CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and incorporates by reference in full the following patent applications: (a) U.S. Provisional Patent Application No. 63/291,033 titled “VEHICLE INTERIOR COMPONENT” filed December 17, 2021; (b) U.S. Patent Application No. 17/592,971 titled “VEHICLE TRIM COMPONENT” filed February 4, 2022. [0002] The present application is related to and incorporates by reference in full the following patent applications: (a) U.S. Provisional Patent Application No. 62/691,595 titled “VEHICLE TRIM COMPONENT” filed June 28, 2018; (b) PCT/International Patent Application No. PCT/US2019/039587 titled “VEHICLE TRIM COMPONENT” filed June 27, 2019; (c) U.S. Patent Application No. 17/006,213 titled “VEHICLE TRIM COMPONENT” filed August 28, 2020.

FIELD

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

[0004] The present invention further relates to a component for a vehicle interior configured to provide a door/panel.

BACKGROUND

[0005] It is known to provide a component for a vehicle interior component such as a panel configured to provide a hinge for a door.

[0006] It would be advantageous to provide an improved vehicle interior component comprising a panel configured with a substrate comprising a reinforcement at a hinge area for a door.

[0007] It would be advantageous to provide an improved vehicle interior component configured to provide a reinforcement such as a thread/thread pattern at the hinge of the hinge area for door of the panel.

SUMMARY

[0008] The present invention relates to a component for a vehicle interior comprising a panel comprising a structural substrate providing a base and a door movable to an open position relative to the base. The panel may comprise a hinge area. The door may be movable relative to the base at the hinge area. A reinforcement may be provided for the panel at the hinge area. The reinforcement may comprise a thread arrangement in the structural substrate. The thread arrangement may comprise a stitch pattern. The door may be configured for movement relative to the base between a closed position and the open position. The hinge area may comprise a hinge. The hinge may comprise a material of the structural substrate and the reinforcement. The stitch pattern may be formed in the structural substrate. The thread arrangement may comprise a thread segment comprising a uniform thread. The thread arrangement may comprise an upper thread and a lower thread; the reinforcement may be configured to retain the door to the base by the upper thread and the lower thread. The panel may comprise a cut for the door. The door may comprise a flap formed at the cut. The door may be configured to be attached to the panel at the hinge area and separated from the panel at the cut. The cut may be formed in the structural substrate. The cut may comprise a set of cuts at each side of the door adjacent to the hinge area. The set of cuts may comprise a set of edges for the door. The hinge area may comprise a recess. The reinforcement may comprise the stitch pattern at the recess. The reinforcement may be configured to reinforce the hinge. The hinge area may comprise a living hinge; the reinforcement may comprise the stitch pattern at the living hinge. The hinge area may comprise a living hinge; the thread arrangement may be configured to reinforce the living hinge. The thread arrangement may comprise a set of thread segments; the set of thread segments may be configured to reinforce the hinge area. The stitch pattern may be formed in the structural substrate of the panel. The reinforcement may comprise the thread arrangement in a stitch panel formed across the hinge area of the structural substrate. The thread arrangement may comprise threads configured to reinforce the hinge area. The reinforcement may be configured to reinforce the hinge area during movement of the door relative to the base. The stitch pattern may comprise threads configured to retain the door to the base. The stitch pattern may comprise thread sewn into the structural substrate. The structural substrate may comprise a surface for the stitch pattern; the stitch pattern may be pressed into the surface of the structural substrate. The structural substrate may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat; (c) a fiber panel. The structural substrate may comprise the door and the base; the reinforcement may be configured to reinforce the hinge area. The component may comprise a cover providing an exterior surface for the panel; the stitch pattern may be concealed at the exterior surface by the cover. The reinforcement may be comprised of at least one of (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (g) polymeric fibers, (h) synthetic fibers. The door may comprise at least one of (a) an access door for a vehicle system; (b) an access door for a compartment behind the panel; (c) an access door configured for movement by a vehicle occupant; (d) a door flap movable at the hinge area. The door may comprise an airbag door configured to be formed by deployment of an airbag through the panel. The airbag may be configured to be deployed at the airbag door from an airbag module. The panel may comprise a weakened area; the airbag door may be formed at the weakened area of the panel. The airbag door may comprise a flap formed at the weakened area. The airbag door may be configured to be attached to the panel at the hinge and separated from the panel at the weakened area. The weakened area may be formed in the structural substrate of the panel. The weakened area may comprise a cut. The door may comprise an airbag door configured to be formed by deployment of an airbag through the panel; the reinforcement may be configured to retain the door to the base at the hinge area upon deployment of the airbag through the panel. The panel may comprise at least one of (a) an instrument panel; (b) a door panel; (c) a trim panel; (d) a trim component; (e) a trim component wherein the door of the panel comprises a pre-formed door; (f) a trim component wherein the door of the panel comprises an access door; (g) a trim component wherein the door of the panel comprises an airbag door.

[0009] The present invention relates to a method for producing a component for a vehicle interior comprising a panel comprising the steps of providing a substrate comprising a base, forming the substrate with a hinge area configured to facilitate the formation of a door movable relative to the base of the substrate at the hinge area, providing a reinforcement in the substrate at the hinge area, and compressing the substrate between the first mold surface and the second mold surface of the mold to form a structural substrate having a shape for the panel. The shape of the structural substrate may be formed at least partially by the first mold surface and the second mold surface. The reinforcement at the hinge area may be configured to reinforce the hinge area. The reinforcement may comprise a stitch pattern formed in the substrate. The method may comprise the step of forming the reinforcement comprising the stitch pattern in the substrate. The method may comprise the step of stitching the reinforcement comprising the stitch pattern in the substrate. The method may comprise the step of forming the panel from the structural substrate. The stitch pattern may comprise thread sewn into the structural substrate. The method may comprise the step of providing a cover for the structural substrate. The method may comprise the step of forming the door for the panel. The step of forming the door may comprise providing a set of cuts in the structural substrate to form the door. The door may comprise a door flap movable at the hinge area. The hinge area may comprise a hinge for the door. The method may comprise the step of forming a cut in the substrate to facilitate formation of the door. The method may comprise the step of forming a cut in the structural substrate to facilitate formation of the door. The step of providing the reinforcement in the substrate may comprise sewing a stitch pattern in the substrate. The panel may be configured for formation of the door; the door may comprise an airbag door configured to be formed by deployment of an airbag through the panel. The hinge area may comprise a living hinge formed in the base of the substrate. The hinge may comprise material from the substrate reinforced by the stitch pattern of the reinforcement.

The hinge area may comprise a recess in the substrate. The step of forming the substrate with a hinge area may comprise at least partially cutting the door from the base and at least partially retaining material for a hinge for the door at the hinge area. The substrate may comprise a fiber panel. The method may comprise the step of providing a cover layer on the substrate; the stitch pattern of the reinforcement may be at least partially concealed by the cover layer. The step of providing the reinforcement in the substrate may comprise sewing a stitch pattern in a surface of the substrate.

[0010] The present invention relates to a component for a vehicle interior comprising a panel comprising a structural substrate formed from a fiber panel and a cover for the structural substrate providing an exterior surface. The structural substrate may comprise a hinge for the panel and a stitch pattern at the hinge. The stitch pattern may comprise a thread arrangement. The stitch pattern may be configured to provide a reinforcement at the hinge. The panel may be configured to provide a base and a flap movable at the hinge relative to the base. The flap may be configured to be formed in the panel. The stitch pattern may comprise thread sewn into the structural substrate. The flap may comprise a door configured to be movable relative to the base at the hinge between a closed position and an open position. The door may comprise at least one of (a) an access door for a vehicle system; (b) an access door for a compartment behind the panel; (c) an access door configured for movement by a vehicle occupant. The door may comprise an airbag door configured to be formed by deployment of an airbag through the panel; the airbag may be configured to be deployed at the airbag door from an airbag module. The door may be movable relative to the base of the panel at the hinge. The panel may comprise a cut for the flap. The flap may comprise a door formed at the cut. The flap may be configured to be attached to the panel at the hinge area and separated from the panel at the cut. The cut may be formed in the structural substrate of the panel. The cut may comprise a set of cuts at each side of the flap adjacent to the hinge area. The flap may be configured for movement relative to the base between a closed position and an open position. The flap may comprise an access door for a compartment behind the panel. The flap may comprise an access door configured for movement by a vehicle occupant. The flap may comprise a door flap movable at the hinge area. The thread arrangement of the reinforcement may comprise threads of the stitch pattern. The threads may comprise uniform threads. The threads may be configured to retain the door to the base of the panel. The stitch pattern may be formed into the structural substrate so that the stitch pattern is not visible at the exterior surface of the cover.

[0011] The present invention relates to a component for a vehicle interior comprising a panel configured to provide a door comprising a structural substrate comprising a base configured to provide the door and a hinge area for the door, and a reinforcement in the structural substrate at the hinge area. The reinforcement may comprise a stitch pattern configured to reinforce the hinge area during movement of the door. The hinge area may comprise a hinge; the hinge may comprise material of the structural substrate and the reinforcement.

[0012] The present invention relates to a component for a vehicle interior comprising a panel formed by a method comprising the steps of providing a substrate comprising a base, forming the substrate with a hinge area configured to facilitate the formation of a door movable relative to the base of the substrate at the hinge area, providing a reinforcement in the substrate at the hinge area, and compressing the substrate between the first mold surface and the second mold surface of the mold to form a structural substrate having a shape for the panel. The shape of the structural substrate may be formed at least partially by the first mold surface and the second mold surface. The reinforcement at the hinge area may be configured to secure the door to the base. The reinforcement may comprise a stitch pattern formed in the substrate. The method may comprise the step of forming the reinforcement comprising the stitch pattern in the substrate. The method may comprise the step of stitching the reinforcement comprising the stitch pattern in the substrate. The method may comprise the step of forming the panel from the structural substrate. The step of forming the panel from the substrate may comprise providing a cover for the structural substrate. The method may comprise the step of forming a cut in the substrate to facilitate formation of the door. The method may comprise the step of forming a cut in the structural substrate to facilitate formation of the door. The hinge area may comprise a hinge for the door. The step of providing the reinforcement in the substrate may comprise sewing a stitch pattern in the substrate. The panel may be configured for formation of the door; the door may comprise an airbag door configured to be formed by deployment of an airbag through the panel. The hinge may comprise a living hinge formed in the base of the substrate. The hinge may comprise material from the substrate reinforced by the stitch pattern of the reinforcement. The hinge area may comprise a recess in the substrate. The step of forming the substrate with a hinge area may comprise at least partially cutting the door from the base of the substrate and at least partially retaining material for a hinge for the door at the hinge area. The substrate may comprise a fiber panel. The method may comprise the step of providing a cover layer on the substrate; the stitch pattern of the reinforcement may be at least partially concealed by the cover layer. The step of providing the reinforcement in the substrate may comprise sewing a stitch pattern in a surface of the substrate. The door may comprise an airbag door configured to be formed by deployment of an airbag through the panel; the reinforcement may be configured to retain the door to the base at the hinge upon deployment of the airbag through the panel.

[0013] The present invention relates to a component for a vehicle interior comprising a panel comprising a structural substrate providing a base and a door movable relative to the base. The panel may comprise a hinge area. The door may be movable relative to the base at the hinge area. A reinforcement may be provided for the panel at the hinge area. The reinforcement may comprise a thread arrangement in the structural substrate. The thread arrangement may comprise a stitch pattern. The door may be configured to move between a closed position and an open position. The reinforcement may be configured to reinforce the hinge area. The hinge area may comprise a hinge. The hinge may comprise a material of the structural substrate and the reinforcement. The thread arrangement of the reinforcement may comprise a stitch pattern formed in the structural substrate of the panel. The thread arrangement may comprise a uniform thread. The thread arrangement may comprise an upper thread and a lower thread. The reinforcement may be configured to retain the door to the base by the upper thread and the lower thread. The panel may comprise a cut for the door. The door may comprise a flap formed at the cut. The door may be configured to be attached to the panel at the hinge area and separated from the panel at the cut. The cut may be formed in the structural substrate of the panel. The cut may comprise a set of cuts at each side of the door adjacent to the hinge area. The door may be configured for movement relative to the base between a closed position and an open position. The door may comprise an access door for a vehicle system. The door may comprise an access door for a compartment behind the panel. The door may comprise an access door configured for movement by a vehicle occupant. The door may comprise a door flap movable at the hinge area. The door may comprise an airbag door configured to be formed by deployment of an airbag through the panel. The panel may comprise a recess. The hinge area may comprise the recess. The reinforcement may comprise the stitch pattern at the recess. The hinge area may comprise a living hinge. The reinforcement may comprise the stitch pattern at the living hinge.

[0014] The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag from an airbag module comprising a panel comprising a structural substrate providing a base and configured to form a door movable relative to the base. The panel may comprise a hinge area. The door may be movable relative to the base at the hinge area. A reinforcement may be provided for the panel at the hinge area. The reinforcement may comprise a thread arrangement in the structural substrate of the panel. The thread arrangement may comprise a stitch pattern. The door may be configured to be formed by deployment of the airbag through the panel from the airbag module. The reinforcement may be configured to retain the door to the base at the hinge upon deployment of the airbag through the panel. The door may comprise an airbag door. The hinge area may comprise a hinge. The hinge may comprise a material of the structural substrate and the reinforcement. The thread arrangement of the reinforcement may comprise a stitch pattern formed in the structural substrate of the panel. The thread arrangement may comprise a thread segment. The thread segment may comprise a uniform thread. The thread arrangement may comprise an upper thread and a lower thread. The reinforcement may be configured to retain the door to the base by the upper thread and the lower thread. The panel may comprise a weakened area; the airbag door may be formed at the weakened area of the panel. The door may comprise a flap formed at the weakened area. The door may be configured to be attached to the panel at the hinge area and separated from the panel at the weakened area. The weakened area may be formed in the structural substrate of the panel. The weakened area may comprise a cut. The panel may comprise a recess. The hinge area may comprise the recess. The reinforcement may comprise the stitch pattern at the recess. The hinge area may comprise a living hinge. The reinforcement may comprise the stitch pattern at the living hinge.

[0015] The present invention relates to a component for a vehicle interior configured to provide a panel configured to be moved between a closed position and an open position comprising a structural substrate comprising a base providing the panel and a hinge area for the panel; and a reinforcement for the panel at the hinge area. The reinforcement may comprise a stitch pattern configured to reinforce the hinge area during movement of the panel. The hinge area may comprise a hinge. The hinge may comprise material of the structural substrate and the reinforcement. The stitch pattern of the reinforcement may comprise thread sewn into the structural substrate. The panel may comprise a door. The structural substrate may comprise a surface for the stitch pattern; the stitch pattern may be pressed into the surface of the structural substrate. The structural substrate may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat; (c) a fiber panel. The structural substrate may comprise a base; the panel may be configured to be movable relative to the base; the reinforcement may be configured to reinforce the panel to the base at the hinge. The component may comprise a cover providing an exterior surface; the stitch pattern may be concealed at the exterior surface by the cover. The reinforcement may be comprised of at least one of (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (g) polymeric fibers, (h) synthetic fibers. The stitch pattern may comprise a sewn thread pattern in the base. The component may comprise at least one of an instrument panel; a door panel; a trim panel; a trim component. The component may be formed by a process comprising the step of injecting resin into a mold after a compression-formed structure comprising the structural substrate is formed to form an ancillary component of a composite structure.

[0016] The present invention relates to a component for a vehicle interior configured to provide a panel configured to be moved between a closed position and an open position prepared in a mold providing a first mold surface and a second mold surface by a method comprising the steps of providing a substrate comprising a base, forming the substrate with a hinge area so that the panel may be configured to be movable relative to the base of the substrate at the hinge area, joining a reinforcement in the substrate at the hinge area for the panel and compressing the substrate between the first mold surface and the second mold surface of the mold to form a structural substrate having a shape. The shape of the structural substrate may be formed at least partially by the first mold surface and the second mold surface. The reinforcement at the hinge area for the panel may be configured to secure the panel to the base for movement between the closed position and the open position. The step of joining the reinforcement in the substrate may comprise sewing a stitch pattern in the substrate. The step of forming the substrate may comprise at least partially cutting the panel from the base of the substrate. The hinge area may comprise a hinge and the panel may comprise a door. The hinge may comprise a living hinge formed in the base of the substrate. The hinge may comprise material from the substrate reinforced by the stitch pattern of the reinforcement. The hinge area may comprise a recess in the substrate. The step of forming the substrate may comprise at least partially cutting the panel from the base of the substrate and at least partially retaining material for a hinge for the panel at the hinge area. The substrate may comprise a pre-form substrate. The substrate may comprise a fiber panel. The method may comprise the step of providing a cover layer on the substrate; the stitch pattern of the reinforcement may be at least partially concealed by the cover layer. The step of providing a cover layer on the substrate may comprise molding the cover layer on the substrate. Joining the reinforcement in the substrate may comprise sewing a stitch pattern in a surface of the substrate. The method may comprise the step of providing a molded cover on an outer surface of the substrate configured to conceal the stitch pattern in the inner surface of the substrate.

[0017] The present invention relates to a component for a vehicle interior configured to provide a panel configured to be moved between a closed position and an open position comprising a structural substrate formed from a fiber panel and a cover for the structural substrate providing an exterior surface. The structural substrate may comprise a hinge for the panel and a stitch pattern at the hinge. The stitch pattern may comprise a thread. The stitch pattern may be configured to provide a reinforcement at the hinge when the panel is rotated between the closed position and the open position. The stitch pattern may be formed into the structural substrate so that the stitch pattern is not visible at the exterior surface of the cover. [0018] The present invention relates to a trim component for a vehicle interior comprising a structural substrate providing at least one door. The structural substrate may comprise a reinforcement configured to secure the at least one door to the structural substrate. The reinforcement may comprise a top stitch and a bottom stitch. The reinforcement may be comprised of bonded nylon thread. The reinforcement may be comprised of at least one of (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (h) polymeric fibers, (i) synthetic fibers. The structural substrate may comprise a panel comprised at least partially of fibers; the reinforcement may be comprised of thread sewn to the panel. Thread may be pressed into a surface of the panel during a compression forming process. The structural substrate may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat. The structural substrate may comprise a living hinge for the at least one door; the reinforcement may be positioned at the living hinge.

[0019] The present invention relates to a vehicle interior component produced in a mold comprising a first surface and a second surface by a process comprising placing a pre-form substrate onto the first surface of the mold, forming a compression-formed structure from the pre- form substrate by compressing the pre-form substrate between the first surface of the mold and the second surface of the mold and applying a cover to the compression-formed structure to form a panel assembly providing a surface effect. The compression-formed substrate may comprise a door and a living hinge for the door. The pre-form substrate may comprise a reinforcement for the living hinge. The pre-form substrate may comprise a fiber panel; the reinforcement may be comprised of thread sewn to the fiber panel. The compression- formed structure may comprise a substrate layer and the reinforcement. The step of forming the compression-formed structure may comprise forming the substrate layer into a generally rigid form. The step of forming the compression-formed structure may comprise forming the reinforcement and the pre-form substrate with a generally continuous surface. A generally smooth texture of the panel assembly may be provided by (a) a surface effect of the cover and (b) a surface effect of the pre-form substrate. The panel assembly may comprise a composite structure with at least partially a shape of the compression-formed structure; the shape may comprise a first contour provided by the first surface of the mold and a second contour provided by the second surface of the mold. The pre-form substrate may comprise a resin; the process may comprise the step of heating the pre-formed substrate and the pre-formed substrate may be compressed as the pre-formed substrate cools. The process may comprise the step of injecting resin into the mold after the compression-formed structure is formed to form an ancillary component of the panel assembly.

[0020] The present invention relates to a component for a vehicle interior providing a hinged panel comprising a composite structure comprising a structural substrate formed from a fiber panel and a cover for the structural substrate providing an exterior surface. The structural substrate may comprise a stitch pattern. The stitch pattern may comprise a thread. The composite structure may be configured so that the stitch pattern provides a reinforcement for the hinged panel so that the hinged panel remains at least partially attached to the composite structure when the hinged panel is rotated at a hinge. The stitch pattern may be provided on the fiber panel. The stitch pattern may be formed into the structural substrate so that the stitch pattern is not visible at the exterior surface of the cover. The set of threads of the stitch pattern may be pressed into a surface of the fiber panel so that the structural substrate comprises a generally flat surface for the cover. The thread may be pressed into a surface of the fiber panel so that the thread is not visible at the exterior surface of the cover of the composite surface. The thread may comprise a network of threads in the fiber panel formed into the structural substrate. The reinforcement may comprise threads for the stitch pattern comprising at least one of (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (g) polymeric fibers, (h) synthetic fibers; (i) bonded nylon. The hinged panel may be configured to remain at least partially attached to the composite structure by the thread. The stitch pattern may provide the reinforcement at a living hinge for the hinged panel. The thread may comprise a set of threads at least partially sewn into the fiber panel of the structural substrate. The component may comprise a feature on the structural substrate. The feature may comprise at least one of (a) a rib; (b) a set of ribs; (c) a feature adjacent to the reinforcement; (d) a feature at the reinforcement; (e) a feature at the hinged panel; (f) a structure for the hinged panel; (g) a resin-formed feature; (h) a resin-formed feature molded on the structural substrate. The composite structure further may comprise a foam layer beneath the cover. The structural substrate may comprise a compression-formed component from the fiber panel. The cover may comprise at least one of (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric; (g) a woven fabric; (h) a non-woven fabric; (i) an applique; (j) vinyl; (k) a foil; (1) coating on the structural substrate; (m) paint on the structural substrate; (n) the exterior surface of the structural substrate. The component may comprise at least one of an instrument panel; a door panel; a trim panel; a trim component.

[0021] The present invention relates to a component for a vehicle interior providing a hinged panel comprising a composite structure comprising a structural substrate formed from a fiber panel providing the hinged panel and a cover for the structural substrate providing an exterior surface. The structural substrate may comprise a reinforcement. The reinforcement may be configured so that the hinged panel remains at least partially attached to the composite structure when the hinged panel is rotated at a living hinge.

[0022] The present invention relates to a trim component for a vehicle interior prepared using a mold by a process comprising the steps of providing a pre-form substrate, joining a reinforcement to the pre- form substrate to form a reinforced pre-form substrate, disposing the reinforced pre- form substrate onto a first surface of the mold and compressing the reinforced pre- form substrate between the first surface and a second surface of the mold to form the reinforced pre- form substrate into a structural substrate having a shape and comprising a living hinge. The shape may correspond to a first contour of the first surface and a second contour of the second surface. The structural substrate may be configured to provide at least one hinged panel. The reinforcement may be configured to secure the at least one hinged panel to the structural substrate at the living hinge. The step of joining a reinforcement to the pre- form substrate may comprise sewing at least one of a thread or a stitch to the pre-form substrate. The step of joining a reinforcement to the pre- form substrate may comprise piercing an opening in the pre-form substrate and joining a stitch to the pre- form substrate at the opening.

[0023] The present invention relates to a method of manufacturing a vehicle trim component comprising the steps of providing a pre- form substrate, joining a reinforcement to the pre- form substrate to form a reinforced pre-form substrate, disposing the reinforced pre- form substrate onto a first surface of the mold; and compressing the reinforced pre-form substrate between the first surface and a second surface of the mold to form the reinforced pre- form substrate into a structural substrate having a shape and a living hinge. The shape may correspond to a first contour of the first surface and a second contour of the second surface. The structural substrate may be configured to provide at least one hinged panel. The reinforcement may be configured to secure the hinged panel to the structural substrate when the hinged panel is rotated at the living hinge.

FIGURES

[0024] FIGURE 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0025] FIGURE IB is a schematic perspective cut-away view of a vehicle showing a vehicle interior according to an exemplary embodiment.

[0026] FIGURES 2A and 2B are schematic perspective views of a vehicle interior component shown as an instrument panel according to an exemplary embodiment. [0027] FIGURE 2C is a schematic partial front view of a vehicle interior component shown as an instrument panel according to an exemplary embodiment.

[0028] FIGURE 3A is a schematic perspective cut-away view of a component for a vehicle interior according to an exemplary embodiment.

[0029] FIGURES 3B and 3C are schematic cutaway perspective views of a vehicle interior component according to an exemplary embodiment.

[0030] FIGURE 3D is a schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.

[0031] FIGURE 3E is a schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0032] FIGURES 4A through 4F are schematic perspective views of a process to form a reinforced fiber panel according to an exemplary embodiment.

[0033] FIGURES 5A through 5D are schematic perspective views of a process to form a structural substrate from a reinforced fiber panel according to an exemplary embodiment. [0034] FIGURE 5E is a schematic perspective cut-away view of a structural substrate according to an exemplary embodiment.

[0035] FIGURE 5F is a schematic perspective cut-away view of a component for a vehicle interior according to an exemplary embodiment. [0036] FIGURES 6A through 6E are schematic partial section views of a process to form a vehicle interior component according to an exemplary embodiment.

[0037] FIGURES 7 A through 7D are schematic cut-away perspective views of a vehicle interior component according to an exemplary embodiment.

[0038] FIGURE 7E is a schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.

[0039] FIGURES 8A and 8B are schematic flow diagrams of a method for forming a vehicle interior component according to an exemplary embodiment.

[0040] FIGURE 9 is a schematic flow diagram of a method for forming a vehicle interior component according to an exemplary embodiment.

[0041] FIGURE 10 is a schematic flow diagram of a method for forming a vehicle interior component according to an exemplary embodiment.

[0042] FIGURES 11A through HE are schematic perspective views of a vehicle interior component shown as an instrument panel according to an exemplary embodiment.

DESCRIPTION

[0043] Referring to FIGURES 1 A and IB, a vehicle V is shown schematically with an interior I comprising components such as trim components, panels, consoles, etc. As indicated schematically according to an exemplary embodiment in FIGURES IB and 2A-2C, the interior I of the vehicle V may comprise interior components such as a trim panel shown as instrument panel IP, door panel DP and floor console FC, etc.

[0044] As indicated schematically in FIGURES IB, 2A-2C, an interior/trim component in vehicle interior I (such as instrument panel IP, etc.) may comprise a component/panel C/CP comprising a base B and configured to provide a door/flap DF movable relative to the base at a hinge area HR; as indicated schematically in FIGURES 2A-2C, door DF may comprise a set of sides shown as cuts CT in the material of base B; door DF may configured for movement at hinge HG of hinge area HR to allow access by a vehicle occupant (e.g. using hand) into an opening OP for a compartment and/or to a module shown as electronic module/fuse box MD/FB. See also FIGURES 11A-11E (moveable door providing an airbag door ABD movable at a hinge area HR and configured to be formed at a tear/weakening line WE in base B during deployment of an airbag AB).

[0045] As shown schematically according to an exemplary embodiment in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, component C/CP may comprise a substrate SB such as a fiber panel FP formed from a fiber mat FM (see FIGURES 4A-4C) into a formed reinforced fiber panel RP comprising a reinforcement shown as a stitch/stitch pattern SP provided at hinge area HR of base B for door DF (see FIGURES 4D-4F); component C/CP may comprise a cover CV providing an exterior surface (see FIGURES 3A-3E); as indicated schematically, component C/CP may comprise a structure such as reinforced fiber panel RFP and/or reinforcing features shown as a rib/frame RB and/or reinforcing frame/rigidifying feature BR that may be formed as molded resin elements/frame features (see FIGURES 5F and 6D-6E). See also FIGURES 8A-8B, 9 and 10 (method/process of forming component with base/door from fiber panel with reinforcement such as thread arrangement/stitch pattern).

[0046] As shown schematically according to an exemplary embodiment in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, component C/CP may be formed from fiber panel FP to provide a panel substrate/structural substrate PS/SB to provide base B and door DF with reinforcement shown as stitch pattem/thread SP/TD at hinge area HR to provide hinge HG (e.g. living hinge formed from material of base/door); as shown schematically, reinforcement shown as stitch pattern/thread arrangement SP/TD may be formed on and/or within the fiber panel/substrate FP/SB. As shown schematically in FIGURES 6A-6C, the reinforcement for substrate SB comprising stitch pattem/thread arrangement SP/TD may comprise a set of threads such as top thread TS and bottom thread BS applied and configured to provide reinforcement for the hinge HG for door/panel DF at the hinge area HR of base/panel B of the component C/CP. See also FIGURES 2A-2B and 3A-3E.

[0047] As shown schematically in FIGURES 6A-6E and 7A-7E, the hinge area HR may comprise a recess RC in the fiber panel/substrate FP/SB with the reinforcement for the fiber panel/substrate FP/SB comprising stitch pattem/thread arrangement SP/TD provided at/across the recess RC and configured to provide reinforcement for the hinge HG for door/panel DF at the hinge area HR of base/panel B of the component C/CP. See also FIGURES 2A-2B and 3A-3E.

Exemplary Embodiments - A

[0048] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a component C/CP for a vehicle interior may comprise a panel such as formed from a fiber panel FP comprising a structural substrate SB providing a base B and a door DF movable to an open position relative to the base; the panel may comprise a hinge area HR; the door may be movable relative to the base at the hinge area; a reinforcement may be provided for the panel at the hinge area; the reinforcement may comprise a thread arrangement TD in the structural substrate; the thread arrangement may comprise a stitch pattern SP; the door may be configured for movement relative to the base between a closed position and the open position. See FIGURES 2A-2B and 11A-1 IE.

[0049] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, the hinge area HR for door DF in the base B of the component C/CP may comprise a hinge HG; the hinge may comprise a material of the structural substrate SB and the reinforcement shown as thread arrangement/stitch pattern SP/TD; the stitch pattern may be formed in the structural substrate; the thread arrangement TD may comprise a thread segment comprising a uniform thread; the thread arrangement may comprise an upper thread shown as top stitch TS and a lower thread shown as bottom stitch BS; the reinforcement may be configured to retain the door to the base by the upper thread and the lower thread. See FIGURES 2A-2B, 3A-3E, 5D-5E and 7A-7E.

[0050] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, the panel may comprise a cut CT for door DF in the base B; the door may comprise a flap formed at the cut; the door may be configured to be attached to the panel at the hinge area and separated from the panel at the cut; the cut may be formed in the structural substrate SB; the cut may comprise a set of cuts at each side of the door adjacent to the hinge area, the set of cuts may comprise a set of edges for the door. See also FIGURES 2A-2B, 5C and 8B.

[0051] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, the hinge area HR for door DF in the base B of the component C/CP may comprise a recess RC in the panel/subslrate FP/SB; the reinforcement may comprise the stitch pattern SP at the recess RC; the reinforcement may be configured to reinforce the hinge HG at the hinge area HR; the hinge area may comprise a living hinge in the pane/substrate FP/SB; the reinforcement may comprise the stitch pattern at the living hinge; the hinge area may comprise a living hinge; the thread arrangement may be configured to reinforce the living hinge; the thread arrangement may comprise a set of thread segments; the set of thread segments may be configured to reinforce the hinge area; the stitch pattern may be formed in the structural substrate of the panel. The reinforcement may comprise the thread arrangement in a stitch panel formed across the hinge area of the structural substrate; the thread arrangement may comprise threads configured to reinforce the hinge area; the reinforcement may be configured to reinforce the hinge area during movement of the door relative to the base; the stitch pattern may comprise threads configured to retain the door to the base; the stitch pattern may comprise thread sewn into the structural substrate. See also FIGURES 8A-8B, 9 and 10.

[0052] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, the component C/CP may comprise a fiber panel FP of the structural substrate SB; the structural substrate SB may comprise a surface for the reinforcement shown as stitch pattern/thread arrangement SP/TD; the stitch pattern may be pressed into the surface of the structural substrate. See FIGURES 8A-8B, 9 and 10.

[0053] According to an exemplary embodiment as indicated schematically in FIGURES 2A- 2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, the structural substrate for the component may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat; (c) a fiber panel. The structural substrate may comprise the door and the base; the reinforcement may be configured to reinforce the hinge area. The component may comprise a cover CV providing an exterior surface for the panel; the stitch pattern may be concealed at the exterior surface by the cover. The reinforcement may be comprised of at least one of (a) KEVEAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (g) polymeric fibers, (h) synthetic fibers.

[0054] According to an exemplary embodiment as indicated schematically in FIGURES IB and 2A-2C, the door for the component may comprise at least one of (a) an access door for a vehicle system; (b) an access door for a compartment behind the panel; (c) an access door configured for movement by a vehicle occupant; (d) a door flap movable at the hinge area. See also FIGURES 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E.

[0055] According to an exemplary embodiment as shown schematically in FIGURES 11A- 1 IE, the component C/CP may comprise an airbag door DF/ABD configured to be formed by deployment of an airbag AB through a panel/base B such as in an instrument panel IP; the airbag may be configured to be deployed at the airbag door from an airbag module; the panel/base B may comprise a weakened area such as a tear line/weakening line WL; the airbag door may be formed at the weakened area of the panel; the airbag door may comprise a flap formed at the weakened area; the airbag door may be configured to be attached to the panel at the hinge and separated from the panel at the weakened area; the weakened area may be formed in the structural substrate of the panel; the weakened area may comprise a cut. As indicated schematically in FIGURES 11A-11E, the component C/CP may comprise an airbag door DF/ABD configured to be formed by deployment of an airbag AB through the panel/base B; the reinforcement shown as thread arrangement/stitch pattern TD/SP may be configured to retain the door to the base at the hinge area HR upon deployment of the airbag through the panel. See also FIGURE IB (showing instrument panel with door/flap) and FIGURE 11A (showing instrument panel with two door/flap sets).

[0056] According to an exemplary embodiment as shown schematically in FIGURES IB, 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E, 7A-7E and 11A-11E, the panel with component may comprise at least one of (a) an instrument panel; (b) a door panel; (c) a trim panel; (d) a trim component; (e) a trim component wherein the door of the panel comprises a pre-formed door; (f) a trim component wherein the door of the panel comprises an access door; (g) a trim component wherein the door of the panel comprises an airbag door.

[0057] According to an exemplary embodiment as shown schematically in FIGURES 4A-4F, 5A-5C, 8A-8B, 9 and 10, a method for producing a component for a vehicle interior comprising a panel may comprise the steps of providing a substrate comprising a base, forming the substrate with a hinge area configured to facilitate the formation of a door movable relative to the base of the substrate at the hinge area, providing a reinforcement in the substrate at the hinge area, and compressing the substrate between the first mold surface and the second mold surface of the mold to form a structural substrate having a shape for the panel. See also FIGURES 2A-2C, 3A-3E, 6A-6E and 7A-7E. The shape of the structural substrate may be formed at least partially by the first mold surface and the second mold surface. The reinforcement at the hinge area may be configured to reinforce the hinge area. The reinforcement may comprise a stitch pattern SP formed in the substrate. The method may comprise the step of forming the reinforcement comprising the stitch pattern in the substrate. The method may comprise the step of stitching the reinforcement comprising the stitch pattern in the substrate. The method may comprise the step of forming the panel from the structural substrate. The stitch pattern may comprise thread sewn into the structural substrate. The method may comprise the step of providing a cover CV for the structural substrate. The method may comprise the step of forming the door for the panel. The step of forming the door may comprise providing a set of cuts in the structural substrate to form the door. The door may comprise a door flap movable at the hinge area. The hinge area may comprise a hinge HG for the door. The method may comprise the step of forming a cut CT in the substrate to facilitate formation of the door. The method may comprise the step of forming a cut CT in the structural substrate to facilitate formation of the door. The step of providing the reinforcement in the substrate may comprise sewing a stitch pattern in the substrate. According to an exemplary embodiment as shown schematically in FIGURES 11A-11E, the panel may be configured for formation of the door; the door may comprise an airbag door configured to be formed by deployment of an airbag through the panel. The hinge area may comprise a living hinge formed in the base of the substrate. The hinge may comprise material from the substrate reinforced by the stitch pattern of the reinforcement.

The hinge area may comprise a recess in the substrate. The step of forming the substrate with a hinge area may comprise at least partially cutting the door from the base and at least partially retaining material for a hinge HG for the door at the hinge area. The substrate may comprise a fiber panel. The method may comprise the step of providing a cover layer on the substrate; the stitch pattern of the reinforcement may be at least partially concealed by the cover layer. The step of providing the reinforcement in the substrate may comprise sewing a stitch pattern in a surface of the substrate.

[0058] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a component for a vehicle interior may comprise a panel comprising a structural substrate formed from a fiber panel and a cover CV for the structural substrate providing an exterior surface. The structural substrate may comprise a hinge HG for the panel and a stitch pattern SP at the hinge. The stitch pattern may comprise a thread arrangement. The stitch pattern may be configured to provide a reinforcement at the hinge. The panel may be configured to provide a base B and a flap movable at the hinge relative to the base. The flap may be configured to be formed in the panel. The stitch pattern may comprise thread sewn into the structural substrate. The flap may comprise a door DF configured to be movable relative to the base at the hinge between a closed position and an open position. The door may comprise at least one of (a) an access door for a vehicle system; (b) an access door for a compartment behind the panel; (c) an access door configured for movement by a vehicle occupant. According to an exemplary embodiment as shown schematically in FIGURES 11A-11E, the door may comprise an airbag door configured to be formed by deployment of an airbag through the panel; the airbag may be configured to be deployed at the airbag door from an airbag module. The door may be movable relative to the base of the panel at the hinge. The panel may comprise a cut CT for the flap. The flap may comprise a door formed at the cut. The flap may be configured to be attached to the panel at the hinge area and separated from the panel at the cut. The cut may be formed in the structural substrate of the panel. The cut may comprise a set of cuts at each side of the flap adjacent to the hinge area. The flap may be configured for movement relative to the base between a closed position and an open position. The flap may comprise an access door for a compartment behind the panel. The flap may comprise an access door configured for movement by a vehicle occupant. The flap may comprise a door flap movable at the hinge area. The thread arrangement of the reinforcement may comprise threads of the stitch pattern. The threads may comprise uniform threads. The threads may be configured to retain the door to the base of the panel. The stitch pattern may be formed into the structural substrate so that the stitch pattern is not visible at the exterior surface of the cover.

[0059] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a component C/CP for a vehicle interior may comprise a panel comprising a structural substrate comprising a base B configured to provide door DF and a hinge area HR for the door, and a reinforcement in the structural substrate at the hinge area; the reinforcement may comprise a stitch pattern SP comprising a thread/thread arrangement TD configured to reinforce the hinge area during movement of the door; the hinge area may comprise a hinge HG; the hinge may comprise material of the structural substrate and the reinforcement.

[0060] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E, 7A-7E, 8A-8B, 9, 10 and 11A-11E, a component C/CP for a vehicle interior may comprise a panel such as a fiber panel FP formed by a method comprising the steps of providing a substrate SB comprising a base B, forming the substrate with a hinge area HR configured to facilitate the formation of a door DF movable relative to the base of the substrate at the hinge area, providing a reinforcement in the substrate at the hinge area, and compressing the substrate between the first mold surface and the second mold surface of the mold to form a structural substrate having a shape for the panel. See also FIGURES 8A-8B, 9 and 10. The shape of the structural substrate may be formed at least partially by the first mold surface and the second mold surface. The reinforcement at the hinge area may be configured to secure the door to the base. The reinforcement may comprise a stitch pattern SP formed in the substrate. The method may comprise the step of forming the reinforcement comprising the stitch pattern in the substrate. The method may comprise the step of stitching the reinforcement comprising the stitch pattern in the substrate. The method may comprise the step of forming the panel from the structural substrate. The step of forming the panel from the substrate may comprise providing a cover CV for the structural substrate. The method may comprise the step of forming a cut CT in the substrate to facilitate formation of the door. The method may comprise the step of forming a cut CT in the structural substrate to facilitate formation of the door. The hinge area may comprise a hinge HG for the door. The step of providing the reinforcement in the substrate may comprise sewing a stitch pattern SP in the substrate. According to an exemplary embodiment as shown schematically in FIGURES 11A-1 IE, the panel may be configured for formation of the door; the door may comprise an airbag door configured to be formed by deployment of an airbag through the panel. The hinge may comprise a living hinge formed in the base of the substrate. The hinge may comprise material from the substrate reinforced by the stitch pattern of the reinforcement. The hinge area may comprise a recess in the substrate. The step of forming the substrate with a hinge area may comprise at least partially cutting the door from the base of the substrate and at least partially retaining material for a hinge HG for the door at the hinge area. The substrate may comprise a fiber panel. The method may comprise the step of providing a cover layer on the substrate; the stitch pattern of the reinforcement may be at least partially concealed by the cover layer. The step of providing the reinforcement in the substrate may comprise sewing a stitch pattern in a surface of the substrate. The door may comprise an airbag door configured to be formed by deployment of an airbag through the panel; the reinforcement may be configured to retain the door to the base at the hinge upon deployment of the airbag through the panel.

[0061] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a component for a vehicle interior may comprise a panel comprising a structural substrate providing a base B and a door DF movable relative to the base. The panel may comprise a hinge area HR. The door may be movable relative to the base B at the hinge area HR; a reinforcement may be provided for the panel at the hinge area; the reinforcement may comprise a thread arrangement TD in the structural substrate; the thread arrangement may comprise a stitch pattern SP; the door may be configured to move at the hinge area between a closed position and an open position; the reinforcement may be configured to reinforce the hinge area; the hinge area may comprise a hinge HG; the hinge may comprise a material of the structural substrate and the reinforcement; the thread arrangement of the reinforcement may comprise a stitch pattern SP formed in the structural substrate of the panel; the thread arrangement may comprise a uniform thread such as thread TD; the thread arrangement may comprise an upper thread TS and a lower thread BS; the reinforcement may be configured to retain the door to the base by the upper thread and the lower thread; the panel/base B may comprise a cut CT for the door; the door may comprise a flap formed at the cut; the door may be configured to be attached to the panel at the hinge area and separated from the panel at the cut; the cut may be formed in the structural substrate of the panel; the cut may comprise a set of cuts at each side of the door adjacent to the hinge area; the door may be configured for movement relative to the base between a closed position and an open position.

[0062] According to an exemplary embodiment as shown schematically in FIGURES IB and 2A-2C, the component C/CP may comprise a door shown as an access door for a vehicle system; the door may comprise an access door for a compartment behind the panel/base; the door may comprise an access door configured for movement by a vehicle occupant; the door may comprise a door flap movable at the hinge area. According to an exemplary embodiment as shown schematically in FIGURES IB and 11A-11E, the component C/CP may comprise a door shown as an airbag door configured to be formed by deployment of an airbag through the panel.

[0063] According to an exemplary embodiment as shown schematically in FIGURES 6A-6E and 7A-7E, the component C/CP may comprise a panel comprising a recess RC; the hinge area HR may comprise the recess RC; the reinforcement may comprise the stitch pattern SP at the recess; the hinge area may comprise a living hinge; the reinforcement may comprise the stitch pattern SP at the living hinge.

[0064] According to an exemplary embodiment as shown schematically in FIGURES IB and 11A-11E, a component C/CP for a vehicle interior configured to facilitate deployment of an airbag AB from an airbag module may comprise a panel comprising a structural substrate providing a base B and configured to form a door DF/ABD movable relative to the base; the panel may comprise a hinge area HR; the door may be movable relative to the base at the hinge area; a reinforcement may be provided for the panel at the hinge area; the reinforcement may comprise a thread arrangement TD in the structural substrate of the panel; the thread arrangement may comprise a stitch pattern SP; the door may be configured to be formed by deployment of the airbag through the panel from the airbag module; the reinforcement may be configured to retain the door to the base at the hinge upon deployment of the airbag through the panel; the door may comprise an airbag door; the hinge area may comprise a hinge HG; the hinge may comprise a material of the structural substrate and the reinforcement; the thread arrangement of the reinforcement may comprise a stitch pattern SP formed in the structural substrate of the panel; the thread arrangement may comprise a thread segment; the thread segment may comprise a uniform thread; the thread arrangement may comprise an upper thread and a lower thread; the reinforcement may be configured to retain the door to the base by the upper thread and the lower thread; the panel may comprise a weakened area; the airbag door may be formed at the weakened area of the panel; the door may comprise a flap formed at the weakened area; the door may be configured to be attached to the panel at the hinge area and separated from the panel at the weakened area; the weakened area may be formed in the structural substrate of the panel; the weakened area may comprise a cut; the panel may comprise a recess; the hinge area may comprise the recess; the reinforcement may comprise the stitch pattern at the recess; the hinge area may comprise a living hinge; the reinforcement may comprise the stitch pattern at the living hinge. See

FIGURES IB and 11 A- HE.

Exemplary Embodiments - B

[0065] Referring to FIGURES 1 A and IB, a vehicle V is shown including an interior I with vehicle interior components shown as an instrument panel IP, door panels DP and a floor console FC. According to an exemplary embodiment, components of vehicle V such as instrument panel IP and door panels DP may include trim components/panels comprised of fiber and plastic. According to an exemplary embodiment, instrument panel IP and door panels DP may provide visible surfaces in the vehicle interior of vehicle V.

Exemplary Embodiments - C

[0066] Referring to FIGURES 1 A and IB, a vehicle V is shown schematically with an interior I comprising components such as trim components, panels, consoles, etc. As indicated schematically according to an exemplary embodiment in FIGURES 2A-2C, the vehicle interior may comprise a component such as a trim panel shown as instrument panel IP configured to provide a base B with a moveable door/panel DF to provide access into an opening OP. See also FIGURES 3A-3E and 7A-7E.

[0067] As shown schematically according to an exemplary embodiment in FIGURES 3A-3E, 4A-4F, 5A-5F and 7A-7E, the component C/CP may comprise a substrate such as a fiber panel FP formed with a reinforcement shown as thread arrangement TD (e.g. arrangement of fiber, thread, uniform thread, variation of threads, sewn/stitched line/thread, etc.) shown as provided in a stitch/stitch pattern SP at a hinge area HR for a hinge HG (shown as a living hinge) for moveable door/panel DF. See also FIGURES 8A-8B, 9 and 10. As indicated schematically in FIGURES 3 AGE, 4A-4F, 5A-5F, 6A-6E, 7A-7E, 8A-8B, 9, 10 and 11A- 1 IB, the component may comprise a panel/base B with a hinge area HR for a door/flap DF that comprises a reinforcement shown as a stitch pattem/thread arrangement SP/TD provided in any of a wide variety of configurations (including sewn, stitched, pressed, formed, etc.); as indicated schematically, reinforcement shown as thread/thread arrangement TD may be provided in a stitch pattern SP at/across the hinge HG of the hinge area HR of the base B for door DF; as indicated schematically, reinforcement shown as stitch pattern SP may be provided by a thread/thread arrangement TD at/across the hinge HG of the hinge area HR of the base B for door DF. See FIGURES 2A-2B and 11A-1 IE. [0068] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a component such as a trim component shown as instrument panel IP for a vehicle interior may be configured to provide a door/panel DF configured to be moved between a closed position and an open position relative to a base B to provide an opening OP. As shown schematically in FIGURES 2A-2B, 3A-3E and 7A-7E, the component may comprise a structural substrate shown as comprising a fiber panel FP, door/panel DF, a hinge area HR for door/panel DF, and a reinforcement shown as thread arrangement TD for door/panel DF at the hinge area AH. The reinforcement shown as thread arrangement TD may comprise a stitch pattern SP configured to reinforce the hinge area HR during movement of door/panel DF; the hinge area HR may comprise a hinge HG; the hinge HG may comprise material of the structural substrate and the reinforcement; the stitch pattern of the reinforcement may comprise thread sewn into the structural substrate; the panel may comprise a door. The structural substrate may comprise a surface for the stitch pattern; the stitch pattern may be pressed into the surface of the structural substrate. See FIGURES 4A- 4F and 5A-5F. As indicated schematically, the structural substrate may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat; (c) a fiber panel. The structural substrate may comprise a base B; the panel may be configured to be movable relative to the base; the reinforcement may be configured to reinforce the panel to the base at the hinge. As indicated schematically in FIGURES 2A-2C, 3A-3E and 7A-7E, the component may comprise a cover CV providing an exterior surface; the stitch pattern may be concealed at the exterior surface by the cover. The reinforcement may be comprised of at least one of (a) KEVEAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (g) polymeric fibers, (h) synthetic fibers. The stitch pattern may comprise a sewn thread pattern in the base. The component may comprise at least one of an instrument panel, a door panel, a trim panel, a trim component, a trim component wherein the panel comprises a door (e.g. formed during manufacture). See also FIGURES 2A-2C.

[0069] As indicated schematically in FIGURES 5A-5F, the component may be formed by a process comprising the step of injecting resin into a mold after a compression-formed structure comprising the structural substrate is formed to form an ancillary component of a composite structure. See also FIGURES 8 A, 8B, 9 and 10.

[0070] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E, 7A-7E, a component for a vehicle interior such as a trim component shown as instrument panel IP configured to provide a door/panel DF configured to be moved between a closed position and an open position may be prepared in a mold M providing a first mold surface MT and a second mold surface MB by a method comprising the steps of providing a substrate FP comprising a base B, forming the substrate with a hinge area HR so that door/panel DF may be configured to be movable relative to the base of the substrate at the hinge area HR, joining a reinforcement shown as thread arrangement TD in the substrate at the hinge area for the panel and compressing the substrate between the first mold surface and the second mold surface of the mold to form a structural substrate having a shape (see FIGURES 5A-5C); the shape of the structural substrate may be formed at least partially by the first mold surface and the second mold surface; the reinforcement at the hinge area for the panel may be configured to secure the panel to the base for movement between the closed position and the open position; the step of joining the reinforcement shown as thread arrangement TD in the substrate may comprise sewing a stitch pattern SP in the substrate (see FIGURES 4A-4F); the step of forming the substrate may comprise at least partially cutting the panel from the base of the substrate with a cut CT; the hinge area may comprise a hinge HG and the panel may comprise a door DF; the hinge HG may comprise a living hinge formed in the base of the substrate (see FIGURES 3A-3E and 7A-7E); the hinge may comprise material from the substrate reinforced by the stitch pattern SP of the reinforcement shown as thread arrangement TD. As indicated schematically according to an exemplary embodiment in FIGURES 6A-6E and 7A-7E, the hinge area HR of the component may comprise a recess RC in the substrate; the step of forming the substrate may comprise at least partially cutting the panel from the base of the substrate with a cut CT and at least partially retaining material for a hinge HG for door/panel DF at the hinge area HR; the substrate may comprise a pre-form substrate; the substrate may comprise a fiber panel. See also FIGURES 2A-2C. As indicated schematically in FIGURES 2A-2C, 3A-3E and 7A-7E, the method may comprise the step of providing a cover layer CV on the substrate FP; the stitch pattern SP of the reinforcement shown as thread arrangement TD may be at least partially concealed by the cover layer; the step of providing a cover layer on the substrate may comprise molding the cover layer on the substrate. As indicated schematically in FIGURES 4A-4F, the step of joining the reinforcement shown as thread arrangement TD in the substrate may comprise sewing a stitch pattern SP in a surface of the substrate; the method may comprise the step of providing a molded cover on an outer surface of the substrate configured to conceal the stitch pattern in the inner surface of the substrate.

[0071] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a component for a vehicle interior configured to provide a door/panel DF configured to be moved between a closed position and an open position may comprise a structural substrate formed from a fiber panel FP and a cover CV for the structural substrate providing an exterior surface; the structural substrate may comprise a hinge HG for the panel and a stitch pattern SP at the hinge; the stitch pattern may comprise a thread; the stitch pattern SP may be configured to provide a reinforcement shown as thread arrangement TD at the hinge when the panel is rotated between the closed position and the open position. As indicated schematically in FIGURES 2A-2C, the stitch pattern SP may be formed into the structural substrate so that the stitch pattern is not visible at the exterior surface of the cover.

Exemplary Embodiments - D

[0072] Referring to FIGURES 1A-1B and 2A-2C, a vehicle V is shown including an interior I with vehicle interior components shown as trim components such as an instrument panel IP, door panels DP and a floor console FC; according to an exemplary embodiment, components of vehicle V such as instrument panel IP and door panels DP may include trim components/panels comprised of fiber and plastic. According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, trim components such as instrument panel IP and doors may provide visible surfaces in the vehicle interior of vehicle V. According to an exemplary embodiment, vehicle interior/trim components such as instrument panel IP and/or door panels may provide at least one moveable door/panel DF and a hinge area HR with living hinge for the panel/door. See FIGURES 2A-2C, 3A-3E and 7A-7E.

[0073] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, instrument panel IP may provide a door/panel DF and a living hinge HG at a hinge area HR for the door/panel DF; the living hinge HG (e.g. a line, score line, cut, notch, groove, discontinuity, interruption, etc.) may be configured to facilitate rotation of the panel/door. According to an exemplary embodiment, instrument panel IP may comprise a base B and a reinforcement shown as thread arrangement TD to secure the door/panel DF at the living hinge HG for movement relative to the base. See FIGURES 3A-3E and 7A-7E.

[0074] According to an exemplary embodiment as shown schematically in FIGURE 4A, a fiber mat FM may comprise 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 as shown schematically in FIGURE 4B, fiber mat FM may be trimmed into a fiber mat FM having a thickness. According to an exemplary embodiment, fiber mat FM may be heated to induce the thermoplastic resin to liquefy. According to an exemplary embodiment as shown schematically in FIGURE 4C, heated fiber mat FM may be partially compressed into a fiber panel FP having a thickness less than the thickness of fiber mat FM. According to an exemplary embodiment as shown schematically in FIGURES 4D through 4F, a reinforcement shown as thread arrangement TD comprising at least one of (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (g) polymeric fibers, (h) synthetic fibers, (i) a stitch may be sewn to fiber panel FP to form a reinforced fiber panel. The reinforcement may be sewn to fiber panel by a needle.

[0075] According to an exemplary embodiment as shown schematically in FIGURES 4A-4F and 5A-5F, a method of manufacturing a vehicle trim component CP may comprise the steps of providing a fiber panel FP, joining a reinforcement shown as thread arrangement TD to fiber panel FP in at least one hinge area to form a reinforced fiber panel RP, disposing the reinforced fiber panel onto a first surface of a mold M, compressing the reinforced fiber panel between a first surface and a second surface of the mold to form the reinforced fiber panel into a structural substrate PS having a shape and attaching a structure (such as a rib RB) on a side of the structural substrate. The shape may correspond to a first contour of the first surface and a second contour of the second surface. Structural substrate PS may be configured to provide at least one panel/door. Reinforcement shown as thread arrangement TD may be configured to secure the panel/door to structural substrate PS.

[0076] According to an exemplary embodiment as shown schematically in FIGURE 5A, a reinforced fiber panel RP may be heated in an oven OV. As shown schematically in FIGURE 5B, heated reinforced fiber panel RP may be transferred into a mold having a mold top MT and mold bottom MB. According to an exemplary embodiment as shown schematically in FIGURES 5C-5E, a component shown as an instrument panel substrate PS may be produced by a process of compression forming heated reinforced fiber panel RP into a structural substrate SB and injection molding resin onto compression formed heated reinforced fiber panel RP. A recess RC of structural substrate SB may be formed in the process. Recess RC may be configured to provide a living hinge for a door of structural substrate SB. Reinforcement shown as thread arrangement TD may be configured to secure the door to structural substrate SB during movement (e.g. opening and/or closing) of the door.

[0077] According to an exemplary embodiment as shown schematically in FIGURE 5F, instrument panel substrate PS may provide a feature shown as a plastic rib RB on a back side of structural substrate SB to improve structural integrity and rigidity of structural substrate SB. Plastic rib RB may comprise a reinforcement to provide structural support. Plastic rib RB may comprise a border to provide reinforcement and/or dimensional accuracy for structural substrate SB. According to an exemplary embodiment, plastic rib RB may be placed at any location on structural substrate SB (e.g. along an edge of structural substrate SB, in the middle of structural substrate SB, etc.). According to an exemplary embodiment, multiple plastic ribs RB may be placed at various different locations on structural substrate SB. According to an exemplary embodiment, plastic rib RB may improve structural integrity of instrument panel substrate PS. According to an exemplary embodiment as shown schematically in FIGURE 5F, plastic rib RB may form a honeycomb shaped pattern to improve structural integrity and rigidity. According to an exemplary embodiment, plastic rib RB may be formed in any configuration according to a specific application (e.g. ancillary features for attaching air vents, speakers or infotainment system, etc.).

[0078] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a trim component for a vehicle interior may comprise a structural substrate providing at least one panel/door. The structural substrate may comprise a reinforcement configured to secure the at least one panel/door to the structural substrate. The reinforcement may comprise a top stitch TS and a bottom stitch BS. The reinforcement may be comprised of bonded nylon thread. The reinforcement may be comprised of at least one of (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (h) polymeric fibers, (i) synthetic fibers. The structural substrate may comprise a panel comprised at least partially of fibers; the reinforcement may be comprised of thread sewn to the panel. Thread may be pressed into a surface of the panel during a compression forming process. The structural substrate may comprise at least one of (a) a compression- formed component; (b) a generally rigid fiber mat. The structural substrate may comprise a living hinge for the at least one door; the reinforcement may be positioned at the living hinge.

[0079] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a vehicle interior component produced in a mold may comprise a first surface and a second surface by a process comprising placing a pre-form substrate onto the first surface of the mold, forming a compression-formed structure from the pre- form substrate by compressing the pre-form substrate between the first surface of the mold and the second surface of the mold and applying a cover to the compression-formed structure to form a panel assembly providing a surface effect. The compression-formed substrate may comprise a door and a living hinge for the door. The pre-form substrate may comprise a reinforcement for the living hinge. The pre-form substrate may comprise a fiber panel; the reinforcement may be comprised of thread sewn to the fiber panel. The compression- formed structure may comprise a substrate layer and the reinforcement. The step of forming the compression-formed structure may comprise forming the substrate layer into a generally rigid form. The step of forming the compression-formed structure may comprise forming the reinforcement and the pre-form substrate with a generally continuous surface. A generally smooth texture of the panel assembly may be provided by (a) a surface effect of the cover and (b) a surface effect of the pre-form substrate. The panel assembly may comprise a composite structure with at least partially a shape of the compression-formed structure; the shape may comprise a first contour provided by the first surface of the mold and a second contour provided by the second surface of the mold. The pre-form substrate may comprise a resin; the process may comprise the step of heating the pre-formed substrate and the pre-formed substrate may be compressed as the pre-formed substrate cools. The process may comprise the step of injecting resin into the mold after the compression-formed structure is formed to form an ancillary component of the panel assembly.

[0080] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a component for a vehicle interior providing a hinged panel may comprise a composite structure comprising a structural substrate formed from a fiber panel and a cover for the structural substrate providing an exterior surface. The structural substrate may comprise a stitch pattern. The stitch pattern may comprise a thread. The composite structure may be configured so that the stitch pattern provides a reinforcement for the hinged panel so that the hinged panel remains at least partially attached to the composite structure when the hinged panel is rotated at a hinge HG. The stitch pattern may be provided on the fiber panel. The stitch pattern may be formed into the structural substrate so that the stitch pattern is not visible at the exterior surface of the cover. The set of threads of the stitch pattern may be pressed into a surface of the fiber panel so that the structural substrate comprises a generally flat surface for the cover. The thread may be pressed into a surface of the fiber panel so that the thread is not visible at the exterior surface of the cover of the composite surface. The thread may comprise a network of threads in the fiber panel formed into the structural substrate. The reinforcement may comprise threads for the stitch pattern comprising at least one of (a) KEVLAR, (b) aramid, (c) nylon, (d) polyester, (e) thread, (f) ceramic fibers, (g) polymeric fibers, (h) synthetic fibers; (i) bonded nylon. The hinged panel may be configured to remain at least partially attached to the composite structure by the thread. The stitch pattern may provide the reinforcement at a living hinge for the hinged panel. The thread may comprise a set of threads at least partially sewn into the fiber panel of the structural substrate. The component may comprise a feature on the structural substrate. The feature may comprise at least one of (a) a rib; (b) a set of ribs; (c) a feature adjacent to the reinforcement; (d) a feature at the reinforcement; (e) a feature at the hinged panel; (f) a structure for the hinged panel; (g) a resin-formed feature; (h) a resin- formed feature molded on the structural substrate. The composite structure further may comprise a foam layer beneath the cover. The structural substrate may comprise a compression- formed component from the fiber panel. The cover may comprise at least one of (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric; (g) a woven fabric; (h) a non-woven fabric; (i) an applique; (j) vinyl; (k) a foil; (1) coating on the structural substrate; (m) paint on the structural substrate; (n) the exterior surface of the structural substrate. The component may comprise at least one of an instrument panel; a door panel; a trim panel; a trim component.

[0081] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a component for a vehicle interior providing a hinged panel may comprise a composite structure comprising a structural substrate formed from a fiber panel providing the hinged panel and a cover for the structural substrate providing an exterior surface. The structural substrate may comprise a reinforcement. The reinforcement may be configured so that the hinged panel remains at least partially attached to the composite structure when the hinged panel is rotated at a living hinge.

[0082] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a trim component for a vehicle interior may be prepared using a mold by a process comprising the steps of providing a pre-form substrate, joining a reinforcement to the pre-form substrate to form a reinforced pre-form substrate, disposing the reinforced pre-form substrate onto a first surface of the mold and compressing the reinforced pre- form substrate between the first surface and a second surface of the mold to form the reinforced pre- form substrate into a structural substrate having a shape and comprising a living hinge. The shape may correspond to a first contour of the first surface and a second contour of the second surface. The structural substrate may be configured to provide at least one hinged panel. The reinforcement may be configured to secure the at least one hinged panel to the structural substrate at the living hinge. The step of joining a reinforcement to the pre- form substrate may comprise sewing at least one of a thread or a stitch to the pre-form substrate. The step of joining a reinforcement to the pre- form substrate may comprise piercing an opening in the pre-form substrate and joining a stitch to the preform substrate at the opening.

[0083] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3E, 4A-4F, 5A-5F, 6A-6E and 7A-7E, a method of manufacturing a vehicle trim component may comprise the steps of providing a pre-form substrate, joining a reinforcement to the pre-form substrate to form a reinforced pre- form substrate, disposing the reinforced pre- form substrate onto a first surface of the mold; and compressing the reinforced pre-form substrate between the first surface and a second surface of the mold to form the reinforced pre- form substrate into a structural substrate having a shape and a living hinge. The shape may correspond to a first contour of the first surface and a second contour of the second surface. The structural substrate may be configured to provide at least one hinged panel. The reinforcement may be configured to secure the hinged panel to the structural substrate when the hinged panel is rotated at the living hinge.

Related Patent Documents - Incorporation by Reference [0084] The present application incorporates by reference (a) U.S. Patent Application No. 13/595,741 titled “SYSTEM AND METHOD FOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSION FORMING AND INJECTION MOLDING” filed August 27, 2012 (now U.S. Patent No. 8,939,745); (b) U.S. Patent Application No. 13/846,529 titled “SYSTEM AND METHOD FOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSION FORMING AND INJECTION MOLDING” filed March 18, 2013 (now U.S. Patent No. 9,149,961); (c) U.S. Patent Application No. 14/424,671 titled “SYSTEM AND METHOD FOR MOUNTING AN AIRBAG CHUTE ASSEMBLY WITHIN A VEHICLE TRIM COMPONENT” filed February 27, 2015 (now U.S. Patent No. 9,481,337); (d) U.S. Patent Application No. 14/808,938 titled “VEHICLE TRIM COMPONENT” filed July 24, 2015 (now U.S. Patent No. 10,118,325); (e) U.S. Patent Application No. 15/331,578 titled “TRIM COMPONENT FOR VEHICLE INTERIOR” filed October 21, 2016 (now U.S. Patent No. 10,093,268).

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[0085] 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.

[0086] 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.