IP and a door DL. According to an exemplary embodiment, interior components of the vehicle V such as the instrument panel IP and the door / door panel DL may include decorative panels. According to an exemplary embodiment, components such as the instrument panel IP and the door DL (and other decorative components) may provide a visible surface within the vehicle interior of the vehicle V. According to an exemplary embodiment, the instrument panel IP and / or the door DL may provide at least one airbag (e.g., configured to deploy from an airbag module) that may be mounted behind / within the interior component (e.g., the instrument panel IP and / or the door DL). See Figure 2A .

[0104] As according to Figure 2AAs schematically shown in the exemplary embodiments herein, a cover / surface of a component such as an instrument panel IP can be configured to provide an area to provide an opening / door for deploying an airbag (e.g., from an airbag module); the cover of the component can include a weakened line / area to facilitate forming an opening / door as shown by the airbag door ABD through which the airbag AB can be deployed (e.g., in the case where the airbag will break through the cover of the component / panel during the intended deployment of the airbag). As Figures 3A - 3F and Figures 4A - 4F As schematically shown in, the component C shown as the instrument panel IP can provide a cover having a seam shown as a tear line TR through which the airbag AB can gradually form an opening at the tear line TR to provide the airbag door ABD, and the airbag AB can be deployed into the vehicle interior through the opening. As Figures 3A - 3F As schematically shown, the tear line TR can include an H shape. As Figures 4A - 4F As schematically shown, the tear line TR can include a U shape.

[0105] According to Figure 23A the exemplary embodiments schematically shown in, the fiber mat FM can 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 Figure 23B the exemplary embodiments schematically shown, the fiber mat FM can be decorated. According to the exemplary embodiments, the fiber mat FM can have a thickness tM. According to the exemplary embodiments, the fiber mat FM can be heated to cause the liquefaction of the thermoplastic resin. According to Figure 23C the exemplary embodiments schematically shown, the fiber mat FM can be heated and partially compressed into a preform PF. According to the exemplary embodiments, the fiber mat FM can be placed in a low-temperature mold and compression molded into a desired shape. According to the exemplary embodiments, when the compressed fiber mat cools, the thermoplastic material in the fiber mat can solidify to establish a substantially rigid composite panel. According to the exemplary embodiments, the preform can have a thickness tP which can be less than the thickness tM.

[0106] According to the exemplary embodiments, the fiber mat FM can include a combination of structural fibers and a thermosetting resin (e.g., epoxy resin, polyester, etc.). According to the exemplary embodiments, the fiber mat FM can be compressed in a heated mold to form a partially compressed fiber mat having a desired shape and cause the curing of the thermosetting resin. According to the exemplary embodiments, a substantially rigid composite panel can be formed after the curing of the thermosetting resin.

[0107] According to Figure 23D the exemplary embodiments schematically shown, a preform PF including a compressed fiber mat can be heated in an oven VN. As Figure 23EAs schematically shown, the heated preform can be transferred into a mold having a mold top MT and a mold bottom MB. According to Figure 23F the exemplary embodiment schematically shown in Figure 23F it, the compression-molded part CF shown as the instrument panel substrate SB can be produced by a process of compression-molding the preform PF. The method can include compression molding. The method can also include injection molding. According to the exemplary embodiment, the heated preform can be further compressed into a fiber panel; plastic resin can be injected into the rear side of the fiber panel to form auxiliary features. According to Figure 23H the exemplary embodiment schematically shown in

[0108] As Figure 24A schematically shown in Figure 24B it, the compression-molded part CF shown as the substrate SB or carrier (e.g., for an instrument panel) can be produced by a compression molding process. According to an exemplary embodiment, the preform PF can be compressed and / or formed to form the compression-molded part CF. Plastic resin can be injection-molded onto the compression-molded part CF to form the compression-molded part CF including a plurality of features. The compression-molded part CF can include a protrusion PN extending from the top surface of the compression-molded part CF. As

[0109] Reference Figures 25A - 25C and Figures 26A - 26D , the construction / formation of the part C is schematically shown according to the exemplary embodiment. The compression-molded part can be formed by compression-molding a fiber mat. As Figure 26A schematically shown in Figures 25B - 25C and Figures 26B - 26D it, the compression-molded part can be covered with the cover layer / cover T; as in Figure 25C and 26CAs schematically shown, the component can provide a surface effect including a generally smooth surface SM and a generally soft form (e.g., covering T).

[0110] According to an exemplary embodiment schematically shown in the drawings, a component C for a vehicle interior can include a substrate SB and a covering T including a surface layer. The component C is configured to provide an opening for deploying an airbag AB through the opening. The surface layer can include an inner surface coupled to the substrate. The surface layer can include a recess RS in the inner surface of the surface layer. The substrate can include a protrusion PN aligned with the recess in the surface layer. The recess in the inner surface of the surface layer and the protrusion of the substrate can be configured to facilitate deploying the airbag through the opening by facilitating forming the opening through the surface layer. The recess can be formed as a depression in the inner surface of the surface layer. The recess can include a notch. The protrusion of the substrate can be in the recess of the surface layer. The protrusion of the substrate can penetrate the inner surface of the surface layer to form the recess of the surface layer. The protrusion can include an inclined surface. The surface layer can be molded on the substrate. The recess can be formed by molding the surface layer on the protrusion of the substrate. The surface layer can include an injection-molded thermoplastic material. The surface layer can include a generally opaque material. The surface layer can include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material. The surface layer can include a surface layer material; the substrate can include a composite material; the surface layer material can be softer than the composite material. The surface layer can be configured to provide the outer surface of the component. The surface layer can include an outer surface opposite the inner surface of the surface layer; the outer surface can include a substantially flat surface opposite the recess in the inner surface of the surface layer. The substrate can include a fiber-containing panel. The substrate can include a fiber panel. The rear side of the substrate can be configured to contact the airbag to establish an opening for deploying the airbag. The rear side of the substrate can be configured to support an airbag module including the airbag. The substrate can include at least one feature FT adjacent the recess of the surface layer at the rear side of the substrate. The at least one feature can include (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The at least one feature can be formed on the rear side of the substrate. The substrate can include a recess RS adjacent the recess of the surface layer at the rear side of the substrate. The recess of the substrate can be configured to facilitate deploying the airbag through the opening by facilitating forming the opening through the surface layer. The surface layer can include a thermoplastic material; the substrate can include a fiber panel; the substrate can include at least one feature FT formed of the thermoplastic material of the surface layer at the rear side of the substrate. The substrate can include an injection-molded component. The component can 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 decorative component.

[0111] According to an exemplary embodiment schematically shown in the accompanying drawings, a component C for a vehicle interior is formed in a mold and configured to facilitate the deployment of an airbag AB. The component C may include a substrate SB and a cover T. The substrate includes a fiber panel, and the cover T includes a surface layer. The surface layer may include an inner surface coupled to the substrate. The surface layer may include a recess RS in the inner surface of the surface layer. The substrate may include a protrusion PN aligned with the recess in the surface layer. The substrate may include a rear side configured to contact the airbag to establish an opening for deploying the airbag. The protrusion of the substrate may be formed by: (a) compressing a first portion of the fiber panel between a first surface and a second surface of the mold to a first thickness; and (b) compressing a second portion of the fiber panel between the first surface and the second surface of the mold to a second thickness. The recess in the surface layer may be formed by molding the surface layer over the protrusion of the substrate.

[0112] According to an exemplary embodiment schematically shown in the accompanying drawings, a method of manufacturing a component C for a vehicle interior, the component being configured to provide an opening in a mold for deploying an airbag AB through the opening, the method may include: (a) providing a preformed substrate PF; (b) disposing the preformed substrate on a first surface of the mold; (c) compressing a first portion of 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 CF having a shape corresponding to a first profile of the first surface and a second profile of the second surface; (d) forming a second portion of the preformed substrate between the first surface of the mold and the second surface of the mold to form a protrusion PN in the compression-molded component; and (e) molding a cover T including a surface layer over the compression-molded component. The inner surface of the surface layer may include a recess RS formed by molding the surface layer over the protrusion of the compression-molded component. The recess in the inner surface of the surface layer and the protrusion of the compression-molded component may be configured to facilitate the deployment of the airbag through the opening by facilitating the formation of the opening through the surface layer. The method may include the step of injecting resin into the mold to form a feature FT on a rear side of the compression-molded component. The step of molding the surface layer over the compression-molded component may include molding the surface layer between the compression-molded component and a third surface of the mold. The step of molding the surface layer over 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.

[0113] According to an exemplary embodiment schematically shown in the drawings, a method of manufacturing a component C for a vehicle interior may include forming a substrate SB in a mold and molding a cover T including a surface layer on the substrate, the component C being configured to provide an opening for deploying an airbag AB through an opening in the mold. The substrate may include protrusions PN. The inner surface of the surface layer may include recesses RS formed by molding the surface layer on the protrusions of the substrate. The step of forming the substrate in the mold may include injection molding the substrate. The step of molding the surface layer on the substrate may include injection molding a thermoplastic material on the substrate. The thermoplastic material may include at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material.

[0114] Reference Figures 37A - 37C and Figures 38A - 38D , the construction / formation of component C is schematically shown according to an exemplary embodiment. As Figure 37A and Figure 38A schematically shown, a substrate SB including an injection molded part PL may provide a surface effect including a substantially rigid form. As Figures 37B - 37C and Figures 38B - 38D schematically shown, the injection molded part may be covered with a cover T; as shown schematically in Figure 37C and Figure 38C , the component may provide a surface effect including a substantially smooth surface SM and a substantially soft form (e.g., the cover T).

[0115] According to as Figures 37A - 37C , Figures 38A - 38D and Figures 39A - 39CIn the exemplary embodiment schematically shown, a component C for a vehicle interior may include a base plate SB and a cover T including a surface layer. The component C is configured to provide an opening for deploying an airbag AB through the opening. The surface layer may include an inner surface coupled to the base plate. The surface layer may include a recess RS in the inner surface of the surface layer. The base plate may include a protrusion PN aligned with the recess in the surface layer. The recess in the inner surface of the surface layer and the protrusion of the base plate may be configured to facilitate the deployment of the airbag through the opening by facilitating the formation of the opening through the surface layer. The recess may be formed as a depression in the inner surface of the surface layer. The recess may include a notch. The protrusion of the base plate may be in the recess of the surface layer. The protrusion of the base plate may penetrate the inner surface of the surface layer to form the recess of the surface layer. The protrusion may include an inclined surface. The surface layer may be molded on the base plate. The recess may be formed by molding the surface layer on the protrusion of the base plate. 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 base plate may include an injection-molded material; the surface layer material may be softer than the composite material. The surface layer may be configured to provide an outer surface of the component. The surface layer may include an outer surface opposite the inner surface of the surface layer; the outer surface may include a substantially flat surface opposite the recess in the inner surface of the surface layer. The rear side of the base plate may be configured to contact the airbag to establish an opening for deploying the airbag. The rear side of the base plate may be configured to support an airbag module including the airbag. The base plate may include a recess RS adjacent the recess of the surface layer at the rear side of the base plate. The recess of the base plate may be configured to facilitate the deployment of the airbag through the opening by facilitating the formation of the opening through the surface layer. The surface layer may include a thermoplastic material; the base plate may include an injection-molded material; the base plate may include at least one feature formed of the thermoplastic material of the surface layer at the rear side of the base plate. 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 decorative component.

[0116] According to Figure 40A In the exemplary embodiment schematically shown in, a method of manufacturing a component C for a vehicle interior, the component C being configured to provide an opening for an airbag AB to deploy through the opening in a mold, the method may include providing a mold including a first surface, a second surface including a recessed portion, and a third 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 having a protrusion; 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.

[0117] According to as Figure 40BIn the exemplary embodiment schematically shown, a method of manufacturing a component C for a vehicle interior may include providing a mold configured to provide an opening for deploying an airbag AB through an opening in the mold. The method includes: providing a mold including a first surface and a second surface, the second surface including a recess; 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 having a protrusion; and molding a cover on the top surface and edges of the compression-molded component to form a component for the vehicle interior.

[0118] It is important to note that the present invention (e.g., inventive concept, etc.) has been described in the specification and / or illustrated in the drawings of this patent document according to the exemplary embodiment; 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 illustrated 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 of this patent document and / or illustrated in the drawings (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 interpreted 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 describing the subject matter of the exemplary embodiments and not as a limitation on the scope of the present invention.

[0119] Equally important, 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 technology (current and / or future) having the 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 implementation) are considered to be within the scope of the present invention in this patent document.

Claims

1. A component for a vehicle interior, the component being configured to facilitate the formation of an opening for deploying an airbag into the vehicle interior, the component comprising: Composite structure, the composite structure comprising a substrate and a cover; Wherein the substrate includes a base layer and features, the features being configured to facilitate the formation of the opening through the cover; Wherein the cover includes a cover layer, the cover layer including an inner surface; Wherein the cover is disposed on the substrate.

2. The component according to claim 1, wherein the features of the substrate are configured to initiate the formation of the opening.

3. The component according to claim 1, wherein the cover is disposed on the base layer of the substrate.

4. The component according to claim 1, wherein the substrate comprises a structural substrate.

5. The component according to claim 1, wherein the features of the substrate include a raised arrangement.

6. The component according to claim 5, wherein the raised arrangement includes at least one protrusion.

7. The component according to claim 5, wherein the raised arrangement includes a set of raised portions.

8. The component according to claim 7, wherein the set of raised portions includes a set of small pieces.

9. The component according to claim 7, wherein the set of raised portions includes a set of ribs.

10. The component according to claim 7, wherein the set of raised portions includes a set of connecting portions connecting a set of small pieces.

11. The component according to claim 5, wherein the base layer comprises a material; wherein the raised arrangement includes a set of raised portions formed from the material.

12. The component according to claim 5, wherein the raised arrangement includes a set of raised portions integrally formed with the base layer.

13. The component according to claim 5, wherein the raised arrangement includes a tear line.

14. The component according to claim 5, wherein the raised arrangement includes raised portions configured to protrude from the base layer towards the cover.

15. The component according to claim 5, wherein the raised arrangement includes raised portions configured to protrude from the base layer into the cover.

16. The component according to claim 1, wherein the cover includes a set of cavities aligned with a set of raised portions of the substrate.

17. The component according to claim 16, wherein the set of raised portions of the substrate is configured to fit within the set of cavities of the cover.

18. The component according to claim 1, wherein the inner surface of the cover layer includes a cavity aligned with the feature of the substrate.

19. The component according to claim 18, wherein the feature of the substrate is configured to fit within the cavity of the inner surface of the cover layer.

20. The component according to claim 1, wherein the feature of the substrate includes a tear initiation portion for forming the opening to deploy the airbag; wherein the tear initiation portion includes a central section configured to initiate the opening and a set of transverse sections configured to complete the opening.

21. The component according to claim 20, wherein the cover includes a feature that includes a tear initiation portion configured to form the opening for deploying the airbag.

22. The component according to claim 21, wherein the feature of the substrate and the feature of the cover together facilitate the formation of the opening for deploying the airbag.

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

24. The component according to claim 1, wherein the cover is molded onto the substrate.

25. The component according to claim 1, wherein the feature of the substrate includes a protrusion within the feature of the inner surface of the cover layer; wherein the feature of the inner surface of the cover layer includes a recess configured to facilitate the formation of the opening through the cover.

26. The component according to claim 25, wherein the protrusion includes a raised arrangement.

27. The component according to claim 26, wherein the raised arrangement includes a pattern of protrusions.

28. The component according to claim 27, wherein the pattern of protrusions includes a central section and a set of transverse sections.

29. The component according to claim 27, wherein the pattern of protrusions includes a set of small blocks and a set of connecting portions.

30. The component according to claim 25, wherein when the cover is formed on the substrate, the feature of the inner surface of the cover layer is formed by the feature of the substrate.

31. The component according to claim 1, wherein the cover includes a feature configured to initiate the formation of the opening through the cover to deploy the airbag into the vehicle interior.

32. The component according to claim 1, wherein the base layer of the substrate includes a rigid fiber panel.

33. The component according to claim 1, wherein the features of the substrate include hard protrusions.

34. The component according to claim 1, wherein the base layer of the substrate includes a compressed fiber panel, and the compressed fiber panel includes the features of the substrate.

35. The component according to claim 34, wherein the features of the substrate include hard protrusions formed in the compressed fiber panel.

36. The component according to claim 34, wherein the features of the substrate include hard protrusions formed on the compressed fiber panel.

37. The component according to claim 34, wherein the features of the substrate include protrusions formed on the compressed fiber panel.

38. The component according to claim 34, wherein the features of the substrate include protrusions integrally formed on the compressed fiber panel.

39. The component according to claim 34, wherein the features of the substrate include protrusions molded on the compressed fiber panel.

40. The component according to claim 34, wherein the features of the substrate include protrusions, and the protrusions include a set of small pieces molded on the compressed fiber panel.

41. The component according to claim 34, wherein the features of the substrate include protrusions, and the protrusions include a set of small pieces injection-molded on the compressed fiber panel.

42. The component according to claim 34, wherein the features of the substrate include protrusions, and the protrusions include a set of small pieces formed of resin on the compressed fiber panel.

43. The component according to claim 1, wherein the substrate includes a front side and a rear side opposite to the front side; wherein the rear side of the substrate is configured to contact the airbag to establish the opening for deploying the airbag; wherein the front side of the substrate includes the features of the substrate.

44. The component according to claim 1, wherein the base layer includes an upper surface providing the features of the substrate and a lower surface including recesses.

45. The component according to claim 44, wherein the recesses are offset from the features of the substrate; wherein the recesses are configured to facilitate the formation of the opening for deploying the airbag.

46. The component according to claim 1, wherein the composite structure is configured to facilitate the formation of the opening of the airbag so as to facilitate the deployment of the airbag.

47. The component according to claim 1, wherein the composite structure includes the cover layer formed on the base layer of the substrate; wherein the cover layer is configured to provide an external surface; and wherein the features of the substrate are not visible on the external surface of the cover.

48. The component according to claim 1, wherein the composite structure includes the cover layer molded on the base layer of the substrate.

49. The component according to claim 1, wherein the cover layer includes a recess configured to facilitate the formation of an opening through the cover.

50. The component according to claim 49, wherein the recess is formed as a depression in the inner surface of the cover layer.

51. The component according to claim 49, wherein the protrusion of the substrate is located in the recess of the cover layer.

52. The component according to claim 49, wherein the protrusion of the substrate penetrates the inner surface of the cover layer to form the recess of the cover layer.

53. The component according to claim 49, wherein the recess is formed by molding the cover layer on the protrusion of the substrate.

54. The component according to claim 49, wherein the substrate includes at least one feature adjacent to the recess at the rear side of the substrate.

55. The component according to claim 54, wherein the at least one feature includes at least one of the following: (a) resin; (b) polypropylene; (c) acrylonitrile butadiene styrene; (d) polycarbonate.

56. The component according to claim 1, wherein the cover layer includes an injection-molded thermoplastic material.

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

58. The component according to claim 1, wherein the inner surface of the cover layer includes features configured to facilitate the formation of the opening through the cover layer.

59. The component according to claim 58, wherein the features of the inner surface of the cover layer include recesses.

60. The component according to claim 59, wherein the recesses in the cover layer have a nominal depth in the range between 0.3 mm and 1.5 mm.

61. The component according to claim 59, wherein the nominal remaining thickness at the recess of the cover layer comprises the nominal thickness of the cover layer minus the nominal depth of the recess in the cover layer; wherein the nominal remaining thickness at the recess of the cover layer is in the range between 0.3 mm and 1.5 mm.

62. The component according to claim 1, wherein the cover layer has a nominal thickness in the range between about 0.7 mm and about 3 mm.

63. The component according to claim 1, wherein the substrate comprises a fiber panel having a nominal thickness between about 1.0 mm and 2.5 mm.

64. The component according to claim 1, comprising 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.

65. A component for a vehicle interior, the component being configured to provide the opening for deploying an airbag through the opening, the component comprising: (a) A substrate including a base layer; And (b) A cover including a cover layer; Wherein the cover layer includes an inner surface coupled to the substrate; Wherein the cover layer includes a recess in the inner surface of the cover layer; Wherein the substrate includes a protrusion aligned with the recess in the cover layer; Wherein the recess in the inner surface of the cover layer and the protrusion of the substrate are configured to facilitate the deployment of the airbag through the opening by facilitating the formation of the opening through the cover layer.

66. The component according to claim 65, wherein the recess is formed as a depression in the inner surface of the cover layer.

67. The component according to claim 65, wherein the protrusion of the substrate is located in the recess of the cover layer.

68. The component according to claim 65, wherein the protrusion of the substrate penetrates the inner surface of the cover layer to form the recess of the cover layer.

69. The component according to claim 65, wherein the cover layer comprises a molded thermoplastic material; wherein the substrate comprises a fiber panel.

70. The component according to claim 65, wherein the cover layer comprises a molded thermoplastic material; wherein the substrate comprises an injection molded component.

71. The component according to claim 65, wherein the cover layer comprises a surface material; Wherein the substrate includes a composite material; Wherein the surface material is softer than the composite material.

72. The component according to claim 65, wherein the cover layer comprises a surface layer; wherein the protrusion comprises a protrusion.

73. The component according to claim 65, wherein the covering layer is molded on the substrate.

74. The component according to claim 65, wherein the recess is formed by molding the covering layer on the protrusion of the substrate.

75. The component according to claim 65, wherein the covering layer includes an outer surface opposite to the inner surface of the covering layer; wherein the outer surface includes a flat surface opposite to the recess in the inner surface of the covering layer.

76. A component for the interior of a vehicle, the component being formed in a mold and configured to facilitate the deployment of an airbag, the component comprising: (a) A substrate including a fiber panel; And (b) A cover including a surface layer; Wherein the surface layer includes an inner surface coupled to the substrate; Wherein the surface layer includes a recess in the inner surface of the surface layer; Wherein the substrate includes a protrusion aligned with the recess in the surface layer; Wherein the substrate includes a rear side configured to contact the airbag to establish the opening for deploying the airbag.

77. The component according to claim 76, wherein the protrusion of the substrate is formed by: (a) compressing a first portion of the fiber panel between a first surface and a second surface of the mold to a first thickness; and (b) compressing a second portion of the fiber panel between the first surface and the second surface of the mold to a second thickness.

78. The component according to claim 76, wherein the recess of the surface layer is formed by molding the surface layer on the protrusion of the substrate.

79. A method of manufacturing a component for the interior of a vehicle, the component being configured to provide an opening for deploying an airbag through an opening in a mold, the method comprising: (a) Provide a preformed substrate; (b) Dispose the preformed substrate on a first surface of the mold; (c) Compress a first portion of 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 part having a shape corresponding to a first profile of the first surface and a second profile of the second surface; (d) Form a second portion of the preformed substrate between the first surface of the mold and the second surface of the mold to form a protrusion in the compression molded part; and (e) Mold a surface layer on the compression molded part; Wherein the inner surface of the surface layer includes a recess formed by molding the surface layer on the protrusion of the compression molded part.

80. The method according to claim 79, wherein the recess in the inner surface of the surface layer and the protrusion of the compression molded component are configured to facilitate the deployment of the airbag through the opening by facilitating the formation of the opening through the surface layer.

81. The method according to claim 79 further includes the step of injecting resin into the mold to form features on the rear side of the compression molded part.

82. The method according to claim 79, wherein the step of molding a surface layer on the compression molded part includes molding the surface layer between the compression molded part and a third surface of the mold.

83. The method according to claim 79, wherein the step of molding a surface layer on the compression molded part includes molding the surface layer on the top surface of the compression molded part and on the edge of the compression molded part.

84. A method of manufacturing a part for a vehicle interior, the part being configured to provide an opening for deploying an airbag through an opening in a mold, the method comprising: (a) Form a substrate in the mold; (b) Mold a surface layer on the substrate; Wherein the substrate includes a protrusion; Wherein the inner surface of the surface layer includes a recess formed by molding the surface layer on the protrusion of the substrate.

85. The method according to claim 84, wherein the step of forming a substrate in the mold includes injection molding the substrate.

86. The method according to claim 84, wherein the step of molding a surface layer on the substrate includes injection molding a thermoplastic material onto the substrate.

87. The method according to claim 86, wherein the thermoplastic material includes at least one of the following: (a) a TPE material; (b) a TPV material; (c) a PU material.

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