WO2024254045A2

WO2024254045A2 - Component for vehicle interior

Info

Publication number: WO2024254045A2
Application number: PCT/US2024/032369
Authority: WO
Inventors: Dale Todd Glynn; Michael Gerard ZIMMER; Jennifer A. STROEBE
Original assignee: Yanfeng International Automotive Technology Co Ltd
Current assignee: Yanfeng International Automotive Technology Co Ltd
Priority date: 2023-06-05
Filing date: 2024-06-04
Publication date: 2024-12-12
Anticipated expiration: 2025-12-05
Also published as: WO2024254045A3

Abstract

A component for a vehicle interior may comprise a composite structure comprising a generally rigid structural substrate formed from a fiber panel and a cover. An exterior surface of the cover may comprise a generally soft material. The structural substrate may comprise a generally rigid panel. The cover may be molded on the substrate. The cover may comprise an injection molded thermoplastic, TPE, TPV or PU material. The cover may comprise a foam core with an integral skin. The cover may be formed with a blowing agent to produce a cellular structure for the cover. The cover may comprise an open cell foam. The cover may comprise a laminate of a thermoplastic elastomer on a foam layer. The component may comprise an instrument panel; dashboard; door panel; steering wheel; console; cockpit; knee bolster; or trim component. A method of manufacturing the component is disclosed.

Description

PATENT APPLICATION

COMPONENT FOR VEHICLE INTERIOR

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and incorporates by reference in full the following patent application: U.S. Provisional Patent Application No. 63/471,149 titled “COMPONENT FOR VEHICLE INTERIOR” filed June 5, 2023.

FIELD

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

BACKGROUND

[0003] It is known to provide a component for a vehicle interior comprising a substrate formed from a fiber panel and a cover for the substrate.

[0004] It would be advantageous to provide an improved component for a vehicle interior comprising a cover that is generally relatively compressible/soft on a substrate formed from a fiber panel that is generally relatively right/hard.

SUMMARY

[0005] The present invention relates to a component for a vehicle interior comprising a composite structure comprising a substrate and a cover. The substrate may comprise a fiber panel. The cover may be provided on the substrate. The substrate may comprise a structural substrate. The cover may comprise an exterior surface for the composite structure. The exterior surface at the cover of the composite structure may comprise a compressible material. The exterior surface at the cover of the composite structure may comprise a generally deformable material. The exterior surface at the cover of the composite structure may comprise a generally soft material. The structural substrate may comprise a generally rigid panel. The exterior surface at the cover of the composite structure may comprise a generally soft surface on the generally rigid fiber panel of the structural substrate of the composite structure. The exterior surface at the cover of the composite structure may comprise a softness; the softness of the exterior surface at the cover of the composite structure may be greater than a softness of the fiber panel of the substrate of the composite structure. The cover may comprise a compressible material. The cover may comprise two- layers of compressible material. The cover may comprise a composite cover comprising an exterior surface layer and a core layer; the core layer may comprise a generally soft material. The generally soft material may be softer than the exterior surface layer of the cover of the composite structure. The generally soft material may be softer than the fiber panel of the structural substrate of the composite structure. The core layer of the cover of the composite structure may comprise a foam material. The core layer of the cover of the composite structure may comprise a foam material; the exterior surface layer of the cover of the composite structure may comprise a skin. The cover comprising the core layer and the skin may be formed from a resin material. The cover may be formed from a self-skinning material. The cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; the cover may comprise a material; the material of the cover may be softer than the substrate. The cover may comprise a molded cover molded over the substrate. The cover may comprise a cover layer and a base layer. The cover may comprise a cover layer and a base layer and an intermediate layer. The cover may comprise a skin and a core. The cover may comprise at least one of (a) a skin and a core layer; (b) a skin and a core formed from a resin material; (c) a formed skin; (d) a formed skin on a core; (e) a skin and a foam material; (f) a pad. The cover may comprise a cover layer and a pad. The cover may comprise at least one of (a) a film; (b) a resin; (c) a pad; (d) a foam; (e) a skin. The cover may comprise at least one of (a) a TPE material; (b) a TPV material; (c) a PU material; (d) a polymer material; (e) a resin material; (f) a plastic material. The composite structure may comprise a feature. The feature may comprise a formed feature at a surface of the cover. The feature may comprise a molded feature. The feature may comprise an indentation and/or a projection. The feature may comprise at least one of (a) a rib; (b) a recess; (c) a notch; (d) a divider; (e) a line; (f) a stitch; (g) a decorative stitch; (h) a molded stitch appearance; (i) a faux stitch; (j) a decorative faux stitch; (k) a groove; (1) a structure; (m) a shape; (n) a form; (o) a curved form. The feature may comprise at least one of (a) a tear line; (b) an initiator for formation of an opening for deployment of an airbag; (c) a recess for formation of an opening for deployment of an airbag; and/or (d) a projection for formation of an opening for deployment of an airbag. The feature may comprise an indicia; the indica may comprise at least one of (a) a raised indicia; (b) a formed indicia; (c) a recessed indicia; (d) an applied indicia; (e) an ink indicia. The feature may comprise a surface effect. The feature may comprise a texture. The feature may comprise an ink. The feature may comprise an applied material; the applied material may comprise at least one of (a) a coating; (b) an ink; (c) a colorant; (d) a film; (e) paint. The composite structure may comprise a functional layer; the functional layer may comprise at least one of (a) an insulating layer; (b) a spacer layer; (c) a sound insulating layer. The composite structure may comprise a functional layer; the functional layer may comprise at least one of (a) a sound deadening layer; (b) a sound deadening material. The composite structure may comprise a functional layer; the functional layer may comprise a fiber mat. The composite structure may comprise a functional layer; the functional layer may comprise a sound insulating layer under the substrate. The composite structure may comprise a functional layer; the functional layer may comprise an insulating fiber material under the cover. The composite structure may comprise a decorative layer. The decorative layer may comprise a surface effect. The surface effect may comprise at least one of (a) a texture; (b) a pattern; (c) a molded effect; (d) a molded layer; (e) a resin; (f) a coating; (g) a paint; (h) an ink; (i) leather appearance; (j) a grain effect. The decorative layer may comprise at least one of (a) a film; (b) a fabric; (c) an applied material; (d) a leather; (e) a synthetic layer. The composite structure may comprise a structure; the structure may comprise at least one of (a) a molded structure formed on the substrate; (b) a housing; (c) an airbag chute. The composite structure may comprise a curved profile. The substrate may be formed from the fiber panel; the cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; the cover may comprise a material; the material comprising the cover may be softer than the substrate. The cover may be molded on the substrate; the cover may comprise an injection molded thermoplastic material. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material; a density of the surface material may be greater than a density of the core material. The surface may be formed as a skin on the core. The cover may comprise a decorative layer on the surface; the decorative layer may comprise at least one of a pattern and/or texture. The cover may comprise a coating on the decorative layer. The material comprising the cover may comprise at least one of (a) a mixture of polyurethane; (b) a combination of a reaction mixture; (c) foam material; (d) polyurethane foam; (e) urethane foam; (f) injection-molded material; (g) injected foam material; (h) plastic; (i) resin. The material comprising the cover may comprise at least one of (a) a foam material; (b) a urethane foam; (c) a compressible foam; (d) a self-skinning foam. The material comprising the cover may comprise a self-skinning material. The cover may comprise an integral skin on a core. The cover may be formed with a foam compound. The cover may comprise a laminate; the laminate may comprise an outer layer and inner layer. The component may comprise a foam material between the laminate and the substrate; the foam material may be configured to bond the laminate to the substrate. The substrate may comprise a compression-formed component formed from the fiber panel. The substrate may comprise at least one feature; the at least one feature may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate; (f) a formed feature. The substrate may comprise at least one feature; the at least one feature may comprise at least one of (a) a rib; (b) a set of ribs; (c) a resin-formed feature; (d) a resin-formed feature molded on the substrate. A surface of the composite structure may comprise a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer. A surface of the composite structure may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. The cover may comprise a skin providing the surface and a core; a surface of the composite structure may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. The fiber panel of the composite structure may comprise a hardness of approximately 95 Shore A Durometer. The component may comprise at least one of (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 bolster; (h) a trim component; (i) a panel; (j) a trim panel. [0006] The present invention relates to a method of manufacturing a component for a vehicle interior in a tool comprising providing a fiber mat in the tool, compressing the fiber mat in the tool to form a structural substrate comprising a compression-formed fiber panel having a shape, and forming a cover on the structural substrate. An exterior surface at the cover may comprise a compressible material. The compression-formed fiber panel of the structural substrate may comprise a generally rigid panel. The cover and the structural substrate comprise a composite structure for the component. The method may comprise the step of providing a functional layer on the structural substrate. The composite structure may comprise the functional layer; the functional layer may comprise a sound insulating layer on the substrate or under the substrate. The step of forming a cover on the structural substrate may comprise molding the cover on the compression-formed fiber panel. The cover may comprise a formed cover with at least one feature. The cover may comprise a formed cover comprising a multi-layer cover comprising a skin layer and a core layer.

[0007] The present invention relates to a component for a vehicle interior comprising a composite structure comprising a substrate and a cover. The substrate may comprise a fiber panel. The cover may be provided on the substrate. The substrate may comprise a structural substrate. The cover may comprise an exterior surface for the composite structure. The exterior surface at the cover of the composite structure may comprise a compliant material. The exterior surface at the cover of the composite structure may comprise a compressible material. The exterior surface at the cover of the composite structure may comprise a generally deformable material. The exterior surface at the cover of the composite structure may comprise a generally soft material. The structural substrate may comprise a generally rigid panel. The structural substrate may comprise a generally rigid fiber panel. The fiber panel of the structural substrate may comprise a generally rigid panel. The fiber panel may comprise a compressed fiber panel. The fiber panel may comprise a compression-formed component. The exterior surface at the cover of the composite structure may comprise a generally soft surface and the fiber panel of the structural substrate of the composite structure may comprise a generally rigid panel. The exterior surface at the cover of the composite structure may comprise a generally soft surface on the generally rigid fiber panel of the structural substrate of the composite structure. The exterior surface at the cover of the composite structure may comprise a softness and the fiber panel of the structural substrate of the composite structure may comprise a hardness. The exterior surface at the cover of the composite structure may comprise a softness. The softness of the exterior surface at the cover of the composite structure may be greater than the softness of the fiber panel of the substrate of the composite structure. The exterior surface at the cover of the composite structure may comprise a softness; the softness of the exterior surface at the cover of the composite structure may be greater than the softness of the fiber panel of the substrate of the composite structure. The cover may comprise at least one layer of material. The cover may comprise a single layer of material. The cover may comprise two-layers of material. The cover may comprise a compressible material. The cover may comprise two-layers of compressible material. The cover may comprise a composite cover comprising an exterior surface layer and a core layer. The core layer may comprise a generally soft material. The core layer of the cover of the composite structure may comprise a foam material. The core layer of the cover of the composite structure may comprise a generally soft material softer than the exterior surface layer of the cover of the composite structure. The core layer of the cover of the composite structure may comprise a generally soft material softer than the fiber panel of the structural substrate of the composite structure. The core layer of the cover of the composite structure may comprise a foam material; the exterior surface layer of the cover of the composite structure may comprise a skin. The cover comprising the core layer and skin may be formed from a resin material. The core layer of the cover of the composite structure may comprise a generally soft foam material softer than the exterior surface layer of the cover of the composite material. The cover may be formed from a self-skinning material. The cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; the cover may comprise a material; the material of the cover may be softer than the substrate. The cover may comprise a molded cover. The cover may be molded on the substrate. The cover may comprise a composite cover or a multi-layer cover. The cover may comprise a single-layer cover. The cover may comprise a multi-layer cover. The cover may comprise a cover layer. The cover may comprise a cover layer and a base layer. The cover may comprise a cover layer and a base layer and an intermediate layer. The cover may comprise a skin. The cover may comprise a skin and a core. The cover may comprise at least one of (a) a skin and a core layer; (b) a skin and a core formed from a resin material; (c) a formed skin; (d) a formed skin on a core; (e) a skin and a foam material; (f) a pad. The cover may comprise a cover layer and a pad. The cover may comprise a decorative layer. A cover layer of the cover may be configured to provide an exterior surface. The cover may be configured to provide an exterior surface for the composite structure. The cover may comprise an exterior layer providing a surface effect. The cover may comprise at least one of (a) a film; (b) a resin; (c) a pad; (d) a foam; (e) a skin. The cover may comprise a cover layer and an inner layer. The cover may comprise a cover layer and an inner layer and an under layer. The cover may comprise at least one of (a) a TPE material; (b) a TPV material; (c) a PU material; (d) a polymer material; (e) a resin material; (f) a plastic material. The composite structure may comprise a feature. The composite structure may comprise a formed feature at a surface of the cover. The composite structure may comprise at least one feature. The feature may comprise a molded feature. The feature may comprise an indentation. The feature may comprise a projection. The feature may comprise an indentation and a projection. The feature may comprise at least one of (a) a rib; (b) a recess; (c) a notch; (d) a divider; (e) a line; (f) a stitch; (g) a decorative stitch; (h) a molded stitch appearance; (i) a faux stitch; (j) a decorative faux stitch; (k) a groove; (1) a structure; (m) a shape; (n) a form; (o) a curved form. The feature may comprise a seam. The feature may comprise at least one of (a) a tear line; (b) an initiator for formation of an opening for deployment of an airbag; (c) a recess for formation of an opening for deployment of an airbag; and/or (d) a projection for formation of an opening for deployment of an airbag. The feature may comprise an indicia. The feature may comprise at least one of (a) a raised indicia; (b) a formed indicia; (c) a recessed indicia; (d) an applied indicia; (e) an ink indicia. The feature may comprise a surface effect. The feature may comprise a texture. The feature may comprise an ink. The feature may comprise an applied material. The feature may comprise at least one of (a) a coating; (b) an ink; (c) an applied material; (d) a film; (e) paint. The composite structure may comprise a functional layer; the functional layer may comprise at least one of (a) an insulating layer; (b) a spacer layer; (c) a sound insulating layer. The sound insulating layer may comprise a sound deadening layer. The sound insulating layer may comprise a sound deadening material. The functional layer may comprise a sound deadening layer; the sound deadening layer may comprise a sound insulating layer. The functional layer may comprise a fiber mat. The functional layer may comprise a sound insulating layer on the substrate. The functional layer may comprise a sound insulating layer under the substrate. The functional layer may comprise an insulating fiber material under the cover. The composite structure may comprise an adhesive material. The composite structure may comprise an adhesive material to couple a functional layer comprising a sound deadening material to the fiber panel comprising the substrate. The composite structure may comprise a decorative layer. The decorative layer may comprise a surface effect. The decorative layer may comprise at least one of (a) a texture; (b) a pattern;

(c) a molded effect; (d) a molded layer; (e) a resin; (f) a coating; (g) a paint; (h) an ink. The decorative layer may comprise at least one of (a) a film; (b) a fabric; (c) an applied material;

(d) a leather; (e) a synthetic layer. The composite structure may comprise a structure; the structure may comprise at least one of (a) a molded structure formed on the substrate; (b) a housing; (c) an airbag chute. The composite structure may comprise a profile. The composite structure may comprise a curved profile. The substrate may be formed from the fiber panel; the cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; the cover may comprise a material; the material comprising the cover may be softer than the substrate. The cover may be molded on the substrate; the cover may comprise an injection molded thermoplastic material. The cover may comprise at least one of (a) a TPE material; (b) a TPV material; (c) a PU material; (d) a generally opaque material. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material; a density of the surface material may be greater than a density of the core material. The surface may be formed as a skin on the core. The cover may comprise a decorative layer on the surface. The decorative layer may comprise at least one of a pattern and/or texture. The cover may comprise a coating on the decorative layer. The material comprising the cover may comprise at least one of (a) a mixture of polyurethane; (b) a combination of a reaction mixture; (c) foam material; (d) polyurethane foam; (e) urethane foam; (f) injection-molded material; (g) injected foam material; (h) plastic; (i) resin. The material comprising the cover may comprise at least one of (a) a foam material; (b) a urethane foam; (c) a compressible foam; (d) a self-skinning foam. The material comprising the cover may comprise a self-skinning material. The cover may comprise an integral skin on a core. The cover may be formed with a foam compound. The cover may be formed from a reactive foam compound. The cover may comprise a laminate. The laminate may comprise an outer layer and inner layer. The component may comprise a foam material between the laminate and the substrate; the foam material may be configured to bond the laminate to the substrate. The substrate may comprise a compression- formed component formed from the fiber panel. The substrate may comprise at least one feature formed on a rear side of the fiber panel. The at least one feature may comprise a formed feature. The cover may comprise at least one feature; the at least one feature may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate; (f) a formed feature. The at least one feature may comprise at least one of (a) a rib; (b) a set of ribs; (c) a resin-formed feature; (d) a resin-formed feature molded on the substrate. The component may comprise at least one of (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 bolster; (h) a trim component; (i) a panel; (j) a trim panel. The composite structure may comprise a surface. The surface of the composite structure may comprise a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer. The surface of the composite structure may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. The cover may comprise a skin providing the surface and a core; surface of the composite structure may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. The fiber panel of the composite structure may comprise a hardness of approximately 95 Shore A Durometer. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material; a density of the surface material may be greater than a density of the core material. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material; the surface may be formed as a skin on the core. The surface may comprise a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer. The composite structure may be configured to form an opening for deployment of an airbag. The composite structure may be configured to form a door for an opening for deployment of an airbag. The composite structure may be configured to form a hinge for an airbag door. The composite structure may comprise a seam configured to form an opening for deployment of an airbag. [0008] The present invention relates to a component for a vehicle interior formed in a tool comprising a composite structure comprising (a) a substrate comprising a compression- formed component and (b) a formed cover. The compression-formed component may be formed by compressing a fiber panel in the tool. The formed cover may be formed on the fiber panel of the compression-formed component of the substrate. The cover may comprise a formed cover formed by molding. The cover may comprise a formed cover with at least one feature. The cover may comprise a formed cover comprising a multi-layer cover formed from a cover material comprising a skin layer and a core layer. The cover material may comprise a self-skinning foam comprising a skin and a core layer comprising a foam. The cover may comprise a formed cover may comprise a single-layer cover. The composite structure may comprise a functional layer. The functional layer may comprise a sound insulating layer on the substrate. The functional layer may comprise a sound insulating fiber layer under the cover. The tool may comprise a mold.

[0009] The present invention relates to a method of manufacturing a component for a vehicle interior in a tool comprising providing a fiber mat in the tool; compressing the fiber mat in the tool to form a structural substrate comprising a compression-formed fiber panel having a shape; and forming a cover on the structural substrate. An exterior surface at the cover may comprise a compressible material. The compression-formed fiber panel of the structural substrate may comprise a generally rigid panel. The cover and the structural substrate may comprise a composite structure for the component. The method may comprise a step of providing a functional layer on the structural substrate. The step of forming a cover on the structural substrate may comprise molding the cover on the compression-formed fiber panel. The cover may comprise a formed cover formed by molding. The cover may comprise a formed with at least one feature. The cover may comprise a formed cover may comprise a multi-layer cover comprising a skin layer and a core layer. The cover may comprise at least one of (a) a cover material; (b) a self-skinning material; (c) a skin layer and a core layer comprising a foam. The composite structure may comprise a functional layer; the functional layer may comprise a sound insulating layer on the substrate or under the substrate. The tool may comprise a mold.

[0010] The present invention relates to a method of manufacturing a component for a vehicle interior in a mold comprising providing a fiber panel, disposing the fiber panel into the mold, compressing the fiber panel between a first surface of the mold and a second surface of the mold to form the fiber panel into a compression-formed component having a shape corresponding to a first contour of the first surface and a second contour of the second surface, and molding a skin layer on the compression-formed component. The step of molding a skin layer on the compression-formed component may comprise molding the skin layer between the compression-formed component and a third surface of the mold. The step of molding a skin layer on the compression-formed component may comprise molding the skin layer on a top surface of the compression-formed component and on an edge of the compression-formed component. The outer layer may comprise a thermoplastic elastomer. The foam material may be configured to bond the laminate to the compression-formed component. The laminate may comprise a foam-backed skin. The method may comprise a step of injecting resin into the mold to form a feature on a rear side of the compression- formed component.

FIGURES

[0011] FIGURE 1 A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0012] FIGURE IB is a schematic perspective cut-away view of a vehicle showing a vehicle interior according to an exemplary embodiment.

[0013] FIGURE 2A is a schematic perspective view of a component for a vehicle interior shown as an instrument panel and a component for a vehicle interior shown as a steering wheel according to an exemplary embodiment.

[0014] FIGURE 2B is a schematic perspective view of a component for a vehicle interior shown as a door panel according to an exemplary embodiment.

[0015] FIGURES 3A through 3C are schematic perspective views of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment.

[0016] FIGURES 4A through 4C are schematic perspective views of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment.

[0017] FIGURES 5A and 5B are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0018] FIGURES 5C and 5D are schematic cutaway section views of a component for a vehicle interior according to an exemplary embodiment.

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

[0020] FIGURE 5F is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0021] FIGURES 6A and 6B are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0022] FIGURES 6C and 6D are schematic cutaway section views of a component for a vehicle interior according to an exemplary embodiment.

[0023] FIGURE 6E is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0024] FIGURE 6F is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0025] FIGURES 7A and 7B are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0026] FIGURES 7C and 7D are schematic cutaway section views of a component for a vehicle interior according to an exemplary embodiment. [0027] FIGURE 7E is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.

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

[0029] FIGURES 8A and 8B are schematic perspective views of a component for a vehicle interior according to an exemplary embodiment.

[0030] FIGURES 8C and 8D are schematic cutaway section views of a component for a vehicle interior according to an exemplary embodiment.

[0031] FIGURE 8E is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0032] FIGURE 8F is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0033] FIGURE 9A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0034] FIGURE 9B is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0035] FIGURE 10A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0036] FIGURE 10B is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0037] FIGURES 11 A and 1 IB are schematic perspective views of a fiber mat being consolidated according to an exemplary embodiment.

[0038] FIGURES 11C and 1 ID are schematic perspective views of a fiber mat/panel being formed into a compression-formed component according to an exemplary embodiment.

[0039] FIGURES 1 IE and 1 IF are schematic perspective views of a compression-formed component according to an exemplary embodiment.

[0040] FIGURE 12A is a schematic perspective view of a compression-formed component according to an exemplary embodiment.

[0041] FIGURE 12B is a schematic section view of a compression-formed component according to an exemplary embodiment.

[0042] FIGURE 13 A is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0043] FIGURE 13B is a schematic exploded section view of a component for a vehicle interior according to an exemplary embodiment. [0044] FIGURE 14A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0045] FIGURE 14B is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0046] FIGURE 15 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0047] FIGURE 16 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0048] FIGURE 17 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0049] FIGURE 18 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0050] FIGURE 19 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0051] FIGURE 20 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0052] FIGURE 21 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0053] FIGURE 22 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0054] FIGURE 23 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0055] FIGURE 24 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0056] FIGURE 25 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0057] FIGURE 26 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0058] FIGURE 27 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0059] FIGURE 28 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0060] FIGURE 29 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment. [0061] FIGURE 30 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0062] FIGURE 31 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0063] FIGURE 32 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0064] FIGURE 33 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0065] FIGURE 34 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0066] FIGURE 35 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0067] FIGURE 36 is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0068] FIGURES 37A through 37D are schematic section views of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment. [0069] FIGURES 38A through 38D are schematic section views of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment. [0070] FIGURES 39A through 39F are schematic section views of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment. [0071] FIGURES 40A through 40D are schematic section views of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0072] FIGURES 41 A through 4 ID are schematic section views of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment. [0073] FIGURES 42A through 42D are schematic section views of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment. [0074] FIGURE 43 A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0075] FIGURE 43B is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0076] FIGURE 43C is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0077] FIGURE 43D is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment. [0078] FIGURES 44A through 44C are schematic section views of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment. [0079] FIGURE 45A is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0080] FIGURE 45B is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0081] FIGURE 45C is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.

[0082] FIGURE 45D is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.

[0083] FIGURES 46A through 46C are schematic section views of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0084] FIGURE 47 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0085] FIGURE 48 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0086] FIGURE 49 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0087] FIGURE 50 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0088] FIGURE 51 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0089] FIGURE 52 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0090] FIGURE 53 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0091] FIGURE 54 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0092] FIGURE 55 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0093] FIGURE 56 is a schematic flow diagram of a method of manufacturing a component for a vehicle interior according to an exemplary embodiment.

[0094] FIGURE 57 is a schematic composite view a component for a vehicle interior according to an exemplary embodiment. DESCRIPTION

[0095] Referring to FIGURES 1 A-1B and 2A-2B, a vehicle V is shown including an interior I comprising components C shown as an instrument panel IP and door panel DP and steering wheel SW and other/trim panel s/component configured to provide visible surfaces in interior I of vehicle V.

[0096] According to an exemplary embodiment as shown schematically in FIGURES 2A-2B, 3A-3C, 4A-4B, 5A-5F, 6A-6F, 7A-7F, 8A-8F, 9A-9B, 10A-10B, 43A-43D, 45A-45D and 57, component C with composite structure CS may be configured to provide a panel such as a trim/other panel or a component such a trim/other component for a functional function and/or decorative function in the interior of the vehicle; the component/composite structure may comprise a cover T configured to provide an exterior surface TX and a surface effect (e.g. appearance/look, softness/hardness/feel, etc.) and a substrate SB shown as a fiber panel FP configured to provide a base/structure (e.g. shape/profile, form, rigidity/strength, etc.).

[0097] According to an exemplary embodiment as shown schematically in FIGURES 2A, 3A-3C and 4A-4C, component C with composite structure CS may be configured to form an opening for deployment of an airbag AB from a module ABM; composite structure CS may be configured to form a door ABD for an opening for deployment of an airbag AB from module ABM; composite structure CS may be configured to form a hinge for an airbag door; composite structure CS may comprise a seam such as a tear line TR configured to facilitate formation of the opening for deployment of airbag AB from a module ABM in a structure ST such as a housing/airbag chute CH through composite structure CS and into the vehicle interior. See also FIGURES 5A-5F, 6A-6F, 7A-7F, 8A-8F, 23, 24, 25, 26, 43A-43D, 45A- 45D and 57.

[0098] According to an exemplary embodiment as shown schematically in FIGURES 2A-2B, 3A-3C, 4A-4B, 5A-5F, 6A-6F, 7A-7F, 8A-8F, 9A-9B, 10A-10B, 43A-43D, 45A-45D and 57, a component C for a vehicle interior may comprise composite structure CS comprising substrate SB and cover T; substrate SB may comprise a fiber panel FP; cover T may be provided on substrate SB; substrate SB may comprise a structural substrate; cover T may comprise exterior surface TX for composite structure CS; composite structure CS may a cover T such as a composite cover with one layer or multiple layers and/or with comprise features FT (such as indentations ND and project! ons/protrusions PR) and structure ST (such as housing/chute CH). See also FIGURES 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34 and 35. As indicated schematically according to an exemplary embodiment in FIGURES 9A-9B, 10A-10B, 11A-11F, 12A-12B, 13A-13B and 14A-14B, substrate SB for composite structure CS may comprise a compression-formed component CF such as fiber panel FP; cover T may be formed on substrate SB such as formed as a molded cover on substrate SB; the molded cover may comprise a molded material such as an injection molded thermoplastic material. See also FIGURES 37A-37D, 38A-38D, 39A-39F, 40A-40D, 41A-41D, 42A-42D, 43A-43D, 44A-44C, 45A-45D and 46A-46C.

[0099] As indicated schematically according to an exemplary embodiment in FIGURES 5 A- 5F, 6A-6F, 7A-7F, 8A-8F, 12A-12B, 13A-13B, 14A-14B, 43D, 45D and 57, exterior surface TX at cover T of composite structure CS may comprise a compressible material; exterior surface TX at cover T of composite structure CS may comprise a generally deformable material; exterior surface TX at cover T of composite structure CS may comprise a generally soft material; structural substrate SB shown as fiber panel CF/FP may comprise a generally rigid panel; exterior surface TX at cover T of composite structure CS may comprise a generally soft surface on generally rigid fiber panel FP of structural substrate SB of composite structure CS; exterior surface TX at cover T of composite structure CS may comprise a softness; the softness of exterior surface TX at cover T of composite structure CS may be greater than a softness of fiber panel FP of substrate SB of composite structure CS. See also TABLE A.

[0100] As indicated schematically according to an exemplary embodiment in FIGURES 5 A- 5F, 6A-6F, 7A-7F, 8A-8F, 12A-12B, 13A-13B, 14A-14B, 43D, 45D and 57, cover T may comprise a compressible material; cover T may comprise a composite cover with multiple layers including one layer or two/multiple layers of generally compressible material. As indicated schematically according to an exemplary embodiment in FIGURES 5 A-5F, 6A-6F, 7A-7F, 8A-8F and 57, cover T may comprise a composite cover T comprising an exterior surface layer shown as skin SK and a core layer CR; core layer CR may comprise a generally soft material; the generally soft material may be softer than exterior surface layer TX/SK of cover T of composite structure CS; the generally soft material may be softer than fiber panel FP of structural substrate SB of composite structure CS. See also FIGURES 17, 18, 23, 24,

25, 26, 30, 33 and 36.

[0101] As indicated schematically according to an exemplary embodiment in FIGURES 16, 27, 28 and 31, the core layer of cover T of composite structure CS may comprise a foam material FM; core layer of cover T of composite structure CS may comprise a foam material such as core material CR configured to form a skin SK; exterior surface TX layer of cover T of composite structure CS may comprise a skin SK. See also FIGURES 17, 18, 23, 24, 25,

26, 30, 33 and 36. [0102] As indicated schematically according to an exemplary embodiment in FIGURES 5 A- 5F, 6A-6F, 7A-7F, 8A-8F, 9A-9B, 10A-10B, 12A-12B, 13A-13B, 14A-14B and 57, substrate SB of composite structure CS may be formed as a compression-formed component/fiber panel CF/FP from a fiber mat FB. See also FIGURES 11 A-l IE. As indicated schematically according to an exemplary embodiment in FIGURES 5 A-5F, 6A-6F, 7A-7F, 8A-8F, 9A-9B, 10A-10B and 57, cover T of composite structure CS may comprise an inner surface coupled to substrate SB and an outer surface providing an exterior surface TX of the component; cover T may comprise a material; the material comprising cover T may be softer than substrate SB. See FIGURES 12A-12B, 13A-13B and 14A-14B. As indicated schematically according to an exemplary embodiment in FIGURES 2A-2B, 3A-3C, 4A-4C 15, 16, 17, 18,

19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34 and 35, composite structure CS may comprise a curved profile (e.g. shape, form, etc.). See also FIGURES 5A-5F, 6A-6F, 7A-7F, 8A-8F, 43A-43D, 45A-45D and 57.

[0103] As indicated schematically in the FIGURES, cover T may comprise a core comprised of a core material and a surface formed on the core comprised of surface material; a density of the surface material may be greater than a density of the core material; a surface providing an exterior surface TX of cover T for composite structure CS may be formed as a skin SK on core CR. See for example FIGURES 5A-5F, 6A-6F, 7A-7F, 8A-8F, 17, 18, 23, 24, 25, 26, 30, 33, 36 and 57.

[0104] As indicated schematically according to an exemplary embodiment in FIGURES 19,

20, 21 and 22, cover T may comprise a top layer TL and/or an intermediate/inner layer NL. See also FIGURES 34 and 35. As indicated schematically in FIGURE 20, cover T may be retained on substrate SB with an adhesive material DH. As indicated schematically according to an exemplary embodiment in FIGURES 21 and 22, cover T may comprise a pad PD under top layer TL and inner layer NL on substrate SB and/or a pad PD under top layer and TL above inner/intermediate layer NL on substrate SB. As indicated schematically according to an exemplary embodiment in FIGURES 29 and 32, cover T may be formed from a resin material R/RN; cover T comprising core layer CR and skin SK may be formed from a resin material R/RN; the cover may be formed from a molded material, injection -molded material, self-skinning material, etc. See also FIGURES 37A-37D, 38A-38D, 39A-39F, 40A-40D, 41A-41D, 42A-42D, 44A-44C and 46A-46C.

[0105] As indicated schematically according to an exemplary embodiment in FIGURES 19, 20, 21 and 22, cover T may comprise an inner surface/layer NL coupled to substrate SB and an outer surface providing an exterior surface TX of component/composite structure CS; cover T may comprise a material; the material of cover T may be softer than substrate SB. Compare FIGURES 12B and 14B. Cover T may comprise a molded cover molded over substrate SB. As indicated schematically according to an exemplary embodiment in FIGURES 19, 20, 21, 22, 34 and 35, cover T may comprise a cover layer TL and/or a base layer NL on substrate SB; cover T may comprise a cover layer TL and a base layer and an intermediate layer; cover T may comprise a skin SK and a core layer CR; cover T may comprise a foam material FM. See also FIGURES 16, 17, 18, 23, 24, 25, 26, 27, 28, 30, 31, 33 and 36. As indicated schematically according to an exemplary embodiment in FIGURES 29 and 32, cover T may comprise and/or be formed from a resin material R/RN.

[0106] As indicated schematically according to an exemplary embodiment in FIGURE 18, cover T may comprise a decorative layer DL at exterior surface TX for composite structure CS; decorative layer DL may comprise a surface effect such as a pattern and/or texture and/or appearance, etc. See also FIGURES 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 and 36. As indicated schematically in the FIGURES, the cover may comprise a coating as and/or on the decorative layer.

[0107] As indicated schematically, the material comprising cover T may comprise at least one of a mixture of polyurethane and/or a combination of a reaction mixture and/or foam material and/or polyurethane foam and/or urethane foam and/or injection-molded material and/or injected foam material and/or plastic and/or resin. As indicated schematically, the material comprising cover T may comprise at least one of a foam material and/or a urethane foam and/or a compressible foam and/or a self-skinning foam/material; the cover may comprise an integral skin on a core. As indicated schematically, cover T may comprise a laminate; the laminate may comprise an outer layer TL and inner layer NL; a resin material and/or a foam material/compound may be provided/formed between/within and/or as the laminate on the substrate; the resin/foam material and/or an adhesive material may be configured to bond the laminate to the substrate. Cover T may comprise at least one of a TPE material and/or a TPV material and/or a PU material and/or a polymer material and/or a resin material and/or a plastic material.

[0108] As indicated schematically according to an exemplary embodiment in FIGURES 5 A- 5F, 6A-6F, 7A-7F and 8A-8F, composite structure CS may comprise a feature FT; feature FT may comprise a formed feature FT at a surface of cover T; feature FT may comprise a molded feature FT; feature FT may comprise an indentation ND and/or a projection PN. See also FIGURES 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 43A-43D, 45A-45D and 57. As indicated schematically according to an exemplary embodiment in FIGURES 5 A-5F, 6A-6F, 7A-7F, 8A-8F, 27, 28, 29, 30, 31, 32, 33, 34, 35 and 36, feature FT may comprise at least one of a rib and/or a recess and/or a notch and/or a divider and/or a line and/or a stitch and/or a decorative stitch and/or a molded stitch appearance and/or a faux stitch and/or a decorative faux stitch and/or a groove and/or a structure and/or a shape and/or a form and/or a curved form. The feature may comprise at least one of a resin and/or a thermoplastic resin and/or polypropylene and/or acrylonitrile butadiene styrene and/or polycarbonate and/or a formed feature; the feature may comprise at least one of a rib and/or a set of ribs and/or a resin- formed feature and/or a resin-formed feature molded on the substrate with the cover and/or under the substrate. As indicated schematically according to an exemplary embodiment in FIGURES 5A-5F, 6A-6F, 7A-7F, 8A-8F, 23, 24, 25, 26 and 57, feature FT may comprise an aesthetic feature and/or a seam such as a tear line and/or an initiator for formation of an opening for deployment of an airbag and/or a recess for formation of an opening for deployment of an airbag and/or a projection for formation of an opening for deployment of an airbag. See also FIGURES 3A-3C and 4A-4C.

[0109] As indicated schematically according to an exemplary embodiment in FIGURES 5 A- 5F, 6A-6F, 7A-7F, 8A-8F, 26 and 57, feature FT may comprise an indicia at exterior surface TX of the cover; the indicia may comprise at least one of a raised indicia and/or a formed indicia and/or a recessed indicia and/or an applied indicia and/or an ink indicia.

[0110] As indicated schematically according to an exemplary embodiment in FIGURES 5 A- 5F, 6A-6F, 7A-7F, 8A-8F, 24, 25, 31, 32 and 33, feature FT may comprise a surface effect that may be provided at exterior surface TX of cover T of composite structure CS; the surface effect provided by feature FT may comprise a texture and/or a pattern. As indicated schematically, feature FT may comprise an applied material; the applied material may comprise at least one of a coating and/or an ink and/or a colorant and/or a film and/or paint. See generally FIGURE 18.

[OHl] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2B, 43A-43D and 45A-45D, composite structure CS may comprise a functional layer; the functional layer may comprise a layer of material FX such as at least one of an insulating layer and/or a spacer layer and/or a sound insulating layer; functional layer SD may comprise at least one of a sound deadening layer and/or a sound deadening material such as fiber mat FB; functional layer SD may comprise a fiber mat/material FB/FX (e.g. commercially available material). As indicated schematically according to an exemplary embodiment in FIGURES 2A-2B, 43 A-43D and 45A-45D, functional layer SD may comprise an insulating material such as a sound insulating layer under substrate SB; functional layer SD may comprise an insulating fiber material FB/FX under cover T.

[0112] As indicated schematically according to an exemplary embodiment in FIGURE 18, composite structure CS may comprise a decorative layer DL at exterior surface TX of cover T; decorative layer DL may comprise a surface effect; the surface effect may comprise at least one of a texture and/or a pattern and/or a molded effect and/or a molded layer and/or a resin and/or a coating and/or a paint and/or an ink and/or leather appearance and/or a grain effect; decorative layer DL may comprise at least one of a film and/or a fabric and/or an applied material and/or a leather and/or a synthetic leather/layer. See also FIGURES 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 and 36.

[0113] As indicated schematically according to an exemplary embodiment in FIGURES 5 A- 5F, 6A-6F, 7A-7F, 43A-43D, 45A-45D and 57, composite structure CS may comprise a structure ST; structure ST may comprise a molded structure formed on substrate SB and/or a housing such as an airbag chute CH.

[0114] A surface of composite structure CS may comprise a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer; composite structure CS of the component may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. See also TABLE A. A surface of composite structure CS may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. See also TABLE A. Fiber panel FP of composite structure CS may comprise a hardness of approximately 95 Shore A Durometer. See also TABLE A.

[0115] As indicated schematically according to an exemplary embodiment in FIGURES 37A-37D, 38A-38D, 39A-39F, 40A-40D, 41A-41D, 42A-42D, 44A-44C and 46A-46C, a method of manufacturing a component for a vehicle interior in a tool may comprise the steps of providing a fiber mat FB/FX in the tool and compressing fiber mat FB/FX in the tool to form a structural substrate SB comprising a compression-formed fiber panel FP having a shape and forming cover T on structural substrate SB; exterior surface TX at cover T may comprise a compressible material; compression-formed fiber panel FP of structural substrate SB may comprise a generally rigid panel; cover T and structural substrate SB comprise a composite structure CS for the component; the method may comprise the step of providing a functional layer SD on structural substrate SB; composite structure CS may comprise functional layer SD; functional layer SD may comprise a sound insulating layer on substrate SB or under substrate SB; the step of forming cover T on structural substrate SB may comprise molding cover T on compression-formed fiber panel CF/FP; cover T may comprise a formed cover with at least one feature FT or structure ST; cover T may comprise a formed cover T comprising a multi-layer cover T comprising a skin SK layer and a core layer CR. See also FIGURES 5A-5F, 6A-6F, 7A-7F, 43 A-43D, 45A-45D and 57.

[0116] As indicated schematically according to an exemplary embodiment in FIGURES 1 A- 1B and 2A-2B, the component may comprise at least one of an instrument panel and/or a dashboard and/or a door panel and/or a steering wheel assembly and/or a console and/or a cockpit and/or a knee bolster and/or a trim component and/or a panel and/or a trim panel.

Exemplary Embodiments - A

[0117] According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior may comprise a composite structure comprising a substrate and a cover. The substrate may comprise a fiber panel. The cover may be provided on the substrate. The substrate may comprise a structural substrate. The cover may comprise an exterior surface for the composite structure. The exterior surface at the cover of the composite structure may comprise a compressible material. The exterior surface at the cover of the composite structure may comprise a generally deformable material. The exterior surface at the cover of the composite structure may comprise a generally soft material. The structural substrate may comprise a generally rigid panel. The exterior surface at the cover of the composite structure may comprise a generally soft surface on the generally rigid fiber panel of the structural substrate of the composite structure. The exterior surface at the cover of the composite structure may comprise a softness; the softness of the exterior surface at the cover of the composite structure may be greater than a softness of the fiber panel of the substrate of the composite structure. The cover may comprise a compressible material. The cover may comprise two-layers of compressible material. The cover may comprise a composite cover comprising an exterior surface layer and a core layer; the core layer may comprise a generally soft material. The generally soft material may be softer than the exterior surface layer of the cover of the composite structure. The generally soft material may be softer than the fiber panel of the structural substrate of the composite structure. The core layer of the cover of the composite structure may comprise a foam material. The core layer of the cover of the composite structure may comprise a foam material; the exterior surface layer of the cover of the composite structure may comprise a skin. The cover comprising the core layer and the skin may be formed from a resin material. The cover may be formed from a self-skinning material. The cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; the cover may comprise a material; the material of the cover may be softer than the substrate. The cover may comprise a molded cover molded over the substrate. The cover may comprise a cover layer and a base layer. The cover may comprise a cover layer and a base layer and an intermediate layer. The cover may comprise a skin and a core. The cover may comprise at least one of (a) a skin and a core layer; (b) a skin and a core formed from a resin material; (c) a formed skin; (d) a formed skin on a core; (e) a skin and a foam material; (f) a pad. The cover may comprise a cover layer and a pad. The cover may comprise at least one of (a) a film; (b) a resin; (c) a pad; (d) a foam; (e) a skin. The cover may comprise at least one of (a) a TPE material; (b) a TPV material; (c) a PU material; (d) a polymer material; (e) a resin material; (f) a plastic material. The composite structure may comprise a feature. The feature may comprise a formed feature at a surface of the cover. The feature may comprise a molded feature. The feature may comprise an indentation and/or a projection. The feature may comprise at least one of (a) a rib; (b) a recess; (c) a notch; (d) a divider; (e) a line; (f) a stitch; (g) a decorative stitch; (h) a molded stitch appearance; (i) a faux stitch; (j) a decorative faux stitch; (k) a groove; (1) a structure; (m) a shape; (n) a form; (o) a curved form. The feature may comprise at least one of (a) a tear line; (b) an initiator for formation of an opening for deployment of an airbag; (c) a recess for formation of an opening for deployment of an airbag; and/or (d) a projection for formation of an opening for deployment of an airbag. The feature may comprise an indicia; the indica may comprise at least one of (a) a raised indicia; (b) a formed indicia; (c) a recessed indicia; (d) an applied indicia; (e) an ink indicia. The feature may comprise a surface effect. The feature may comprise a texture. The feature may comprise an ink. The feature may comprise an applied material; the applied material may comprise at least one of (a) a coating; (b) an ink; (c) a colorant; (d) a film; (e) paint. The composite structure may comprise a functional layer; the functional layer may comprise at least one of (a) an insulating layer; (b) a spacer layer; (c) a sound insulating layer. The composite structure may comprise a functional layer; the functional layer may comprise at least one of (a) a sound deadening layer; (b) a sound deadening material. The composite structure may comprise a functional layer; the functional layer may comprise a fiber mat. The composite structure may comprise a functional layer; the functional layer may comprise a sound insulating layer under the substrate. The composite structure may comprise a functional layer; the functional layer may comprise an insulating fiber material under the cover. The composite structure may comprise a decorative layer. The decorative layer may comprise a surface effect. The surface effect may comprise at least one of (a) a texture; (b) a pattern; (c) a molded effect; (d) a molded layer; (e) a resin; (f) a coating; (g) a paint; (h) an ink; (i) leather appearance; (j) a grain effect. The decorative layer may comprise at least one of (a) a film; (b) a fabric; (c) an applied material; (d) a leather; (e) a synthetic layer. The composite structure may comprise a structure; the structure may comprise at least one of (a) a molded structure formed on the substrate; (b) a housing; (c) an airbag chute. The composite structure may comprise a curved profile. The substrate may be formed from the fiber panel; the cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; the cover may comprise a material; the material comprising the cover may be softer than the substrate. The cover may be molded on the substrate; the cover may comprise an injection molded thermoplastic material. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material; a density of the surface material may be greater than a density of the core material. The surface may be formed as a skin on the core. The cover may comprise a decorative layer on the surface; the decorative layer may comprise at least one of a pattern and/or texture. The cover may comprise a coating on the decorative layer. The material comprising the cover may comprise at least one of (a) a mixture of polyurethane; (b) a combination of a reaction mixture; (c) foam material; (d) polyurethane foam; (e) urethane foam; (f) injection -molded material; (g) injected foam material; (h) plastic; (i) resin. The material comprising the cover may comprise at least one of (a) a foam material; (b) a urethane foam; (c) a compressible foam; (d) a self-skinning foam. The material comprising the cover may comprise a self-skinning material. The cover may comprise an integral skin on a core. The cover may be formed with a foam compound. The cover may comprise a laminate; the laminate may comprise an outer layer and inner layer. The component may comprise a foam material between the laminate and the substrate; the foam material may be configured to bond the laminate to the substrate. The substrate may comprise a compression- formed component formed from the fiber panel. The substrate may comprise at least one feature; the at least one feature may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate; (f) a formed feature. The substrate may comprise at least one feature; the at least one feature may comprise at least one of (a) a rib; (b) a set of ribs; (c) a resin-formed feature; (d) a resin- formed feature molded on the substrate.

[0118] A surface of the composite structure may comprise a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer. See also TABLE A. See also TABLE A. A surface of the composite structure may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. See also TABLE A. The cover may comprise a skin providing the surface and a core; a surface of the composite structure may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. See also TABLE A. The fiber panel of the composite structure may comprise a hardness of approximately 95 Shore A Durometer. See also TABLE A.

[0119] The component may comprise at least one of (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 bolster; (h) a trim component; (i) a panel; (j) a trim panel.

[0120] According to an exemplary embodiment as shown schematically in the FIGURES, a method of manufacturing a component for a vehicle interior in a tool may comprise providing a fiber mat in the tool, compressing the fiber mat in the tool to form a structural substrate comprising a compression-formed fiber panel having a shape, and forming a cover on the structural substrate. An exterior surface at the cover may comprise a compressible material. The compression-formed fiber panel of the structural substrate may comprise a generally rigid panel. The cover and the structural substrate comprise a composite structure for the component. The method may comprise the step of providing a functional layer on the structural substrate. The composite structure may comprise the functional layer; the functional layer may comprise a sound insulating layer on the substrate or under the substrate. The step of forming a cover on the structural substrate may comprise molding the cover on the compression-formed fiber panel. The cover may comprise a formed cover with at least one feature. The cover may comprise a formed cover comprising a multi-layer cover comprising a skin layer and a core layer.

Exemplary Embodiments - B

[0121] According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior may comprise a composite structure comprising a substrate and a cover. The substrate may comprise a fiber panel. The cover may be provided on the substrate. The substrate may comprise a structural substrate. The cover may comprise an exterior surface for the composite structure. The exterior surface at the cover of the composite structure may comprise a compliant material. The exterior surface at the cover of the composite structure may comprise a compressible material. The exterior surface at the cover of the composite structure may comprise a generally deformable material. The exterior surface at the cover of the composite structure may comprise a generally soft material. The structural substrate may comprise a generally rigid panel. The structural substrate may comprise a generally rigid fiber panel. The fiber panel of the structural substrate may comprise a generally rigid panel. The fiber panel may comprise a compressed fiber panel. The fiber panel may comprise a compression-formed component. The exterior surface at the cover of the composite structure may comprise a generally soft surface and the fiber panel of the structural substrate of the composite structure may comprise a generally rigid panel. The exterior surface at the cover of the composite structure may comprise a generally soft surface on the generally rigid fiber panel of the structural substrate of the composite structure. The exterior surface at the cover of the composite structure may comprise a softness and the fiber panel of the structural substrate of the composite structure may comprise a hardness. The exterior surface at the cover of the composite structure may comprise a softness. The softness of the exterior surface at the cover of the composite structure may be greater than the softness of the fiber panel of the substrate of the composite structure. The exterior surface at the cover of the composite structure may comprise a softness; the softness of the exterior surface at the cover of the composite structure may be greater than the softness of the fiber panel of the substrate of the composite structure. The cover may comprise at least one layer of material. The cover may comprise a single layer of material. The cover may comprise two-layers of material. The cover may comprise a compressible material. The cover may comprise two-layers of compressible material. The cover may comprise a composite cover comprising an exterior surface layer and a core layer. The core layer may comprise a generally soft material. The core layer of the cover of the composite structure may comprise a foam material. The core layer of the cover of the composite structure may comprise a generally soft material softer than the exterior surface layer of the cover of the composite structure. The core layer of the cover of the composite structure may comprise a generally soft material softer than the fiber panel of the structural substrate of the composite structure. The core layer of the cover of the composite structure may comprise a foam material; the exterior surface layer of the cover of the composite structure may comprise a skin. The cover comprising the core layer and skin may be formed from a resin material. The core layer of the cover of the composite structure may comprise a generally soft foam material softer than the exterior surface layer of the cover of the composite material. The cover may be formed from a self-skinning material. The cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; the cover may comprise a material; the material of the cover may be softer than the substrate. The cover may comprise a molded cover. The cover may be molded on the substrate. The cover may comprise a composite cover or a multi-layer cover. The cover may comprise a single-layer cover. The cover may comprise a multi-layer cover. The cover may comprise a cover layer. The cover may comprise a cover layer and a base layer. The cover may comprise a cover layer and a base layer and an intermediate layer. The cover may comprise a skin. The cover may comprise a skin and a core. The cover may comprise at least one of (a) a skin and a core layer; (b) a skin and a core formed from a resin material; (c) a formed skin; (d) a formed skin on a core; (e) a skin and a foam material; (f) a pad. The cover may comprise a cover layer and a pad. The cover may comprise a decorative layer. A cover layer of the cover may be configured to provide an exterior surface. The cover may be configured to provide an exterior surface for the composite structure. The cover may comprise an exterior layer providing a surface effect. The cover may comprise at least one of (a) a film; (b) a resin; (c) a pad; (d) a foam; (e) a skin. The cover may comprise a cover layer and an inner layer. The cover may comprise a cover layer and an inner layer and an under layer. The cover may comprise at least one of (a) a TPE material; (b) a TPV material; (c) a PU material; (d) a polymer material; (e) a resin material; (f) a plastic material. The composite structure may comprise a feature. The composite structure may comprise a formed feature at a surface of the cover. The composite structure may comprise at least one feature. The feature may comprise a molded feature. The feature may comprise an indentation. The feature may comprise a projection. The feature may comprise an indentation and a projection. The feature may comprise at least one of (a) a rib; (b) a recess; (c) a notch; (d) a divider; (e) a line; (f) a stitch; (g) a decorative stitch; (h) a molded stitch appearance; (i) a faux stitch; (j) a

T1 decorative faux stitch; (k) a groove; (1) a structure; (m) a shape; (n) a form; (o) a curved form. The feature may comprise a seam. The feature may comprise at least one of (a) a tear line;

(b) an initiator for formation of an opening for deployment of an airbag; (c) a recess for formation of an opening for deployment of an airbag; and/or (d) a projection for formation of an opening for deployment of an airbag. The feature may comprise an indicia. The feature may comprise at least one of (a) a raised indicia; (b) a formed indicia; (c) a recessed indicia; (d) an applied indicia; (e) an ink indicia. The feature may comprise a surface effect. The feature may comprise a texture. The feature may comprise an ink. The feature may comprise an applied material. The feature may comprise at least one of (a) a coating; (b) an ink; (c) an applied material; (d) a film; (e) paint. The composite structure may comprise a functional layer; the functional layer may comprise at least one of (a) an insulating layer; (b) a spacer layer; (c) a sound insulating layer. The sound insulating layer may comprise a sound deadening layer. The sound insulating layer may comprise a sound deadening material. The functional layer may comprise a sound deadening layer; the sound deadening layer may comprise a sound insulating layer. The functional layer may comprise a fiber mat. The functional layer may comprise a sound insulating layer on the substrate. The functional layer may comprise a sound insulating layer under the substrate. The functional layer may comprise an insulating fiber material under the cover. The composite structure may comprise an adhesive material. The composite structure may comprise an adhesive material to couple a functional layer comprising a sound deadening material to the fiber panel comprising the substrate. The composite structure may comprise a decorative layer. The decorative layer may comprise a surface effect. The decorative layer may comprise at least one of (a) a texture; (b) a pattern; (c) a molded effect; (d) a molded layer; (e) a resin; (f) a coating; (g) a paint; (h) an ink. The decorative layer may comprise at least one of (a) a film; (b) a fabric;

(c) an applied material; (d) a leather; (e) a synthetic layer. The composite structure may comprise a structure; the structure may comprise at least one of (a) a molded structure formed on the substrate; (b) a housing; (c) an airbag chute. The composite structure may comprise a profile. The composite structure may comprise a curved profile. The substrate may be formed from the fiber panel; the cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; the cover may comprise a material; the material comprising the cover may be softer than the substrate. The cover may be molded on the substrate; the cover may comprise an injection molded thermoplastic material. The cover may comprise at least one of (a) a TPE material; (b) a TPV material; (c) a PU material; (d) a generally opaque material. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material; a density of the surface material may be greater than a density of the core material. The surface may be formed as a skin on the core. The cover may comprise a decorative layer on the surface. The decorative layer may comprise at least one of a pattern and/or texture. The cover may comprise a coating on the decorative layer. The material comprising the cover may comprise at least one of (a) a mixture of polyurethane; (b) a combination of a reaction mixture; (c) foam material; (d) polyurethane foam; (e) urethane foam; (f) injection-molded material; (g) injected foam material; (h) plastic; (i) resin. The material comprising the cover may comprise at least one of (a) a foam material; (b) a urethane foam; (c) a compressible foam; (d) a self-skinning foam. The material comprising the cover may comprise a self-skinning material. The cover may comprise an integral skin on a core. The cover may be formed with a foam compound. The cover may be formed from a reactive foam compound. The cover may comprise a laminate. The laminate may comprise an outer layer and inner layer. The component may comprise a foam material between the laminate and the substrate; the foam material may be configured to bond the laminate to the substrate. The substrate may comprise a compression-formed component formed from the fiber panel. The substrate may comprise at least one feature formed on a rear side of the fiber panel. The at least one feature may comprise a formed feature. The cover may comprise at least one feature; the at least one feature may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate; (f) a formed feature. The at least one feature may comprise at least one of (a) a rib; (b) a set of ribs; (c) a resin-formed feature; (d) a resin-formed feature molded on the substrate. The component may comprise at least one of (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 bolster; (h) a trim component; (i) a panel; (j) a trim panel. The composite structure may comprise a surface.

[0122] The surface of the composite structure may comprise a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer. See also TABLE A. See also TABLE A. The surface of the composite structure may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. See also TABLE A. The cover may comprise a skin providing the surface and a core; surface of the composite structure may comprise a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer. See also TABLE A. The fiber panel of the composite structure may comprise a hardness of approximately 95 Shore A Durometer. See also TABLE A. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material; a density of the surface material may be greater than a density of the core material. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material; the surface may be formed as a skin on the core. The surface may comprise a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer. See also TABLE A.

[0123] According to an exemplary embodiment as shown schematically in the FIGURES, the composite structure may be configured to form an opening for deployment of an airbag. The composite structure may be configured to form a door for an opening for deployment of an airbag. The composite structure may be configured to form a hinge for an airbag door. The composite structure may comprise a seam configured to form an opening for deployment of an airbag.

[0124] According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior formed in a tool may comprise a composite structure comprising (a) a substrate comprising a compression-formed component and (b) a formed cover. The compression-formed component may be formed by compressing a fiber panel in the tool. The formed cover may be formed on the fiber panel of the compression-formed component of the substrate. The cover may comprise a formed cover formed by molding. The cover may comprise a formed cover with at least one feature. The cover may comprise a formed cover comprising a multi-layer cover formed from a cover material comprising a skin layer and a core layer. The cover material may comprise a self-skinning foam comprising a skin and a core layer comprising a foam. The cover may comprise a formed cover may comprise a single-layer cover. The composite structure may comprise a functional layer. The functional layer may comprise a sound insulating layer on the substrate. The functional layer may comprise a sound insulating fiber layer under the cover. The tool may comprise a mold.

[0125] According to an exemplary embodiment as shown schematically in the FIGURES, a method of manufacturing a component for a vehicle interior in a tool may comprise providing a fiber mat in the tool; compressing the fiber mat in the tool to form a structural substrate comprising a compression-formed fiber panel having a shape; and forming a cover on the structural substrate. An exterior surface at the cover may comprise a compressible material. The compression-formed fiber panel of the structural substrate may comprise a generally rigid panel. The cover and the structural substrate may comprise a composite structure for the component. The method may comprise a step of providing a functional layer on the structural substrate. The step of forming a cover on the structural substrate may comprise molding the cover on the compression-formed fiber panel. The cover may comprise a formed cover formed by molding. The cover may comprise a formed with at least one feature. The cover may comprise a formed cover may comprise a multi-layer cover comprising a skin layer and a core layer. The cover may comprise at least one of (a) a cover material; (b) a selfskinning material; (c) a skin layer and a core layer comprising a foam. The composite structure may comprise a functional layer; the functional layer may comprise a sound insulating layer on the substrate or under the substrate. The tool may comprise a mold.

[0126] According to an exemplary embodiment as shown schematically in the FIGURES, a method of manufacturing a component for a vehicle interior in a mold may comprise providing a fiber panel, disposing the fiber panel into the mold, compressing the fiber panel between a first surface of the mold and a second surface of the mold to form the fiber panel into a compression-formed component having a shape corresponding to a first contour of the first surface and a second contour of the second surface, and molding a skin layer on the compression-formed component. The step of molding a skin layer on the compression- formed component may comprise molding the skin layer between the compression-formed component and a third surface of the mold. The step of molding a skin layer on the compression-formed component may comprise molding the skin layer on a top surface of the compression-formed component and on an edge of the compression-formed component. The outer layer may comprise a thermoplastic elastomer. The foam material may be configured to bond the laminate to the compression-formed component. The laminate may comprise a foam -backed skin. The method may comprise a step of injecting resin into the mold to form a feature on a rear side of the compression-formed component.

Exemplary Embodiments - C

[0127] As indicated schematically according to an exemplary embodiment in FIGURE 2A, a component such as an instrument panel IP or a steering wheel SW may comprise a substrate SB covered by a cover T. See also FIGURES 5A-5F, 6A-6F, 7A-7F, 8A-8F, 43 A-43D, 45A- 45D and 57. As indicated schematically according to an exemplary embodiment in FIGURE 2B, a component such as a door panel DP may comprise a substrate SB covered by a cover T. [0128] According to an exemplary embodiment as shown schematically in FIGURES 5A-5F, 6A-6F, 7A-7F, 8A-8F, 43 A-43D, 45A-45D and 57, a component C for a vehicle interior may comprise a substrate SB formed from a compression-formed component CF. Component C may comprise a base shown as a chute CH (e.g. for an airbag). Chute CH may be coupled to substrate SB. Substrate SB may be covered by a cover T.

[0129] According to an exemplary embodiment as shown schematically in the FIGURES, a component C for a vehicle interior shown as an instrument panel IP may comprise a substrate SB formed from a compression-formed component CF. Substrate SB may be covered by a cover T.

[0130] According to an exemplary embodiment as shown schematically in FIGURE 11 A, a fiber mat FB may include a combination of fibers (e.g. natural and/or synthetic fibers) and thermoplastic resin (e.g. polypropylene (PP), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), etc.). According to an exemplary embodiment, fiber mat FB may have a thickness ta. According to an exemplary embodiment, fiber mat FB may be heated to induce the thermoplastic resin to liquefy. According to an exemplary embodiment as shown schematically in FIGURE 1 IB, fiber mat FB may be heated and consolidated (e.g. partially compressed). According to an exemplary embodiment, the consolidated fiber mat may have a thickness tb, which may be smaller than thickness ta. According to an exemplary embodiment, fiber mat FB may be placed into a low-temperature mold and compression molded into a desired shape. According to an exemplary embodiment, as the compressed fiber mat cools, the thermoplastic within the fiber mat may solidify to establish a substantially rigid composite panel.

[0131] According to an exemplary embodiment, fiber mat FB may comprise a combination of structural fibers and thermoset resin (e.g. epoxy, polyester, etc.). According to an exemplary embodiment, fiber mat FB may be compressed within a heated mold to form a partially compressed fiber mat with a desired shape and to induce curing of the thermoset resin. According to an exemplary embodiment, a substantially rigid composite panel may be formed after the thermoset resin is cured.

[0132] According to an exemplary embodiment as shown schematically in FIGURE 11C, a consolidated fiber mat may be heated in an oven VN. As shown schematically in FIGURE 1 ID, the heated fiber mat may be transferred into a mold having a mold top MT and a mold bottom MB. According to an exemplary embodiment as shown schematically in FIGURES 1 IE and 1 IF, a compression-formed component CF shown as a substrate SB may be produced by a process of compression forming. The process may comprise compression forming. The process may also comprise injection molding. According to an exemplary embodiment, the heated fiber mat may be compressed into a fiber panel; plastic resin may be injected on the fiber panel to form an ancillary feature and/or a border for the fiber panel. [0133] Referring to FIGURES 12A-12B, 13A-13B and 14A-14B, construction/formation of a component C is shown schematically according to an exemplary embodiment. A compression-formed component may be formed by compression forming a fiber mat. As shown schematically in FIGURE 12B, the compression-formed component may provide a surface effect comprising a generally rigid form. As shown schematically in FIGURES BABB and 14A-14B, the compression-formed component may be covered with a cover T; as shown schematically in FIGURE 14B, the component may provide a surface effect comprising a generally soft form (e.g. from cover T).

[0134] According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior may comprise a substrate formed from a fiber panel and a cover for the substrate. The cover may comprise an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component. The cover may comprise a material; the material of the cover may be softer than the substrate. The cover may be molded on the substrate. The cover may comprise an injection molded thermoplastic material. The cover may comprise a generally opaque material. The cover may comprise at least one of (a) a TPE material, (b) a TPV material and/or (c) a PU material. The cover may comprise a core comprised of core material and a surface formed on the core comprised of surface material. A density of the surface material may be greater than a density of the core material. The surface may be formed as a skin on the core. The surface may comprise a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer. See also TABLE A. The cover may comprise a softness of greater than approximately 24 pounds and less than approximately 36 pounds on a 25 percent indentation force deflection scale. The cover may comprise a decorative layer on the surface opposite the core. The decorative layer may comprise at least one of a pattern and/or texture. The cover may comprise a coating on the decorative layer. The material of the cover may comprise at least one of (a) a mixture of polyurethane, (b) a combination of a reaction mixture, (c) foam material, (d) polyurethane foam, (e) urethane foam, (f) injection-molded material, (g) injected foam material, (h) plastic and/or (i) resin. The material of the cover may comprise at least one of (a) a foam material, (b) a urethane foam and/or (c) a compressible foam. The cover may comprise an integral skin on a core. The cover may be formed from reactive foam compounds. The cover may be formed with a blowing agent to produce a cellular structure for the cover. The cover may comprise a cellular structure. The cover may comprise an open cell foam. The cover may comprise a laminate. The laminate may comprise an outer layer and inner layer. The outer layer may comprise a thermoplastic elastomer. The inner layer may comprise a pad (e.g. a foam pad). The component may comprise a foam material between the laminate and the substrate. The foam material may be configured to bond the laminate to the substrate. The fiber panel may comprise a panel comprising fibers. The substrate may comprise a compression-formed component formed from the fiber panel. The substrate may comprise at least one feature formed on a rear side of the fiber panel. The at least one feature may comprise at least one of (a) a resin, (b) a thermoplastic resin, (c) polypropylene, (d) acrylonitrile butadiene styrene and/or (e) polycarbonate. The at least one feature may comprise at least one of (a) a rib, (b) a set of ribs, (c) a resin-formed feature and/or (d) a resin-formed feature molded on the substrate. The component may comprise at least one of (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 bolster and/or (h) a trim component.

[0135] According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior formed in a mold may comprise (a) a substrate comprising a compression-formed component and (b) a cover comprising a skin layer. The compression- formed component may be formed by compressing a fiber panel between a first surface of the mold and a second surface of the mold. The skin layer may be formed by molding the skin layer on the compression-formed component.

[0136] According to an exemplary embodiment as shown schematically in the FIGURES, a method of manufacturing a component for a vehicle interior in a mold may comprise (a) providing a fiber panel, (b) disposing the fiber panel into the mold, (c) compressing the fiber panel between a first surface of the mold and a second surface of the mold to form a compression-formed component having a shape corresponding to a first contour of the first surface and a second contour of the second surface and (d) molding a skin layer on the compression-formed component. The step of molding a skin layer on the compression- formed component may comprise molding the skin layer between the compression-formed component and a third surface of the mold. The step of molding a skin layer on the compression-formed component may comprise molding the skin layer on a top surface of the compression-formed component and on an edge of the compression-formed component. The step of molding a skin layer on the compression-formed component may comprise injecting a blowing agent between a third surface of mold and the compression-formed component. The step of molding a skin layer on the compression-formed component may comprise mixing reactive foam compounds and injecting the reactive foam compounds between the compression-formed component and a third surface of the mold. The step of molding a skin layer on the compression-formed component may comprise curing reactive foam compounds. The method may comprise a step of applying a layer of paint on a surface of the mold. The step of molding a skin layer on the compression-formed component may comprise bonding the layer of paint on the skin layer. The step of molding a skin layer on the compression- formed component may comprise injecting an open cell foam in the mold. The method may comprise a step of expanding the open cell foam in the mold. The method may comprise a step of applying a laminate on a surface of the mold. The laminate may comprise an outer layer and inner layer. The outer layer may comprise a thermoplastic elastomer. The inner layer may comprise a pad (e.g. a foam pad). The method may comprise a step of injecting a foam material between the laminate and the compression-formed component. The foam material may be configured to bond the laminate to the compression-formed component. The laminate may comprise a foam-backed skin. The method may comprise a step of applying an adhesive on the fiber panel; the adhesive may be configured to adhere the skin layer on the compression-formed component. The method may comprise a step of injecting resin into the mold to form a feature on a rear side of the compression-formed component.

Methods of Manufacturing

[0137] According to an exemplary embodiment as shown schematically in FIGURES 47, 48, 49, 50, 51, 52, 53, 54, 55 and 56, a method of manufacturing a component for a vehicle interior may comprise providing a mold/tool, placing a fiber mat in the mold/tool, compressing the fiber mat in the mold/tool to form a compression-formed component, forming a cover (e.g. with feature and/or structure ) onto the compression-formed component, and removing a component/composite structure from the mold/tool. See also FIGURES 37A-37D. 38A-38D, 39A-39F, 40A-40D, 41A-41D, 42A-42D, 44A-44C and 46A-46C. [0138] According to an exemplary embodiment as shown schematically in FIGURE 47, a method of manufacturing a component for a vehicle interior may comprise providing a mold/tool, placing a fiber mat in the mold/tool, compressing the fiber mat in the mold/tool to form a compression-formed component, forming a cover (e.g. with feature) onto the compression-formed component, and removing a component/composite structure from the mold/tool.

[0139] According to an exemplary embodiment as shown schematically in FIGURE 48, a method of manufacturing a component for a vehicle interior may comprise providing a mold/tool, placing a fiber mat in the mold/tool, compressing the fiber mat in the mold/tool to form a compression-formed component, and forming a cover (e.g. with feature) on the compression-formed component to form a component/composite structure.

[0140] According to an exemplary embodiment as shown schematically in FIGURE 49, a method of manufacturing a component for a vehicle interior may comprise providing a mold/tool, placing a fiber mat in the mold/tool, compressing the fiber mat in the mold/tool [0141] to form a compression-formed component, applying a treatment/coating to the mold/tool, forming a cover with core and skin onto the compression-formed component, and removing a component/composite structure from the mold/tool.

[0142] According to an exemplary embodiment as shown schematically in FIGURE 50, a method of manufacturing a component for a vehicle interior may comprise providing a mold/tool, placing a fiber mat in the mold/tool, compressing the fiber mat in the mold/tool to form a compression-formed component, injecting resin/material to form a cover onto the compression-formed component, separating the mold/tool from the compression-formed component, supplying gas to facilitate expansion of the cover on the compression-formed component, and removing the component/composite structure.

[0143] According to an exemplary embodiment as shown schematically in FIGURE 51, a method of manufacturing a component for a vehicle interior may comprise cutting/consolidating a fiber mat/substrate, providing material for a cover including a skin and a pad, cutting/forming the cover, providing a mold/tool, placing the fiber mat and cover into the mold/tool, compressing the fiber mat and cover in the mold/tool to form a compression-formed component with the cover, and removing a component/composite structure from the mold/tool.

[0144] According to an exemplary embodiment as shown schematically in FIGURE 52, a method of manufacturing a component for a vehicle interior may comprise providing a mold comprising a first surface, a second surface and a third surface; placing a fiber panel in the mold; compressing the fiber panel between the first surface of the mold and the second surface of the mold to form the fiber panel into a compression-formed component; molding a cover between the compression-formed component and the third surface of the mold; and removing the component from the mold.

[0145] According to an exemplary embodiment as shown schematically in FIGURE 53, a method of manufacturing a component for a vehicle interior may comprise providing a mold comprising a first surface and a second surface; placing a fiber panel in the mold; compressing the fiber panel between the first surface of the mold and the second surface of the mold to form a compression-formed component; and molding a cover on a surface and an edge of the compression-formed component to form the component.

[0146] According to an exemplary embodiment as shown schematically in FIGURE 54, a method of manufacturing a component for a vehicle interior may comprise providing a mold comprising a first surface, a second surface and a third surface; placing the fiber panel in the mold; compressing the fiber panel between the first surface of the mold and the second surface of the mold to form a compression-formed component; applying a coating to the third surface of the mold; molding a surface/skin of a cover and a base of the cover between the compression-formed component and the third surface of mold; and removing the component from the mold.

[0147] According to an exemplary embodiment as shown schematically in FIGURE 55, a method of manufacturing a component for a vehicle interior may comprise providing a mold comprising a first surface, a second surface and a third surface; placing a fiber panel in the mold; compressing the fiber panel between the first surface of the mold and the second surface of the mold to form a compression-formed component; injecting material between the compression-formed component and the third surface of the mold; moving the third surface of the mold away from the compression-formed component; injecting a blowing agent between the third surface of mold and the compression-formed component; and removing the component from the mold.

[0148] According to an exemplary embodiment as shown schematically in FIGURE 56, a method of manufacturing a component for a vehicle interior may comprise providing a foam- backed skin; cutting the foam -backed skin to provide a cover; cutting/consolidating a fiber mat; providing a mold comprising a first surface and a second surface; placing the fiber mat and the cover between the first surface of the mold and the second surface of the mold; compressing the fiber panel and the cover between the first surface of mold and the second surface of mold to form a compression-formed component with a cover; and removing the component from the mold.

[0149] It is important to note that the present inventions (e.g. inventive concepts, etc.) have been described in the specification and/or illustrated in the FIGURES of the present patent document according to exemplary embodiments; the embodiments of the present inventions are presented by way of example only and are not intended as a limitation on the scope of the present inventions. The construction and/or arrangement of the elements of the inventive concepts embodied in the present inventions as described in the specification and/or illustrated in the FIGURES is illustrative only. Although exemplary embodiments of the present inventions have been described in detail in the present patent document, a person of ordinary skill in the art will readily appreciate that equivalents, modifications, variations, etc. of the subject matter of the exemplary embodiments and alternative embodiments are possible and contemplated as being within the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. It should also be noted that various/other modifications, variations, substitutions, equivalents, changes, omissions, etc. may be made in the configuration and/or arrangement of the exemplary embodiments (e.g. in concept, design, structure, apparatus, form, assembly, construction, means, function, system, process/method, steps, sequence of process/method steps, operation, operating conditions, performance, materials, composition, combination, etc.) without departing from the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. The scope of the present inventions is not intended to be limited to the subject matter (e.g. details, structure, functions, materials, acts, steps, sequence, system, result, etc.) described in the specification and/or illustrated in the FIGURES of the present patent document. It is contemplated that the claims of the present patent document will be construed properly to cover the complete scope of the subject matter of the present inventions (e.g. including any and all such modifications, variations, embodiments, combinations, equivalents, etc.); it is to be understood that the terminology used in the present patent document is for the purpose of providing a description of the subject matter of the exemplary embodiments rather than as a limitation on the scope of the present inventions.

[0150] It is also important to note that according to exemplary embodiments the present inventions may comprise conventional technology (e.g. as implemented and/or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or may comprise any other applicable technology (present and/or future) with suitability and/or capability to perform the functions and processes/operations described in the specification and/or illustrated in the FIGURES. All such technology (e.g. as implemented in embodiments, modifications, variations, combinations, equivalents, etc.) is considered to be within the scope of the present inventions of the present patent document.

Claims

CLAIMS The invention claimed is:

1. A component for a vehicle interior comprising: a composite structure comprising a substrate and a cover; wherein the substrate comprises a fiber panel; wherein the cover is provided on the substrate; wherein the substrate comprises a structural substrate; and wherein the cover comprises an exterior surface for the composite structure.

2. The component of Claim 1 wherein the exterior surface at the cover of the composite structure comprises a compressible material.

3. The component of Claim 1 wherein the exterior surface at the cover of the composite structure comprises a generally deformable material.

4. The component of Claim 1 wherein the exterior surface at the cover of the composite structure comprises a generally soft material.

5. The component of Claim 1 wherein the structural substrate comprises a generally rigid panel.

6. The component of Claim 5 wherein the exterior surface at the cover of the composite structure comprises a generally soft surface on the generally rigid fiber panel of the structural substrate of the composite structure.

7. The component of Claim 1 wherein the exterior surface at the cover of the composite structure comprises a softness; wherein the softness of the exterior surface at the cover of the composite structure is greater than a softness of the fiber panel of the substrate of the composite structure.

8. The component of Claim 1 wherein the cover comprises a compressible material.

9. The component of Claim 1 wherein the cover comprises two-layers of compressible material.

10. The component of Claim 1 wherein the cover comprises a composite cover comprising an exterior surface layer and a core layer; wherein the core layer comprises a generally soft material.

11. The component of Claim 10 wherein the generally soft material is softer than the exterior surface layer of the cover of the composite structure.

12. The component of Claim 10 wherein the generally soft material is softer than the fiber panel of the structural substrate of the composite structure.

13. The component of Claim 10 wherein the core layer of the cover of the composite structure comprises a foam material.

14. The component of Claim 10 wherein the core layer of the cover of the composite structure comprises a foam material; wherein the exterior surface layer of the cover of the composite structure comprises a skin.

15. The component of Claim 10 wherein the cover comprising the core layer and the skin is formed from a resin material.

16. The component of Claim 1 wherein the cover is formed from a self-skinning material.

17. The component of Claim 1 wherein the cover comprises an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; wherein the cover comprises a material; wherein the material of the cover is softer than the substrate.

18. The component of Claim 1 wherein the cover comprises a molded cover molded over the substrate.

19. The component of Claim 1 wherein the cover comprises a cover layer and a base layer.

20. The component of Claim 1 wherein the cover comprises a cover layer and a base layer and an intermediate layer.

21. The component of Claim 1 wherein the cover comprises a skin and a core.

22. The component of Claim 1 wherein the cover comprises at least one of (a) a skin and a core layer; (b) a skin and a core formed from a resin material; (c) a formed skin; (d) a formed skin on a core; (e) a skin and a foam material; (f) a pad.

23. The component of Claim 1 wherein the cover comprises a cover layer and a pad.

24. The component of Claim 1 wherein the cover comprises at least one of (a) a film; (b) a resin; (c) a pad; (d) a foam; (e) a skin.

25. The component of Claim 1 wherein the cover comprises at least one of (a) a TPE material; (b) a TPV material; (c) a PU material; (d) a polymer material; (e) a resin material; (f) a plastic material.

26. The component of Claim 1 wherein the composite structure comprises a feature.

27. The component of Claim 26 wherein the feature comprises a formed feature at a surface of the cover.

28. The component of Claim 26 wherein the feature comprises a molded feature.

29. The component of Claim 26 wherein the feature comprises an indentation and/or a projection.

30. The component of Claim 26 wherein the feature comprises at least one of (a) a rib; (b) a recess; (c) a notch; (d) a divider; (e) a line; (f) a stitch; (g) a decorative stitch; (h) a molded stitch appearance; (i) a faux stitch; (j) a decorative faux stitch; (k) a groove; (1) a structure; (m) a shape; (n) a form; (o) a curved form.

31. The component of Claim 26 wherein the feature comprises at least one of (a) a tear line; (b) an initiator for formation of an opening for deployment of an airbag; (c) a recess for formation of an opening for deployment of an airbag; and/or (d) a projection for formation of an opening for deployment of an airbag.

32. The component of Claim 26 wherein the feature comprises an indicia; wherein the indica comprises at least one of (a) a raised indicia; (b) a formed indicia; (c) a recessed indicia; (d) an applied indicia; (e) an ink indicia.

33. The component of Claim 26 wherein the feature comprises a surface effect.

34. The component of Claim 26 wherein the feature comprises a texture.

35. The component of Claim 26 wherein the feature comprises an ink.

36. The component of Claim 26 wherein the feature comprises an applied material; wherein the applied material comprises at least one of (a) a coating; (b) an ink; (c) a colorant; (d) a film; (e) paint.

37. The component of Claim 1 wherein the composite structure comprises a functional layer; wherein the functional layer comprises at least one of (a) an insulating layer; (b) a spacer layer; (c) a sound insulating layer.

38. The component of Claim 1 wherein the composite structure comprises a functional layer; wherein the functional layer comprises at least one of (a) a sound deadening layer; (b) a sound deadening material.

39. The component of Claim 1 wherein the composite structure comprises a functional layer; wherein the functional layer comprises a fiber mat.

40. The component of Claim 1 wherein the composite structure comprises a functional layer; wherein the functional layer comprises a sound insulating layer under the substrate.

41. The component of Claim 1 wherein the composite structure comprises a functional layer; wherein the functional layer comprises an insulating fiber material under the cover.

42. The component of Claim 1 wherein the composite structure comprises a decorative layer.

43. The component of Claim 42 wherein the decorative layer comprises a surface effect.

44. The component of Claim 43 wherein the surface effect comprises at least one of (a) a texture; (b) a pattern; (c) a molded effect; (d) a molded layer; (e) a resin; (f) a coating; (g) a paint; (h) an ink; (i) leather appearance; (j) a grain effect.

45. The component of Claim 42 wherein the decorative layer comprises at least one of (a) a film; (b) a fabric; (c) an applied material; (d) a leather; (e) a synthetic layer.

46. The component of Claim 1 wherein the composite structure comprises a structure; wherein the structure comprises at least one of (a) a molded structure formed on the substrate; (b) a housing; (c) an airbag chute.

47. The component of Claim 1 wherein the composite structure comprises a curved profile.

48. The component of Claim 1 wherein the substrate is formed from the fiber panel; wherein the cover comprises an inner surface coupled to the substrate and an outer surface providing an exterior surface of the component; wherein the cover comprises a material; wherein the material comprising the cover is softer than the substrate.

49. The component of Claim 1 wherein the cover is molded on the substrate; wherein the cover comprises an injection molded thermoplastic material.

50. The component of Claim 1 wherein the cover comprises a core comprised of core material and a surface formed on the core comprised of surface material; wherein a density of the surface material is greater than a density of the core material.

51. The component of Claim 50 wherein the surface is formed as a skin on the core.

52. The component of Claim 50 wherein the cover comprises a decorative layer on the surface; wherein the decorative layer comprises at least one of a pattern and/or texture.

53. The component of Claim 52 wherein the cover comprises a coating on the decorative layer.

54. The component of Claim 50 wherein the material comprising the cover comprises at least one of (a) a mixture of polyurethane; (b) a combination of a reaction mixture; (c) foam material; (d) polyurethane foam; (e) urethane foam; (f) injection-molded material; (g) injected foam material; (h) plastic; (i) resin.

55. The component of Claim 50 wherein the material comprising the cover comprises at least one of (a) a foam material; (b) a urethane foam; (c) a compressible foam; (d) a self-skinning foam.

56. The component of Claim 50 wherein the material comprising the cover comprises a self-skinning material.

57. The component of Claim 50 wherein the cover comprises an integral skin on a core.

58. The component of Claim 1 wherein the cover is formed with a foam compound.

59. The component of Claim 1 wherein the cover comprises a laminate; wherein the laminate comprises an outer layer and inner layer.

60. The component of Claim 59 further comprising a foam material between the laminate and the substrate; wherein the foam material is configured to bond the laminate to the substrate.

61. The component of Claim 1 wherein the substrate comprises a compression- formed component formed from the fiber panel.

62. The component of Claim 1 wherein the substrate comprises at least one feature; wherein the at least one feature comprises at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate; (f) a formed feature.

63. The component of Claim 1 wherein the substrate comprises at least one feature; wherein the at least one feature comprises at least one of (a) a rib; (b) a set of ribs; (c) a resin-formed feature; (d) a resin-formed feature molded on the substrate.

64. The component of Claim 1 wherein a surface of the composite structure comprises a hardness of greater than approximately 20 Shore A Durometer and less than approximately 60 Shore A Durometer.

65. The component of Claim 1 wherein a surface of the composite structure comprises a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer.

66. The component of Claim 1 wherein the cover comprises a skin providing the surface and a core; wherein a surface of the composite structure comprises a hardness of greater than approximately 40 Shore A Durometer and less than approximately 85 Shore A Durometer.

67. The component of Claim 1 wherein the fiber panel of the composite structure comprises a hardness of approximately 95 Shore A Durometer.

68. The component of Claim 1 comprising at least one of (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 bolster; (h) a trim component; (i) a panel; (j) a trim panel.

69. A method of manufacturing a component for a vehicle interior in a tool comprising:

(a) providing a fiber mat in the tool;

(b) compressing the fiber mat in the tool to form a structural substrate comprising a compression-formed fiber panel having a shape; and

(c) forming a cover on the structural substrate; wherein an exterior surface at the cover comprises a compressible material; wherein the compression-formed fiber panel of the structural substrate comprises a generally rigid panel; wherein the cover and the structural substrate comprise a composite structure for the component.

70. The method of Claim 69 further comprising the step of providing a functional layer on the structural substrate.

71. The method of Claim 70 wherein the composite structure further comprises the functional layer; wherein the functional layer comprises a sound insulating layer on the substrate or under the substrate.

72. The method of Claim 69 wherein the step of forming a cover on the structural substrate comprises molding the cover on the compression-formed fiber panel.

73. The method of Claim 69 wherein the cover comprises a formed cover with at least one feature.

74. The method of Claim 69 wherein the cover comprises a formed cover comprising a multi-layer cover comprising a skin layer and a core layer.