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Title:
SYSTEM AND METHOD FOR PRODUCING A VEHICLE INTERIOR COMPONENT
Document Type and Number:
WIPO Patent Application WO/2017/004458
Kind Code:
A2
Abstract:
A system and method for producing a vehicle interior component is disclosed. The system and method is configured to a method of manufacturing a vehicle trim component utilizing a mold that includes at least a first part and a second part, wherein each of the first and second parts includes a surface that defines a cavity. The method comprises supplying a material comprising fibers into the cavity, compressing the material between at least one of the first and second parts of the mold to form the material into a formed component comprising a first side and a second side, cutting at least a portion of the formed component to form the vehicle trim component and removing the vehicle trim component from the cavity. The system and method is provided an improved system and method for producing a vehicle interior component from a panel providing for variations in thickness and/or density to provide options useful for design and configuration variations for the component such as rigidification, weight, reduction, etc.

Inventors:
GALAN JESUS (DE)
Application Number:
PCT/US2016/040571
Publication Date:
January 05, 2017
Filing Date:
June 30, 2016
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
SHANGHAI YANFENG JINQIAO AUTOMOTIVE TRIM SYSTEMS CO LTD (US)
International Classes:
B29C39/02
Domestic Patent References:
WO2016001763A22016-01-07
Foreign References:
US5759594A1998-06-02
US20080290547A12008-11-27
US5596915A1997-01-28
US5393474A1995-02-28
US20130052412A12013-02-28
Attorney, Agent or Firm:
ZIMMERMAN, Walter (US)
Download PDF:
Claims:
CLAIMS

1. A method of manufacturing a vehicle trim component utilizing a mold that includes at least a first part and a second part and a surface that defines a cavity comprising the steps of:

(a) supplying a material comprising fibers into the cavity;

(b) compressing the material between at least one of the first and second parts of the mold to form the material into a formed component comprising a first side and a second side;

(c) cutting at least a portion of the formed component to form the vehicle trim component; and

(d) removing the vehicle trim component from the cavity.

2. The method of manufacturing of Claim 1 wherein the portion of the formed component is cut as the formed component is compressed between the at least one of the first and second parts of the mold.

3. The method of manufacturing of Claim 1 wherein cutting at least a portion of the formed component comprises trimming an end of at least one fiber of the material comprising fibers.

4. The method of manufacturing of Claim 3 wherein the end of the at least one fiber is adjacent a nozzle configured to supply the material comprising fibers into the cavity.

5. The method of manufacturing of Claim 1 wherein the portion of the formed component is cut by a cutting tool.

6. The method of manufacturing of Claim 5 wherein the cutting tool is positioned adjacent the mold.

7. The method of manufacturing of Claim 5 wherein the cutting tool comprises two opposing blades configured to cut the formed component from the first side of the formed component and the second side of the formed component.

8. The method of manufacturing of Claim 1 further comprising heating at least one of the first and second parts of the mold.

Page 1 of 4 FIP 14AI029-PCT2

9. The method of Claim 1 wherein supplying the material comprising fibers includes blowing the fibers directly between the mold surfaces of the first and second parts.

10. The method of Claim 9 wherein the fibers of the material are blown into the cavity with at least one of a binder, a reinforcing material, and a filler.

11. The method of Claim 10 wherein the surface of the first part that defines the cavity is permeable to air, but is impermeable to the fibers and the at least one of the binder, the reinforcing material, and the filler.

Page 2 of 4 FIP 14AI029-PCT2

12. A method of manufacturing a vehicle interior component utilizing a mold that includes at least a first part and a second part and defines a cavity comprising the steps of:

(a) disposing a material comprising fibers onto the first part of the mold;

(b) compressing at least portion of the material comprising fibers between a tool and the first part of the mold;

(c) compressing the material comprising fibers between at least one of the first and second parts of the mold to form the material into a formed component comprising a first side and a second side; and

(d) removing the vehicle trim component from the cavity.

Page 3 of 4 FIP 14AI029-PCT2

13. A vehicle interior component made by a method utilizing a mold that includes at least a first part and a second part and defines a cavity comprising the steps of:

(a) disposing a material comprising fibers onto the first part of the mold;

(b) compressing at least portion of the material comprising fibers between a tool and the first part of the mold;

(c) compressing the material comprising fibers between at least one of the first and second parts of the mold to form the material into a formed component comprising a first side and a second side.

Page 4 of 4 FIP 14AI029-PCT2

Description:
PATENT APPLICATION

SYSTEM AND METHOD FOR PRODUCING A VEHICLE INTERIOR COMPONENT

FIELD

[0001] The present invention relates to a system and method for producing a vehicle interior component. The present invention also relates to a vehicle interior component.

BACKGROUND

[0002] It is well-known to provide a vehicle interior component formed from a panel. The panel may be formed into various components including an instrument panel or door panel.

[0003] It would be advantageous to provide an improved system and method for producing a vehicle interior component from a panel providing for variations in thickness and/or density to provide options useful for design and configuration variations for the component such as rigidification, weight, reduction, etc.

CROSS REFERENCE TO RELATED APPLICATION

[0004] The present application claims priority from and the benefit of and incorporates by reference in entirety of the following applications: (a) U.S. Application No. 62/187,692 titled "METHOD FOR PRODUCING A MOLDED BODY FROM A MATERIAL COMPRISING FIBERS AND A DEVICE FOR REALIZING THE METHOD" filed July 1, 2015; (b) International Application No. PCT/IB2015/001744 titled "METHOD FOR PRODUCING A MOLDED BODY FROM A MATERIAL COMPRISING FIBERS AND A DEVICE FOR REALIZING THE METHOD" filed July 1, 2015. SUMMARY

[0005] The present invention relates to a method of manufacturing a vehicle trim component utilizing a mold that includes at least a first part and a second part and a surface that defines a cavity. The method comprises the steps of supplying a material comprising fibers into the cavity, compressing the material between at least one of the first and second parts of the mold to form the material into a formed component comprising a first side and a second side, cutting at least a portion of the formed component to form the vehicle trim component and removing the vehicle trim component from the cavity. The portion of the formed component may be cut as the formed component is compressed between the at least one of the first and second parts of the mold; cutting at least a portion of the formed component may comprise trimming an end of at least one fiber of the material comprising fibers. The end of the at least one fiber may be adjacent a nozzle may be configured to supply the material comprising fibers into the cavity.

The portion of the formed component is cut by a cutting tool; the cutting tool may be positioned adjacent the mold; the cutting tool may comprise two opposing blades configured to cut the formed component from the first side of the formed component and the second side of the formed component. The method may further comprise heating at least one of the first and second parts of the mold. Supplying the material may comprise fibers includes blowing the fibers directly between the mold surfaces of the first and second parts; the fibers of the material are blown into the cavity with at least one of a binder, a reinforcing material and a filler. The surface of the first part that defines the cavity may be permeable to air but impermeable to the fibers and the at least one of the binder, the reinforcing material and the filler.

[0006] The present invention also relates to a method of manufacturing a vehicle interior component utilizing a mold that includes at least a first part and a second part and defines a cavity. The method comprises the steps of disposing a material comprising fibers onto the first part of the mold, compressing at least portion of the material comprising fibers between a tool and the first part of the mold, compressing the material comprising fibers between at least one of the first and second parts of the mold to form the material into a formed component comprising a first side and a second side and removing the vehicle trim component from the cavity.

[0007] The present invention further relates to a vehicle interior component made by a method utilizing a mold that includes at least a first part and a second part and defines a cavity. The method comprises the steps of disposing a material comprising fibers onto the first part of the mold, compressing at least portion of the material comprising fibers between a tool and the first part of the mold, compressing the material comprising fibers between at least one of the first and second parts of the mold to form the material into a formed component comprising a first side and a second side.

[0008] The present invention further relates to a component for use within an interior of a vehicle. The component comprises a first section having a first density and a first thickness, a second section having a second density and a second thickness, and a transition between the first section and the second section. The first section may comprise a material comprising fibers having an orientation; the second section may comprise a material comprising fibers having an orientation. The transition of the orientation of fibers of the first section and the orientation of fibers of the second section are generally maintained; the fibers are supplied to the first section and to the second section in an operation.

[0009] The first thickness of the first section may be greater than the second thickness of the second section; the second density of the second section may be greater than the first density of the first section. The second thickness of the second section is configured relative to the orientation; the first density and the first thickness of the first section provide an integrity of the second section that is greater than an integrity of the first section. Integrity may be maintained across the transition; each integrity may comprise structural integrity; the structural integrity may be selected from one of a strength and a durability. The transition may comprise a gradually progressive profile; the transition may be a continuous transition; the transition may comprise a discontinuity. The first section and second section may be integrally formed.

[0010] The operation may comprise supplying fibers to form the first section and the second section; the operation may comprise a first operation and a second operation; the first operation may comprise supplying fibers to form the first section. The second operation may comprise supplying fibers to form the second section; the second operation may comprise compression. The operation may comprise blowing of the fibers into the first section; the operation may comprise blowing of the fibers into the second section. The second thickness of the second section may be reduced in the operation; the second density of the second section may be increased in the operation. The transition is formed in the operation; the operation may comprise compression; the operation may comprise an application of heat; the operation may be performed in a tool; the operation may be a forming operation in the tool. The fibers are supplied into the material of the first section and the material of the second section; the second section may be adjacent the first section; the second section may be adjacent the first section on a first side and a second side and the transition may comprise a transition on the first side and a transition on the second side.

[0011] The structural integrity may comprise strength; the first section may be configured to be subjected to a first load and the second section may be configured to be subjected to a second load that is higher than the first load. The orientation of the fibers of each section may be configured such that a strength of the second section may be greater than a strength of the first section; the orientation of the fibers may comprise fibers that are aligned longitudinally; the orientation of the fibers may comprise a plurality of stacked layers of the fibers. The component may be selected from one of a door panel, an instrument panel and a center console of the vehicle.

[0012] The present invention also relates to a method of making a component for use in a vehicle from a material comprising fibers utilizing a mold that includes at least a first part and a second part; each of the first and second parts includes a surface that defines a cavity. The method comprises heating at least one of the first and second parts of the mold to a first temperature, supplying a material comprising fibers into the cavity and compressing the material using at least one of the first and second parts of the mold to form the component. The surface of the first part that defines the cavity may be permeable to air; the first part of the mold remains unheated during the process of supplying the material into the cavity. The method further comprises moving the second part of the mold in a lateral direction relative to the first part to align the second part with a third part of the mold that is provided adjacent to the first part and moving the third part toward the second part to compress the material between the surface of the second part and a surface of the third part to form the component. The method further comprises heating the surface of the third part of the mold to at least the first temperature prior to compressing the material between the surface of the second part and the surface of the third part to form the component. The surface of the second part of the mold may be impermeable to the fibers of the material and to air and wherein the surface of the third part of the mold is impermeable to the fibers of the material and to air. The method further comprises heating at least one of the second and third parts of the mold to a second temperature prior to compressing the material between the surface of the second part and the surface of the third part to form the component; the second temperature is higher than the first temperature. Both the second and third parts of the mold are heated to the second temperature prior to compressing the material between the surface of the second part and the surface of the third part to form the component; the first temperature may be at least 150 degree Celsius; the first temperature may be in a range from 150 degrees Celsius to 300 degrees Celsius.

[0013] Supplying the material comprising fibers may include blowing the fibers directly between the mold surfaces of the first and second parts; the fibers of the material are blown into the cavity with at least one of a binder, a reinforcing material and a filler. The surface of the first part that defines the cavity is permeable to air but is impermeable to the fibers and the at least one of the binder, the reinforcing material, and the filler. The first temperature is at least equal to a threshold activation temperature of the fibers of the material; compressing the material includes applying a compression force using at least one of the first and second parts of the mold to form the component.

[0014] The present invention further relates to a system for producing a component for use in a vehicle from a material comprising fibers. The system comprises a first mold comprising

[0015] A first part having a surface and a second part that is movable relative to the first part between a closed position and an open position, the second part having a surface; the surfaces of the first and second parts define a first cavity. A feeder may be configured to introduce the fibers of the material into the first cavity when the first mold is in the closed position. A second mold may comprise the first part and a third part that is movable relative to the first part between an open position and a closed position, the third part having a surface and a heater configured to heat at least one of the first, second and third parts to a first temperature. When the second part is in the open position, the first part is movable from the first mold to the second mold to move the fibers from the first mold to the second mold for compression between the surfaces of the first and third parts when the second mold is in the closed position.

[0016] The first temperature may be in a range from 150 degree Celsius to 300 degree Celsius and at least one of the first and third parts is heated to a second temperature that is higher than the first temperature; the first temperature may be at least equal to an activation temperature of the fiber of the material. The surface of the second part may be permeable to air but impermeable to the fibers of the material and the surfaces of the first and third parts may be impermeable to air and to the fibers of the material; when the second part is in the closed position with the first part both fibers of the material remain uncompressed.

FIGURES

[0001] FIGURE 1 A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0002] FIGURE IB is a schematic perspective view of a vehicle interior according to an exemplary embodiment.

[0003] FIGURES 2 and 3 are schematic side views of a mold apparatus for manufacturing a trim component for the vehicle interior according to an exemplary embodiment.

[0004] FIGURE 4 is a schematic diagram of a process for manufacturing the trim component for the vehicle interior according to an exemplary embodiment.

[0005] FIGURES 5A, 5B, 6A and 6B are schematic perspective views of trim components for the vehicle interior according to an exemplary embodiment.

[0006] FIGURES 7A and 7B are schematic diagrams of a process for manufacturing a trim component for the vehicle interior according to an exemplary embodiment.

[0007] FIGURES 8, 9 and 10 are schematic cross-section views of a method for manufacturing a trim component for the vehicle interior according to an exemplary embodiment.

[0008] FIGURES 11 and 12 are schematic cross-section views of the trim components according to an exemplary embodiment.

[0009] FIGURE 13 is a schematic diagram showing the density of a trim component with respect to the length of the trim component according to an exemplary embodiment.

[0010] FIGURES 13B, 13C and 13D are schematic side views of trim components with variations of density within the trim components according to an exemplary embodiment.

[0011] FIGURE 14 is a schematic diagram showing the density of a trim component with respect to the length of the trim component according to an exemplary embodiment. [0012] FIGURES 14B and 14C are schematic cross-section views of trim components with variations of density within the trim components according to an exemplary embodiment.

[0013] FIGURE 15A is a schematic cross-section view of a method for trimming a material within a mold according to an exemplary embodiment.

[0014] FIGURE 15B is a schematic cross-section view of a method for trimming a material within a mold according to an exemplary embodiment.

[0015] FIGURE 16A is a schematic cross-section view of a method for compressing a material within a mold according to an exemplary embodiment.

[0016] FIGURE 16B is a schematic cross-section view of a method for compressing a material within a mold according to an exemplary embodiment.

DESCRIPTION

[0017] Referring to FIGURES 1 A and IB, a vehicle 100 is shown including an interior 101 with doors 110, an instrument panel 112 and a floor console 114. According to an exemplary embodiment, interior trim components of vehicle 100 such as doors 110, instrument panel 112 and floor console 114 may include trim panels made with a mixture of fiber in a base material such as a binder or binding agent (e.g. resin, glue, moldable plastic material, etc.) function as a substrate.

[0018] According to an exemplary embodiment, a mold apparatus is provided to perform a compression forming process; material is supplied into a mold cavity; the material comprises a mixture of fiber in a binder (e.g. resin, glue, moldable plastic, etc.); the mold is heated to activate the binder within the material to induce curing and hardening of the material within the mold to form a trim component.

[0019] As shown schematically in FIGURE 2, a mold apparatus comprises a mold 20 and an injection unit 40; mold 20 comprises a mold top 22 (i.e. the top part of mold 20) and a mold bottom 21 (i.e. the bottom part of mold 20). As shown schematically in FIGURE 2, mold top 22 provides a channel 27; mold bottom 21 provides a channel 26. According to an exemplary embodiment, channel 27 and channel 26 are configured for flowing fluid (e.g. oil, water, etc.) as a thermal conductor. According to an exemplary embodiment, the fluid is configured to conduct and transfer heat within mold 20 (e.g. heating or cooling the mold). According to an exemplary embodiment, oil is used to serve as a heat-transfer medium; the oil is circulated through a heating device to heat mold top 22 and mold bottom 21 to a temperature of approximately 220 degree Celsius. As shown schematically in FIGURE 2, injection unit 40 (i.e. a feeder to mold 20) provides a device 41 configured to feed a material 15 through a nozzle 42 into the mold cavity of mold 20. According to an exemplary embodiment, material 15 comprises a mixture of fiber in a binder (e.g. resin, glue, moldable plastic, etc.). According to an exemplary embodiment, when material 15 is supplied (e.g. fed, injected, blown, etc.) within the heated mold surfaces of mold top 22 and mold bottom 21, the binder within material 15 is activated to bind the fiber within material 15 together.

[0020] As shown schematically in FIGURE 3, mold 20 is at a closed position; a press 50 applies a force to material within mold 20; material 15 is compressed between mold top 22 and mold bottom 21 to conform the shape of a mold cavity 25; a component 10 is formed after the material is cured and hardened.

[0021] A method for producing trim components is shown schematically in FIGURE 4. As shown schematically in FIGURE 4, a first material feeder 40a feeds material to a first blow molder 41a; material is injected into a first mold 20a. As shown schematically in FIGURE 4, a second material feeder 40b feeds material to a second blow molder 41b; material is injected into a second mold 20b. As shown schematically in FIGURE 4, a press 50 is configured to compress first mold 20a and second mold 20b. According to an exemplary embodiment,

feeding/supplying material into a mold takes a longer period of time than the subsequent step of pressing the mold; press 50 may compress mold 20a and mold 20b alternatively. According to an exemplary embodiment, press 50 compresses first mold 20a while material is fed/supplied into second mold 20b; press 50 then compresses second mold 20b after completing the pressing process for first mold 20a; material is fed/supplied into first mold 20a while press 50 is compressing second mold 20b.

[0022] As shown schematically in FIGURE 5 A, a trim component 210 comprises two end portions 213 and a middle portion 215; middle portion 215 is offset from end portions 213. According to an exemplary embodiment, trim component 210 has a generally uniform thickness throughout; trim component 210 also has a generally uniform density throughout. According to an exemplary embodiment, the trim component may be modified to withstand higher loading at certain areas of the trim component (e.g. increase density (see FIGURE 6B) and/or thickness (see FIGURE 6A) of the trim component). As shown schematically in FIGURE 5B, trim component 210 may include a feature shown as a support 220 intended to reinforce the structure of trim component 210 according to an exemplary embodiment.

[0023] As shown schematically in FIGURE 6A, a trim component 310 comprises two end portions 313 and a middle portion 315; middle portion 315 is offset from end portions 313. According to an exemplary embodiment, middle portion 315 is intended to withstand higher loading than end portions 313 of trim component 410; the thickness Tl of middle portion 315 is greater than the thickness T2 of end portions 313.

[0024] As shown schematically in FIGURE 6B, a trim component 410 comprises two end portions 413 and a middle portion 415; middle portion 415 is offset from end portions 413. According to an exemplary embodiment, middle portion 415 is intended to withstand higher loading than end portions 413 of trim component 410; the density of middle portion 415 is greater than the density of end portions 413.

[0025] A diagram of a method for manufacturing a trim component shown as a door panel 510 for vehicle interior is shown schematically in FIGURE 7A. According to an exemplary embodiment, the method is intended to provide variations in material strength and/or structural rigidity within door panel 510. As shown schematically in FIGURE 7A, a fiber mat 515 is produced; fiber mat 515 is then compression molded into a trim component shown as a door panel; plastic is injection molded onto the backside of door panel 510 to form features (e.g. supports for the areas of door panel 510) that are intended to withstand higher load. See also FIGURES 5B and 11. According to an exemplary embodiment, the method may be applied to manufacture a variety of trim components within a vehicle interior (e.g. a door panel, an instrument panel, a trim piece for a floor console or center console, etc.)

[0026] As shown schematically in FIGURE 7B, a diagram illustrates a method for

manufacturing a trim component shown as a door panel 610 for vehicle interior. According to an exemplary embodiment, the method is intended to provide variations in thickness and/or density within trim component 610. As shown schematically in FIGURE 7B, material 615 is fed/supplied into a mold; material 615 is then compression molded into a trim component shown as a door panel 610; the backside of door panel 610 may provide areas with greater thickness and/or greater density. According to an exemplary embodiment, areas within door panel 610 with greater density and/or thickness may be configured to withstand higher load/stress. See also FIGURES 6A, 6B and 12. According to an exemplary embodiment, the method may be applied to manufacture a variety of trim components within a vehicle interior (e.g. a door panel, an instrument panel, a trim piece for a floor console or center console, etc.)

[0027] A diagram for a method of manufacturing a trim component 710 is shown schematically in FIGURE 8.

[0028] As shown schematically in FIGURE 8(A), material 715 is supplied (e.g. fed, injected, blown, etc.) into a mold cavity 725 of a mold 720 through a nozzle 741. According to an exemplary embodiment, material 715 comprises a mixture of fibers in a binder (e.g. resin, glue, moldable plastic, etc.). As shown schematically in FIGURE 8(A), mold 720 comprises a mold bottom 722, a first mold top 721 and a second mold top 723. According to an exemplary embodiment, mold bottom 722 and mold top 723 are heated by a heating mechanism 760. [0029] As shown schematically in FIGURES 8(B) and 8(C), after mold cavity 725 is filled with material 715, mold top 721 is replaced with mold top 723.

[0030] As shown schematically in FIGURE 8(D), material 715 is compressed between heated mold bottom 722 and heated mold top 723 to induce curing and hardening of the binding agent within the material.

[0031] As shown schematically in FIGURE 8(E), a trim component 710 is formed with generally consistent thickness and density throughout the trim component 710.

[0032] As shown schematically in FIGURE 9, a trim component 810 may be produced with different thicknesses at different locations of trim component 810.

[0033] As shown schematically in FIGURE 9(A), material 815 is supplied (e.g. fed, injected, blown, etc.) into a mold cavity of a mold 820 through a nozzle 841. According to an exemplary embodiment, material 815 comprises a mixture of fibers in a binder (e.g. resin, glue, moldable plastic, etc.). As shown schematically in FIGURE 9(A), mold 820 comprises a mold bottom 822, a first mold top 821 and a second mold top 823.

[0034] As shown schematically in FIGURES 9(B) and 9(C), after the mold cavity is filled with material 815, mold top 821 is replaced with mold top 823.

[0035] As shown schematically in FIGURE 9(D), the material is compressed between heated mold bottom 822 and heated mold top 823 to form a trim component 810; mold surface 826 and mold surface 827 correspond to the shape of trim component 810.

[0036] As shown schematically in FIGURE 8(E), trim component 810 is formed with generally consistent density throughout the trim component 810; trim component 810 has a thickness Tl at a first end 811, a thickness T2 at a second end 812 and a thickness T3 at a middle portion 813. According to an exemplary embodiment, thickness Tl, thickness T2 and thickness T3 are substantially different.

[0037] As shown schematically in FIGURE 10, a trim component 910 may be produced with variations of densities within trim component 910.

[0038] As shown schematically in FIGURE 10(A), material 915 is supplied (e.g. fed, injected, blown, etc.) into a mold cavity 925 of a mold 920. According to an exemplary embodiment, material 915 comprises a mixture of fibers in a binder (e.g. resin, glue, moldable plastic, etc.). As shown schematically in FIGURE 10(A), mold 920 comprises a mold bottom 922, a first mold top 921 and a second mold top 923. As shown schematically in FIGURES 10(A) and 10(B), material 915 has a greater thickness at the middle portion within mold cavity 925; material 915 fills mold cavity 925 with a raised middle portion; material 915 has a generally consistent density throughout mold cavity 925.

[0039] As shown schematically in FIGURES 10(B) and 10(C), after mold cavity 925 is filled with material 915, mold top 921 is replaced with mold top 923.

[0040] As shown schematically in FIGURE 10(D), the material is compressed between heated mold bottom 922 and heated mold top 923 to form a trim component 810; mold surface 926 and mold surface 927 correspond to the shape of trim component 910. As shown schematically in FIGURES 10(C) and 10(D), mold surface 926 is intended to be parallel to mold surface 927 when mold top 923 and mold bottom 922 are at the closed position.

[0041] As shown schematically in FIGURE 10(E), trim component 910 is formed with generally consistent thickness throughout the trim component 910; trim component 910 has a greater density at a middle portion 913 than an end portion 911 and an end portion 912. [0042] As shown schematically in FIGURE 11, trim component 510 is made using the method shown in FIGURE 7A; trim component 510 is made from compressing a fiber mat into a desired shape; the orientations of fibers 515 within trim component 510 are arbitrarily orientated.

[0043] As shown schematically in FIGURE 12, trim component 610 is made using the method shown in FIGURE 7B; trim component 610 is made from fiber supplied (e.g. fed, injected, blown, etc.) into a mold; the orientations of fibers 615 within trim component 610 are substantially uniform.

[0044] As shown schematically in FIGURES 13, 13B, 13C and 13D, a trim component 510 is manufactured using the method shown in FIGURE 7A; a fiber mat S2 is molded onto a fiber mat SI to increase the density of a middle portion 512 of trim component 510. As shown

schematically in FIGURES 13C and 13D, middle portion 512 of trim component 510 has a density of D2 greater than density Dl of end portions 511 of trim component 510. As shown schematically in FIGURE 13, a graph shows the difference between density Dl of end portion 511 and density D2 of middle portion 512. As shown schematically in FIGURE 13, trim component 510 has a distinct transition in density between end portion 511 (i.e. the low density area) and middle portion 512 (i.e. the high density area). According to an exemplary

embodiment, a distinct transitional area within a trim component may create weakness (e.g. a weak spot, a weakened area, etc.) within trim component.

[0045] As shown schematically in FIGURES 14, 14B and 14C, trim component 610 is manufactured using the method shown in FIGURE 7B. As shown schematically in FIGURE 14B, trim component 610 has a generally consistent density throughout the trim component 610; trim component 610 comprises a portion 611 and a portion 612 connected by a portion 613; portion 611 has a reduced thickness than the thickness of portion 612. [0046] As shown schematically in FIGURE 14C, trim component 610 comprises a portion 611 and a portion 612 connected by a portion 613; portion 612 has a greater density than the density of portion 611; portion 612 has a greater thickness than the thickness of portion 611.

[0047] As shown schematically in FIGURE 14, a graph illustrates the variation between density Dl of portion 611 and density D2 of portion 612. As shown schematically in FIGURE 14, trim component 610 has a gradual transition in density between portion 611 (i.e. the low density area) and portion 612 (i.e. the high density area). According to an exemplary embodiment, a distinct transitional area within a trim component may create weakness within trim component; the gradual transition in density may reduce the likelihood of having a weaken area within a trim component.

[0048] As shown schematically in FIGURE 15 A, after mold cavity is filled with material 1015, top mold 1021 is removed; material 1015 is torn creating a tom section 1050 when nozzle 1041 is detached from material 1015.

[0049] As shown schematically in FIGURE 15B, a cutting tool 1127 is provided to cut material 1115 after the mold cavity is filled with material 1115; cutting tool 1127 provides a blade 1128 and a blade 1129 configured to cut material 1115 between mold 1120 and nozzle 1141.

According to an exemplary embodiment, cutting material 1115 is intended to provide a consistent and repeatable end portion for the trim component (adjacent to the nozzle).

[0050] As shown schematically in FIGURE 16A, a trim component 1210 may have a distinct transitional area; the distinct transitional area may be torn during the compression forming process.

[0051] As shown schematically in FIGURE 16B, a pressing tool 1230 may be used compress material 1215 into an intermediate thickness (see step A and step B in FIGURE 16B) before material 1215 is compressed within mold top 1223 and mold bottom 1222. According to an exemplary embodiment, the step (step A and step B shown in FIGURE 16B) of pressing material 1215 prior to compression forming within mold top 1223 and mold bottom 1222 is intended to provide a consistent and repeatable process without tearing the trim component. According to an exemplary embodiment, pre-pressing the material into an intermediate thickness is intended to reduce the likelihood of a tear or a rupture of the substrate/panel when the material is compressed between mold top 1223 and mold bottom 1222. Compare FIGURES 16A and 16B.

Exemplary Embodiments

[0052] Referring to the FIGURES according to an exemplary embodiment, various components (e.g. molded bodies, panels, etc.) for use in vehicles and methods for producing the components from a material comprising fibers are disclosed as well as devices suitable to realize the methods which can be configured to reduce the manufacture expense to produce the components. The components may be produced having different densities and/or different thicknesses in different sections (e.g. regions, portions, parts, etc.); according to an exemplary embodiment components may be configured for anticipated load conditions when assembled and in use in a vehicle.

[0053] According to an exemplary embodiment, the methods for producing molded bodies from material comprising fibers utilize a mold that includes at least one bottom part and at least one top part able to be moved toward one another to exert a pressing force on the material comprising fibers, such that they define an intermediate mold space for the molded body to be produced. According to an exemplary embodiment, the method includes the following three method steps or processes in the order provided; the first step involves bringing or holding at least one of the mold parts to/at a first and/or the first process temperature able to at least partly activate the respective material comprising fibers; the second step involves introducing the material comprising fibers into the at least partly open mold; the third step involves bringing the mold into its closed position and exerting the pressing force to form the molded body.

[0054] According to an exemplary embodiment, the mold can be moved from an open into a closed position, wherein the closed (or partly closed) position is to be understood as that position at which the introducing of the material comprising fibers for the molded body to be produced (e.g. blowing in by means of a blow nozzle) is as unobstructed as possible. The pressing force required for molding is not applied until the mold is in its closed position.

[0055] According to an exemplary embodiment, at least one of the mold parts (i.e. at least the top part or the bottom part), or also both parts, is configured to already be at a temperature suitable to at least partly activate the material comprising fibers at least in the areas which come into contact with the material comprising fibers to be pressed when the material comprising fibers is introduced into the intermediate mold space. The temperature constitutes the first process temperature.

[0056] According to an exemplary embodiment, if the respective part or respective parts of the mold are already at this first process temperature prior to the first method step, it is of course not necessary to initially bring them to said first process temperature; if different process temperatures are employed, as will be described further below, the respective part or respective parts of the mold are thus brought to this first process temperature in the first method step.

[0057] According to an exemplary embodiment, the activating of the material comprising fibers is generally a thermal activation of a duroplastic binding agent in the material comprising fibers to the temperature which the parts of the mold are already at. Before the setting process is finished, the mold is then brought into its closed position and the pressing force applied so that a very stable molded body having outstanding mechanical properties is formed in the desired three-dimensional shape.

[0058] According to an exemplary embodiment, the intermediate mold space can be formed in the partly open state of the mold; i.e. the material introduced into the intermediate mold space (e.g. blown in). The contact pressure is not applied on the mold until the material comprising fibers is introduced; i.e. this state at which the contact pressure is applied is then designated the closed state of the mold. The inventive solution yields numerous advantages. Since no separate heated flow of air needs to be introduced into the closed mold in order to heat up the fibers (as in the conventional solutions ) the entire molding process can transpire directly in one suitable (heavyweight) molding tool able to be subjected to high pressing force in a press. According to an exemplary embodiment, the pressing force can be in the range of approximately two tons.

[0059] According to an exemplary embodiment, the molded body does not need to be transported between multiple molding tools to be formed and does not need to be brought into different molding tools, which reduces the amount of work required. Producing a semi-finished product is unnecessary; the inventive method enables forming the finished molded body directly.

[0060] Directly heating at least one of the parts of the mold (i.e. the molding tool) ensures a continuous duroplastic molding process which may improve the mechanical properties of the molded body produced.

[0061] The first process temperature is in a range of between 150 degrees Celsius and 300 degrees Celsius and preferably approximately 220 degrees Celsius (e.g. suitable temperature range to enable the curing process of the advantageously utilized binding agents). It is at the same time ensured that the entire molding process proceeds reliably and consistently so as to be able to obtain a uniform material quality to the molded body to be produced. [0062] It can be provided for at least one of the parts of the mold, e.g. both parts of the mold, to be brought to or held at a second process temperature during the method step of bringing the mold into its closed position and applying the pressing force for forming the molded body. The second process temperature is higher than the first process temperature; doing so can achieve a pre-activation and then a final activation of the components of the material comprising fibers (particularly when various different binding agents are used) and even better material properties can be obtained and/or various more complex forms are able to be achieved. (The temporal aspect to the method step of bringing the mold into its closed position and applying the pressing force for forming the molded body is hereby to be understood as the second process temperature being reached at the same time as or prior to this step.)

[0063] According to one advantageous further development of the invention, it is provided for all the parts of the mold; i.e. the top and bottom part, to be brought to or held at the first process temperature in the first method step. When provision is made for a second process temperature, it can then be additionally provided for all the mold parts to be brought to or held at this second process temperature. A particularly homogenous molding and a shortening of the molding time may be achievable.

[0064] According to an exemplary embodiment, it can further be provided for the part or parts of the mold to be brought to or respectively held at the first and/or second process temperature particularly by flowing a heat-transmitting liquid through them. Heat-transmitting liquid is advantageous a thermal oil which serves as a heat-transfer medium and is transported through the mold part, advantageously through all the mold parts. The thermal oil can be transported through a heat source by means of a circulation pump (e.g. to enable a particularly simple and safe (by being non-pressurized) supplying of the mold parts with the heat required to reach the respective process temperature; other solutions for warming the part(s) are of course also conceivable (e.g. an electric heater able to be integrated into the part(s) or by induction).

[0065] According to a further aspect of the invention, the bottom part of the mold comprises a surface impermeable to the material comprising fibers to be introduced. In other words: No air outlet openings are provided in the bottom part of the mold; according to an exemplary embodiment, outlets are not necessary since in contrast to conventional molding tools, no hot air needs to be introduced into the mold in the inventive method to thermally activate the binding agent; the mold part(s) themselves are heated to the required process temperature. A complex discharge and/or recirculation of material comprising fibers inadvertently blown out during the blowing process are no longer necessary at the bottom part of the mold. The top part of the mold can be designed to be air-permeable (i.e. provided with air outlet holes). These then only serve in equalizing pressure when the mold is brought from its open into its closed state.

[0066] According to an exemplary embodiment, the material comprising fibers can contain a percentage of synthetic fibers, particularly polymer fibers and/or carbon fibers. Particularly polyethylene (PE), polypropylene (PP) and/or polyethersulfone (PES) are conceivable as polymer fibers.

[0067] According to an exemplary embodiment, the material comprising fibers can also contain a percentage of natural fibers (e.g. wood fibers and/or cotton fibers).

[0068] With respect to the device for realizing the inventive method, it is provided for the device to comprise a mold having a bottom part and at least one top part able to move in relation thereto for applying a pressing force on a material comprising fibers introducible into an intermediate mold space formed between the parts, whereby the bottom part of the mold has a surface which is impermeable to the material comprising fibers to be introduced, and whereby at least one of the mold parts is designed to be brought to a selectable process temperature by means of a heat- transmitting liquid flowing through said part, particularly a thermal oil.

[0069] According to an exemplary embodiment, it is provided for the bottom part of the mold to be able to move between an introducing position and a pressing position, whereby at least one top part of the mold is provided at the introducing position and at least one top part of the mold is provided at the pressing position.

[0070] According to an exemplary embodiment, a suitable top part (e.g. heated to the first process temperature) can be furnished to the bottom part for realizing the method steps up to and including the introduction of the material comprising fibers. To this end, a blow molder supplied with material comprising fibers at a blowing station by a material comprising fibers feed device, and which then dispenses it to a blow nozzle arranged in the mold can be used.

[0071] The bottom part is then subsequently transported to a further top part which can be a part of a pressing device and used to realize the method step of exerting the pressing force. The molded body is fully formed without interrupting the curing process so as to enable the achieving of a continuous duroplastic process.

[0072] It is also possible for only one pressing device to be provided, same being successively fed correspondingly prepared bottom parts by a plurality of blowing stations. Doing so takes advantage of the fact that introducing the material comprising fibers takes longer than the subsequent pressing process. This enables the inventive method to be executed more

economically.

[0073] As shown schematically in FIGURES 1 A and IB, a vehicle 100 provides an interior passenger compartment 101 configured to include one or more components (e.g. trim panels). According to an exemplary embodiment, the vehicle 100 may include a door assembly including one or more door trim panels 110 and an instrument panel (IP) assembly including one or more IP panels 112. According to an exemplary embodiment, the vehicle 100 may include a seat assembly including one or more seat trim panels; the vehicle 100 may also include a center console assembly that includes one or more trim panels 114. The vehicle 100 may include additional trim panels associated with other assemblies of the vehicle 100. (Any of the components of the vehicle 100 may be configured according to any of the embodiments disclosed and/or may be manufactured (e.g. made) according to any of the methods disclosed).

[0074] As shown schematically in FIGURE 2, a device is configured for realizing the method for producing trim component according to an exemplary embodiment. As shown schematically in FIGURE 2, a blow molder 41 supplies a blow nozzle 42 with a material 15 which is supplied by a material feed device of the blow molder 41; according to an exemplary embodiment, material 15 comprises fibers. According to an exemplary embodiment, supply nozzle 42 is arranged with its outlet opening at the bottom half 21 of a mold 20 so that material 15 will be blown out onto bottom half 21 of mold 20. Material 15 may comprise a percentage of natural fibers (e.g. cotton fibers) and a proportion of a binding agent which can be thermally activated and hardens duroplastically.

[0075] As shown schematically in FIGURE 2, top half 22 of the mold 20 is provided opposite the bottom half 21 and spaced from bottom half 21 so as not to impede the introduction of material 15. According to an exemplary embodiment, the distance between bottom half 21 and top half 22 is may be arranged very close together when material 15 is being blown in; the distance of separation between bottom half 21 and top half 22 is such that no pressing force is applied in this state. [0076] The bottom half 21 of mold 20 is provided with a fluid channel 26; the top half 22 of mold 20 is provided with a fluid channel 27 through which heated thermally conductive liquid (e.g. thermal oil) is conducted. The thermal oil serves as a heat-transfer medium and is circulated through a heating device so that the top half 22 and the bottom half 21 are heated to a temperature of approximately 220 degrees Celsius. The material 15 is deposited on heated mold surfaces when blown out; the binding agent component is already activated upon being blown onto bottom half 21 and top half 22. The bottom half 21 of the mold is of solid configuration (constitutes a heavyweight tool) and has no air openings or the like on its surface receiving material 15 so that no recirculating (e.g. discharging, etc.) needs to be provided for surplus material 15.

[0077] As shown schematically in FIGURE 3, the method continues according to an exemplary embodiment. Before the duroplastic hardening of the portion of binding agent in the material 15 no longer permits any further simple forming action, the mold 20 is brought into a closed position so that an intermediate mold space 25 forms between the top half 22 and the bottom half 21. A pressing device 50 applies a pressing force on material 15 in the intermediate mold space 25 so that a molded body 10 is produced by duroplastic action, which is finished following curing.

[0078] As shown schematically in FIGURE 4 according to an exemplary embodiment, each of the individual parts can be designed in conjunction with the first embodiment. The method according to the second embodiment only provides for one pressing device 50 for pressing mold 20 and pressing mold 20b, associated with their own blow molder 41a and blow molder 41b supplied by its own material 15 feed device 40a and feed device 40b. [0079] According to an exemplary embodiment, blowing the material into hot mold 20a and hot mold 20b takes a longer period of time than subsequent pressing. According to an exemplary embodiment, blow molder 41a having a cycle time of 60 seconds and blow molder 41b also having a cycle time of 60 seconds can supply a single pressing device 50, which improves cost- effectiveness.

[0080] As shown schematically in FIGURES 5 A and 5B, a component 210 for a vehicle is made from a material comprising fibers; component 210 includes a pair of ends 213 and an

intermediate portion 215 extending between the ends 213. The intermediate portion 215 may offset from the ends 213 (e.g. the intermediate portion 215 is non-planar relative to the ends 213). The component 210 has a substantially uniform (e.g. constant) thickness throughout the component; the thickness of the intermediate portion 215 is substantially the same as the thickness of each end 213. The component 210 has a substantially uniform (e.g. constant) density throughout the component; the density of the intermediate portion 215 is substantially equal to the density of each end 213. According to an exemplary embodiment, the component 210 is configured to carry a relatively constant load throughout the component, if the component 210 may be used in an assembly where a portion of the component 210 is subjected to a high load area (e.g. a load that would otherwise be higher than the load carrying ability of the component) then the component 210 may be modified to accommodate the high load. According to an exemplary embodiment, a modification may be to increase the thickness of the entire component 210 to accommodate the high load; the modification would increase the weight of the component and over design the portions of the component not subjected to the high load.

According to an exemplary embodiment, another modification may be to include a support (e.g. a structural support, support member, etc.) that reinforces the component 210 local to the location where the component is subjected to the high load. As shown schematically in FIGURE 5B, a support 220 is located behind the portion of the component 210 which is subjected to the high load (shown to be the intermediate portion 215); support 220 carries load transferred into the portion of the component 210. The support 220 may be coupled to a back side (e.g. a rear surface) of the intermediate portion 215 of the component 210.

[0081] As shown schematically in FIGURES 6A and 6B, other modifications may be applied to the components. As shown schematically in FIGURE 6A, component 310 is made from the material comprising fibers (e.g. loose fibers); the component 310 may include a pair of ends 313 and an intermediate portion 315 extending between the ends 313. As shown schematically in FIGURE 6A, the intermediate portion 315 has a thickness Tl that is larger than a thickness T2 of the ends 313, which configures the intermediate portion 315 to carry a relative higher load compared to the ends 313. According to an exemplary embodiment, density of the intermediate portion 315 may be the same as the density of the ends 313 and the component 310 provides a higher load carrying ability through the intermediate portion 315. The thicknesses Tl and T2 may be tailored to a specific application for the component.

[0082] As shown schematically in FIGURE 6B, a component 410 is made from the material comprising fibers; the component 410 may include a pair of ends 413 and an intermediate portion 415 extending between the ends 413. As shown schematically in FIGURE 6B, the intermediate portion 415 has a thickness that is substantially the same as the thickness of the ends 413. The intermediate portion 415 has a density that is higher (e.g. larger, etc.) compared to the density of the ends 413; the intermediate portion 415 is configured to carry a relative higher load compared to the ends 413. According to an exemplary embodiment, the densities of the intermediate portion 415 and the ends 413 may be tailored to a specific application for the component.

[0083] Referring to FIGURES 6 A and 6B, the intermediate portions 315 of component 310 and intermediate portion 415 of components 410 can be subjected to a higher load relative to the end 313 and end 413 and by increasing the thickness and/or the density of the intermediate portion 315 and intermediate portion 415 compared to the thickness/density of the end 313 and end 413. The sections having increased thickness and/or density are configured to increase (e.g. improve) the integrity (e.g. strength, durability, etc.) of the component. According to an exemplary embodiment, one or both ends of the component 310 and component 410 may be configured having a larger thickness and/or density relative to the intermediate portion to allow for carrying the relative higher load in other portions of the components; each component may have a greater thickness and/or density at a location other (or in addition to) than the intermediate portions shown. According to an exemplary embodiment, the components may also be configured having more than one location having a greater thickness and/or density to provide a component that can carry a relatively high load in one or more locations and carry a relative low load in one or more locations; the components may include a plurality of sections configured with more than two different thicknesses and/or densities (to carry more than two different loads in three or more different sections).

[0084] As shown schematically in FIGURES 7A and 7B, diagrams show the methods (e.g. processes) for making (e.g. manufacturing) components (e.g. panels) for use with a vehicle (e.g. components such as door panel 510 and door panel 610) configured to be subjected to more than one load. As shown schematically in FIGURE 7A, a fiber mat 515 is utilized to produce door panel 510. The first step is producing the fiber mat 515 in accordance with conventional techniques; in the second step the fiber mat 515 is formed into the door panel 510 having a substantially uniform thickness and density throughout the panel. To allow the door panel 510 to withstand more than one load condition at different locations of the panel, a support (e.g. the support 220) is injection molded to a backside of the door panel 510 at each location of relative high loading in a third step.

[0085] As shown schematically in FIGURE 7B, loose fibers 615 are utilized to produce the door panel 610. The first step is supplying (e.g. blowing) the loose fibers 615 into a tool (e.g. molding equipment) that produces a door panel 610 having an increased thickness and/or an increased density at each location of relative high loading of the panel; in the second step, the door panel 610 is produced by the tool. Since the door panel 610 can withstand a similar load condition as the door panel 510 without having the support, the cost and timing (e.g. to manufacture) associated with adding the support can be eliminated.

[0086] As shown schematically in FIGURE 8, a component 710 (e.g. a panel) for a vehicle in five steps (e.g. processes). In the first step (labeled A), loose fibers 715 (e.g. separate fibers) are blown (e.g. injected, introduced, disposed such as by a fluid medium, etc.) into a cavity 725 of a tool 720 (e.g. mold), such as by a feeder 740. The fibers 715 may be blown into the cavity 725 with other elements; the separate fibers may be blown into the cavity along with a binder, a reinforcing material (e.g. carbon fibers, glass fibers, etc.), and/or a filler. A nozzle 741 may be fluidly connected to a compartment of the feeder 740 that holds the loose fibers 715 by a fluid conduit 743 (e.g. hose, tube, pipe, etc.). The separate fibers 715 are blown into the cavity 725 via the nozzle 741, which may be coupled to a part of the tool 720.

[0087] As shown schematically in FIGURE 8, the tool 720 includes a first (e.g. upper, top) part 721 and a second (e.g. bottom, lower) part 722, where at least one of the first and second parts is movable relative to the other part between an open position and a closed position. In the first step, loose fibers 715 are blown into the cavity 725 formed between the first and second parts 721, 722 in the closed position. As shown schematically in FIGURE 8, the fibers 715 are deposited on a mold surface of the second part 722 between the mold surface of the second part 722 and a mold surface of the first part 721. According to an exemplary embodiment, at least one mold surface is permeable to air, but impermeable to the separate fibers of the material 715 being blown into the mold. The arrangement allows the air medium that is blown in with the separate fibers to escape without the cavity without the fibers escaping the cavity. As shown schematically in FIGURE 8, the first part 721 includes a mold surface 724 that is configured to be permeable to air, but impermeable to the separate fibers 715; the mold surface 724 of the first part 721 may include a screen that has a shape that conforms the fibers to a specific geometry without allow the fibers to pass through apertures in the screen; air is permitted to pass through the apertures of the screen in the mold surface 724. According to an exemplary embodiment, at least one mold surface is impermeable to both air and to the fibers. As shown in FIGURE 8, the second part 722 includes a mold surface 727 that is impermeable to both air and to the fibers 715 blown into the cavity 725; the mold surface 727 may be solid (e.g. continuous).

[0088] One or both of the first part 721 and second part 722 may be heated to a first temperature prior to introducing the fibers 715 into the cavity. The first temperature may be configured to activate at least some of the fibers 715 (where polymerization and/or cross-linking of fibers 715 occurs); the first temperature is above a threshold temperature of the material comprising fibers to begin activating the material comprising fibers. Activating at least some of the fibers may help retain all of the fibers 715 in place until all of the fibers are activated. [0089] As shown schematically in FIGURE 8, the second part 722 and third part 723 of the tool 720 are heated, while the first part 721 remains unheated; the second part 722 may be preheated to a first temperature, which is above the threshold temperature of the material comprising fibers, prior to blowing in the fibers 715, then may be heated to a second temperature that is greater than the first temperature between blowing in the fibers 715 and compressing the fibers 715 into the component 710. The third part 723 of the tool 720 may be similarly preheated, then heated to the second temperature while compressing the fibers 715 between the second part 722.

[0090] Also shown schematically in FIGURE 8, the system includes a heater 760 (e.g. heating mechanism, etc.) that is configured to heat the tool 720, such as one or more parts. As shown, the heating mechanism is configured to heat the second part 722 and the third part 723 of the tool 720. The heater 760 can be configured to heat any one part or any combination of parts of the tool. According to an exemplary embodiment, the heater 760 utilizes a heated fluid to heat the tool. The heater 760 may include a heater and a pump where the heater heats the fluid and the pump pumps it through the system. According to an exemplary embodiment, the heater 760 may utilize electric heat or any suitable conventional heating technique.

[0091] One or both of the first part 721 and the second part 722 may be configured as heavyweight tool parts; a heavyweight tool part is configured having a mold surface 724 and a mold surface 727 for forming the part (e.g. the component 710) that is continuous or unbroken by openings (e.g. holes, apertures, etc.), such as to allow air flow into/out of the cavity 725. The arrangement advantageously prevents the fibers 715 from flowing through any such openings, which could otherwise lead to voids in the parts being formed and/or damage to the tool 720. According to an exemplary embodiment, the mold surface of a heavyweight tool is devoid of any openings, other than an opening that forms a feature on the component, such as a protrusion, tab, or similar element.

[0092] In the second step (labeled B in FIGURE 8), one of the first and second parts 721, 722 of the tool 720 moves to the open position. As shown, the first part 721 moves in an upward (e.g. vertical) direction away from the second part 722 until the first part 721 clears the fibers 715 to allow the second part 722 (and the fibers 715 on top of the second part 722) to move relative to the first part 721 in a direction transverse to the direction that the first part 721 moves in.

[0093] In the third step (labeled C in FIGURE 8), the part of the tool 720 having the fibers 715 is moved. As shown, the second part 722 moves in a transverse direction (e.g. horizontal) relative to the direction that the first part 721 moves in the second step to position the second part 722 (and the fibers 715) under a third part 723 of the tool 720.

[0094] In the fourth step (labeled D in FIGURE 8), the third part 723 of the tool 720 is moved downward relative to the second part 722 to bring the third and second parts into a closed position, in which mating mold surfaces of the second part 722 and third part 723 compress the fibers 715 with a pressure from force F to form a component 710. The length of time that the first part 722 and second part 723 are in the closed position may depend on the temperature of the tool (e.g. each part) and the pressure used to compress the fibers 715. The third part 723 may be heated to a temperature (e.g. the first temperature) prior to moving to the closed position with the second part 722. During the fourth step, such as following closing of the tool, one or both of the second part 722 and third part 723 may be heated to a temperature, such as a second temperature that is higher than the first temperature, to facilitate activating all of the fibers 715. The third part 723 of the tool 720 may be configured as a heavyweight tool part. [0095] In the fifth step (labeled E in FIGURE 8), the third part 723 of the tool 720 is moved from the closed position to the open position to allow the component 710 to be removed from the second part 722 of the tool 720. The component 710 can be removed manually (e.g. by an operator) or automatically (e.g. by the tool 720). As shown, the shapes of the mating mold surfaces of the second and third parts 722, 723 define the geometry (e.g. shape) of the component 710. The mating mold surfaces may form a component 710 having a uniform thickness.

[0096] FIGURE 9 shows producing a component 810 (e.g. a panel) for a vehicle having different sized (e.g. thickness) portions using the same five steps (e.g. processes) described in the process shown in FIGURE 8. For consistency, the steps of the process shown in FIGURE 9 are labeled A-E, which correspond to the counterpart step (i.e. A, B, C, D, and E) of the process shown in FIGURE 8.

[0097] As shown in FIGURE 9, the fibers 815 form a shape that is generally similar to the shape of the finished component 810 (see steps A, B via the first part 821 and second part 822 of the tool 820). Then, the partially activated fibers 815 forming the general shape is moved with the second part 822 in the third step C. Then, the component 810 is formed between the second part 822 and the third part 823 of the tool 820 in the fourth step D and the fifth step E. The relative spacing between the mold surface 827 of the second part 822 and the mold surface 826 of the third part 823 defines the thickness of the component 810 in that specific location (e.g. section, region, area, etc.). The component 810 may be formed having different thicknesses in different sections of the component. According to the example shown in FIGURE 9, the component 810 includes a first end 811 having a thickness of Tl, a second end 812 (opposite to the first end 811) having a thickness of Tz, and an intermediate section 813 located between the first and second ends that has a thickness of T3. The thicknesses Tl, T2, and T3 are different from one another. The thickness Tl may be less than the thickness T2, which may be less than the thickness T3. Also shown in FIGURE 9, a first transition section 818 extends between the first end 811 and the intermediate section 813, and a second transition section 819 extends between the second end 812 and the intermediate section 813; each transition section 818, 819 may have a thickness that varies along the section, such as transitioning from the thicknesses of the respective connected sections (e.g. end, intermediate section, etc.).

[0098] According to an exemplary embodiment, the thicknesses of the sections of other components may be different than what is shown in the component 810, which is intended to be illustrative and not limiting in nature.

[0099] The component 810 is configured having different thicknesses in different sections of the component, which may be tailored to the load conditions that each section is subject to in vehicle; the component 810 may carry different levels of loading in the different sections of the component without having to vary the density of the component from section to section. The third part 823 may be configured to compress the fibers 815 in the different sections by approximately the same amount to maintain a relatively constant density throughout the component 810.

[0100] FIGURE 10 shows another exemplary method for producing a component 910 (e.g. a panel) for a vehicle having different densities in different sections (e.g. portions) using the same five steps (e.g. processes) described in the process shown in FIGURE 8. The steps of the process shown in FIGURE 10 are labeled to the process step (i.e. step A, step B, step C, step D, and step E). [0101] As shown in FIGURE 10, the component 910 produced has a relatively constant thickness, but is configured having different densities in different sections. First and second sections 911, 912 of the component 910 may be configured having a first density, and a third section 913 of the component 910 may be configured having a second density that is different (e.g. greater, lower) than the first density. According to an exemplary embodiment, the process provides a second density that is greater than the first density but other components may be configured differently. The component 910 may be formed having different densities by compressing more fibers into a similar cross-sectional size (e.g. thickness) in sections having relatively greater densities (e.g. achieved through the tooling).

[0102] Shown in FIGURE 10, the mold surface 924 of the first part 921 is configured having a greater offset distance (e.g. recessed) relative to the mold surface 927 of the second part 922 through the region corresponding to the third section 913 of the component 910 relative to the regions corresponding to the first and second sections 911, 912 of the component. The mold surface 924 may have a recess in the region of the third section 913 relative to the regions of the first and second sections 911, 912. During the first and second steps A, B, a greater number of fibers 915 are blown into the portion of the cavity 925 that forms the third section 913 of the component 910 compared to the first and second sections 911, 912. The mold surface 926 of the third part 923 of the tool is configured having a substantially similar offset distance to the mold surface 927 of the second part 922 through the first, second, and third regions corresponding to the first, second, and third sections 911, 912, 913, respectively. During step four D, the fibers 915 are compressed between the second and third parts 922, 923. Since more fibers are being compressed into a similar cross-sectional size in the third section 913 (compared to the first and second sections 911, 912), the density of the third section 913 is greater than the densities of the first and second sections 911, 912. The component 910 is produced having a substantially uniform (e.g. constant) size (e.g. thickness) between the three sections, with the third section 913 having a greater density. The component 910 is configured for use in a vehicle application where the third section 913 is subjected to a relatively higher load condition then the load conditions of the first and second sections 911, 912. The component 910 could be made to include more than two different densities in any number of locations.

[0103] FIGURES 11 and 12 show portions of exemplary embodiments of components made using the methods shown in FIGURES 7 A and 7B, respectively. As shown in FIGURE 11, the orientation of the fibers 515 of the component 510 formed from a mat are randomly orientated (e.g. arranged, aligned, etc.), whereas the fibers 615 of the component 610 formed by blowing loose fibers into the mold (e.g. via the methods shown in FIGURES 7B and 8) may have a longitudinal orientation and/or a stacked orientation throughout the component. The fibers 615 may form layers that are stacked on top of one another. This arrangement may provide a more homogenous substrate or matrix of the material of the component 610, which may

advantageously increase the integrity, such as the strength, of the component 610 or a section of the component.

[0104] FIGURE 13 shows a graph illustrating the change in density of a component made using two mats of fibers (the first mat SI and the second mat S2 shown on top of the first mat SI in FIGURE 13B) to provide a multi-density component 510 (FIGURE 13C). As shown in FIGURE 13B, the second mat S2 is placed on top of the first mat SI prior to compression. Then, after compressing the two mats SI, S2 together, the section 511 (which include both mats) has a higher density D2 than the sections 511 (which included only the first mat SI) having the density Dl . Typically, the section 512 will also be thicker than each section 511. This method may result in a sharp transition in density (depicted as 513 in FIGURE 13) between the lower density Dl of section 511 and the higher density D2 of section 512, which may induce a weak spot (e.g. via a stress riser). FIGURE 13D shows another exemplary embodiment of a component 510 showing partial integration of the two mats 511, 512, where the density is greater in the integrated portion compared to the density in the non-integrated portion.

[0105] FIGURES 14 and 14C show a multi-density component made using blown fibers of material. As shown in FIGURE 14C, the density of the transition 613 (located between the thinner section 611 and the thicker section 612) gradually (e.g. progressively) transitions between a relatively higher density in the section 612 to the relatively lower density in the section 611 to eliminate the potential weak spot. As shown in FIGURE 14B, the thickness of the transition 613 (located between the thinner section 611 and the thicker section 612) gradually (e.g. progressively) transitions to eliminate the potential weak spot; the density of the transition section 613 (located between the low density section 611 and the high density section 612 shown in FIGURE 14) may gradually transition to eliminate the weak spot.

[0106] FIGURES 15A and 15B show two alternative ways to trim the ends of the fibers 1015, 1115 in the tools 1020, 1120, respectively. As shown in FIGURE 15A, the end of the fibers 1015 adjacent to the nozzle 1041 can be torn when the first part 1021 of the tool 1020 is moved upwardly to the open position from the closed position with the second part 1022 of the tool 1020. While less expensive and complicated (compared to the method of FIGURE 15B), the tear 1050 in the fibers 1015 produces an uneven end (e.g. edge) and may lead to part quality concerns, such as voids and/or changes (e.g. reductions) in density in the panel in the regions near the tear 1050. [0107] As shown in FIGURE 15B, the end of the fibers 1115 adjacent to the nozzle 1141 can be cut by a cutting tool 1 127 that is located just outside the tool 1120 adjacent to the nozzle 1141. The cutting tool 1127 includes at least one blade (e.g. knife-edge, etc.) that is capable of cutting through the fibers 1115. As shown, the cutting tool 1127 includes two opposing blades 1128, 1129, where each blade 1128, 1129 is configured to move toward the opposite blade to cut the fibers 1115 from two sides. The blade 1128 may be located above the fibers 1115 and configured to move downwardly into the fibers 1115 to cut at least a portion of the fibers 1115, while the blade 1129 may be located below the fibers 1115 and configured to move upwardly into the fibers 1115 to cut at least a portion of the fibers 1115. According to one example, the step of cutting is provided between the first step of filling the fibers and a second step of moving the first part 1121 of the tool 1120 to an open position relative to the second part 1122 of the tool 1120. As shown in FIGURE 15B, the step A2 of cutting is provided between the filling step AI and the step B of moving the first part 1121 of the tool 1120; cutting the fibers 1115 provides a more consistent and repeatable end (adjacent to the nozzle), which produces a better quality panel having fewer voids and/or changes in density compared to the panel produced by tearing the fibers.

[0108] FIGURE 16B shows an exemplary method of eliminating a weak spot 1214 in a panel 1210 that might otherwise form from the process shown in FIGURE 16 A. FIGURE 16A shows a panel 1210 having a first section 1211, a second section 1212, and a third section 1213 provided between the first and second sections 1211, 1212. The first and second sections 1211, 1212 are offset from one another and generally extend from the third section 1213 is opposite directions. The third section 1213 is aligned at an angle relative to the first and second sections 1211, 1212. A weak spot 1214 may form in the third section 1213 when the angle becomes too high (e.g. too sharp) and/or the part is too thin (e.g. cross-sectional thickness). The third part 1223 of the tool may include an inclined surface that may move fibers 1215 from the location of the third section 1213 toward the first section 1211 when the third part 1223 is moved

downwardly toward the closed position. The loss of fibers 1215 in the third section 1213 may result in a void or reduction in density that could possibly lead to a weak spot 1214 in the panel 1210.

[0109] To eliminate a weak spot 1214, an additional step may be introduced into the

method/process. As shown in FIGURE 16B, prior to compressing the fibers 1215 between the second and third parts 1222, 1223 of the tool, the second and third sections 1212, 1213 of the fibers 1215 are pre-pressed down by a lighter load tool. According to one example, a manual pressing tool 1230 may be used to compress the second and third sections 1212, 1213 of the fibers by a first amount (see the step labeled A and B in FIGURE 16B). Then, following the initial pressing of the fibers 1215, the third part 1223 of the tool is closed relative to the second part 1222 to compress the fibers 1215 (by a second amount in the second and third sections 1212, 1213 and a third amount in the first section 1211) to form the panel 1210 without any weak spots. According to an exemplary embodiment, the manual pressing tool can be automated.

[0110] According to another exemplary embodiment, a three step method for producing a molded body from a material comprising fibers is provided. The method utilizes a mold that includes at least one bottom part and at least one top part able to be moved toward one another to exert a pressing force on the material comprising fibers. The top and bottom parts define an intermediate mold space for the molded body to be produced in. The first step of the method involves bringing or holding at least one of the parts of the mold to/at a first and/or the first process temperature able to at least partly activate the respective material comprising fibers; the second step of the method involves introducing the material comprising fibers into the at least partly open mold; the third step of the method involves bringing the mold into its closed position and applying the pressing force to form the molded body.

[0111] The first process temperature may be in a range of between 150 degrees Celsius and 300 degrees Celsius (e.g. approximately 220 degrees Celsius).

[0112] At least one of the parts of the mold may be brought to or held at a second and/or the second process temperature, which is higher than the first process temperature, such as during the method step of bringing the mold into its closed position and applying the pressing force for forming the molded body.

[0113] All the parts of the mold can be brought to or held at the first process temperature and/or the second process temperature, according to other examples.

[0114] The part or parts of the mold may be brought to or held at the first process temperature and/or the second process temperature by a heat-transmitting liquid (e.g. a thermal oil) at the respective temperature flowing through the part(s); the bottom part of the mold may include a surface that is impermeable to the material comprising fibers introduced into the mold.

[0115] The material comprising fibers may contain a percentage of synthetic fibers (e.g.

polymer fibers and/or carbon fibers); the material comprising fibers may contain a percentage of natural fibers (e.g. wood fibers and/or cotton fibers).

[0116] An exemplary embodiment of a device for realizing any method described above may include a mold having a bottom part and at least one top part able to move in relation thereto for applying a pressing force on a material comprising fibers introduced into an intermediate mold space formed between the parts. The bottom part of the mold may have a surface that is impermeable to the material comprising fibers introduced. At least one of the parts of the mold may be configured to be brought to a selectable process temperature by means of a heat- transmitting liquid, such as a thermal oil, flowing through said part.

[0117] The bottom part of the mold may be movable between an introducing position and a pressing position. For this example, at least one top part of the mold is provided at the introducing position and at least one different top part of the mold is provided at the pressing position.

* * *

[0118] It is noted at this point that the invention is not limited to the embodiments as described; they are rather to be understood as being examples. Modifications and amendments of individual features will be familiar to the person skilled in the art.

[0119] The terms "approximately," "about," "substantially", and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0120] The terms "coupled," "connected," etc. mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g. permanent) or moveable (e.g. removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0121] References to the positions of elements (e.g. "top," "bottom," "above," "below," etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0122] The construction and arrangement of the elements of the panels, molded bodies, tooling, etc. as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g.

variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited.

Elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied.

[0123] Additionally, the word "exemplary" is used to mean serving as an example, instance, or illustration. Any embodiment or design described as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments or designs (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). Rather, use of the word "exemplary" is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

[0124] Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. Any element (e.g. panel, molded body, tooling part, etc.) disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

[0125] According to exemplary and alternative embodiments, the methods and systems can be used to produce a wide variety of component forms and provide a wide variety of effects, enhanced strength/material properties (e.g. by material selection, fiber selection/orientation, etc.), reduced weight/mass properties (e.g. by forming with composite or layered material, with voids, etc.), visual, decorative effects (e.g. color, color gradations, differing or multi-color

fibers/additives, variations in surface effect, translucence, simulated stitching, simulated effects, etc.), environmental-friendly composition (e.g. use of scrap and/or recycled material s/fibers), alternative geometries/shapes (e.g. with strengthening/reinforcement such as with fiber), cost (e.g. using combinations of bulk and/or high performance materials selectively),

function/performance (e.g. using material s/fibers and fiber orientation to enhance functionality such as strength, cycle life, resilience, stain/wear resistance, etc.), etc. by variations of the constituents of the component formed by the system and method. According to any of the embodiments, layers or materials can be formed as or on a substrate or base. As indicated in the FIGURES, any of a wide variety of components can be formed, including but not limited to a wide variety of automotive interior components and assemblies, such as instrument panels, consoles, door panels, trim, inserts, decorative elements, lighting, functional modules, containers, and covers, and various other modules/components of such components and assemblies.

[0126] It is noted at this point that the invention is not to be limited to the exemplary

embodiments depicted in the flow charts and figures but rather yields from a synopsis of all the features disclosed together. Modifications and amendments will be familiar to the person skilled in the art.

[0127] The embodiments disclosed provide components for vehicles and methods of forming the components. Besides those embodiments depicted in the figures and described in the above description, other embodiments of the present invention are also contemplated; any single feature of one embodiment of the present invention may be used in any other embodiment of the present invention. Given the disclosure of the present invention, one versed in the art would appreciate that there may be other embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present invention within the scope and spirit of the present invention are to be included as further embodiments of the present invention.

[0128] It is important to note that the construction and arrangement of the elements of the inventive concepts and inventions as described in this application and as shown in the figures above is illustrative only. Although some embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible without materially departing from the novel teachings and advantages of the subject matter recited. Accordingly, all such

modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions.

[0129] It is important to note that the system and method of the present inventions can comprise conventional technology (e.g. as implemented in present configuration) or any other applicable technology (present or future) that has the capability to perform the functions and

processes/operations indicated in the FIGURES. All such technology is considered to be within the scope of the present inventions and application.