CROSS REFERENCE TO RELATED APPLICATION

[0002] The present application claims priority from and the benefit of U.S. Provisional Patent Application Serial No. 62/311 ,221 filed March 21, 2016 entitled "Vehicle Interior Component." The entirety of this application is hereby incorporated herein by reference in its entirety.

BACKGROUND

[0003] Vehicle interior components may comprise trim parts which are provided throughout the interior of a typical passenger vehicle. Interior components provide many of the visible surfaces directly facing and defining the interior of the vehicle; the look and feel of the vehicle interior is influenced by visible features of the interior components. Interior components may cover, conceal and protect functional components within the vehicle such as within the doors, behind the dashboard, at the center console, etc. Stitching (and seams) may be applied to the surfaces of components visible in the interior of a vehicle; stitching indicates handcrafted detail and signifies product quality (e.g. combination with visible cover materials and surfaces).

[0004] It would be advantageous to provide an improved interior component for a vehicle in which a variety of different materials, colors and/or patterns would be available for selection and/or combination. It would also be advantageous to provide a vehicle interior component indicating handcrafted details (e.g. seam/stitching) visible on surfaces and trim. It would be advantageous to provide for manufacturing of vehicle interior components having decorative seam/stitching between two materials. It would further be advantageous to provide for a method of forming decorative seams are available for selection by a vehicle manufacturer or consumer. It would be advantageous to provide for methods of forming in a reliable and cost-effective manner a decorative seam to provide a visible appearance indicating to handcrafted detail.

[0005] The present invention relates to a trim component for a vehicle interior. The trim component may comprise a substrate providing a structure, a cover comprising a skin and a support layer coupled to the skin and a core layer configured to attach the cover to the substrate. The cover may comprise stitching extending through the skin and the support layer and a sealant coupled to the support layer at the stitching. The skin may comprise a thermoplastic material provided in a generally uniform thickness less than 0.7 mm. The support layer may be provided in a thickness in a range between 1 mm and 4 mm. The core layer may comprise a foam layer; the foam layer may be formed from a foam material applied as a liquid and may be configured to attach the cover to the substrate, the foam layer may comprise a foam material provided in a thickness in a range between 3 and 15 mm. The core layer may comprise a foam material provided to solidify to attach the cover to the substrate. The support layer may have a density between 3 and 7 pounds per cubic foot; the support layer may be configured to at least partially prevent deformation of the skin when force is applied to the cover; deformation may comprise at least one of (a) stretching and/or (b) elongating. The substrate may comprise a fiber panel and a resin structure providing a border formed about at least a portion of a periphery of the fiber panel. The substrate may comprise a fiber panel and a resin structure configured to reinforce the fiber panel in a gap in the fiber panel. The sealant may comprise at least one of (a) a thermoset material, (b) polyurethane, (c) reactive polyurethane, (d) an adhesive and/or (e) a hot melt polyurethane reactive adhesive.

[0006] The present invention also relates to a trim component for a vehicle interior prepared by a process using a mold. The trim component comprises providing a skin; applying a support layer to the skin, stitching a thread to the skin and the support layer, applying a sealant to the support layer to form a cover comprising the skin, the support layer and the thread; providing the cover in the mold; providing a substrate in the mold; and injecting a thermoset material between the cover and the substrate. The thermoset material may attach the cover and the substrate. The cover may comprise skin of a generally uniform thickness of less than 0.7 mm; the thermoset material may comprise a foam material; the process may comprise the step of the foam material solidifying to attach the cover to the substrate. The skin may comprise a thermoplastic olefin material. The support layer may comprise a foam comprising polypropylene and polyethylene with a density between 3 and 7 pounds per cubic foot and a thickness in a range between 1 and 4 mm. The substrate may comprise at least one of (a) fiber panel and a resin structure providing a border formed about at least a portion of a periphery of the fiber panel, and (b) a fiber panel and a resin structure configured to reinforce the fiber panel in a gap in the fiber panel.

[0007] The present invention further relates to a method using a mold for forming a trim component for a vehicle interior. The method comprises providing a skin as a sheet made of a thermoplastic material having a substantially uniform thickness less than 0.7 mm; applying a support layer to the skin; stitching a thread to the skin and the support layer, applying a sealant to the support layer to form a cover comprising the skin, the support layer and the thread; providing the cover in the mold; providing a substrate in the moid; injecting a thermoset material between the cover and the substrate; and solidifying the thermoset material to form a core layer to attach the cover to the substrate. The thermoset material may comprise a foam material; the core layer may comprise a foam layer; solidifying the foam material may comprise at least one of (a) hardening and (b) curing. Applying the support layer to the skin may comprise laminating the support layer to the skin. The method may comprise providing a gap between the cover and the substrate; the thermoset material may be injected to fill the gap to form the core layer. The method may comprise applying a resin border to a peripher' of a fiber panel to form the substrate. The method may comprise applying a resin structure to a gap in a fiber panel the substrate.

FIGURES

[0008] FIGURE 1 A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0009] FIGURE IB is a schematic perspective cut-away view of a vehicle showing a vehicle interior according to an exemplary embodiment.

[0010] FIGURE 1C is a schematic perspective view of a portion of a front seating area of a vehicle interior according to an exemplary embodiment.

[0011] FIGURE 2A is a schematic perspective detail view of vehicle interior components according to an exemplary embodiment.

[0012] FIGURE 2B is a schematic perspective detail view of vehicle interior components according to an exemplary embodiment.

[0013] FIGURE 3 A is a schematic cross-section view of a cover for a vehicle interior component comprising a skin and a support layer according to an exemplary embodiment.

[0014] FIGURE 3B is a schematic partial cross-section view of a cover according to an exempl ary embodiment.

[0015] FIGURE 3C is a schematic partial cross-section view of a cover with thread stitched through the skin and the support layer according to an exemplary embodiment.

[0016] FIGURE 3D is a schematic partial cross-section view of a cover with adhesive applied along the support layer according to an exemplary embodiment.

[0017] FIGURE 3E is a schematic partial cross-section view of the cover with bi-laminated sealant applied along the support layer according to an exemplary embodiment. [0018] FIGURE 4A is a schematic cross-section view of a mold shown in an open position with a cover and a substrate positioned between top and bottom parts of the moid according to an exemplar}' embodiment.

[0019] FIGURE 4B is a schematic cross-section view of a mold shown in an open position with a cover positioned along a bottom part of the mold and a substrate positioned along a top part of the mold according to an exemplar}' embodiment.

[0020] FIGLIRE 4C is a schematic cross-section view of a mold shown in a closed position with a gap between the cover and the substrate according to an exemplary embodiment,

[0021] FIGURE 4D is a fourth schematic cross-section view of a mold shown in a closed position with a foam substance being introduced into the gap between the cover layer and the substrate according to an exemplar}' embodiment.

[0022] FIGURE 4E is a schematic cross-section view of a mold shown in a closed position with the gap between the cover and the substrate filled with a foam substance according to an exemplaiy embodiment.

[0023] FIGLIRE 4F is a schematic cross-section view of a mold shown in an open position with a vehicle interior component formed according to an exemplary embodiment.

DESCRIPTION

[0024] As shown schematically in FIGURES I A, IB and 1C, a vehicle V is shown including an interior I with instrument panel IP and floor console FC; vehicle also provides doors D and seats ST, According to an exemplary embodiment as shown schematically in FIGURES IB and 1 C, interior components of the vehicle V such as instrument panel IP, floor console FC, doors D, and seats ST may include trim components made with thermoplastic parts (e.g. foamed thermoplastic parts having a cover with seam/stitching S). Interior trim components may provide visible surfaces in the vehicle,

[0025] As shown schematically in FIGURES 2 A and 2B, according to an exemplary

embodiment, seam S may be provided on a trim component to improve structure, rigidity and visual appearance. According to exemplary embodiments shown schematically in FIGURES 2A and 2B, vehicle trim components may be provided in a form to provide cushioning at various sections; the visual characteristics of the trim component (e.g. color, form, etc.) as well as texture or feel may be provided by selected materials (e.g. leather, PVC, etc.). As shown schematically in FIGURES 2A and 2B, the trim component may display stitches S to provide an intended visual effect,

[0026] As shown schematically in FIGURE 3A, a bi-laminate sheet or cover 10 (e.g. to form the top section of a vehicle trim panel) is shown according to an exemplary embodiment. As shown schematically in FIGURE 3 A, cover 10 according to an exemplary embodiment may have a multi-layered structure comprising an exterior covering or skin 22 and an internal backing or support layer 20. According to exemplary embodiments, the covering or skin 22 (e.g. a surface that the occupants of the vehicle can see and touch) may be a flexible layer of material (e.g. a skin of a type made of a relatively soft or flexible material such as polymeri c material (e.g. a thermoplastic olefin (TPO), polyurethane, polyvinylchloride (PVC))). According to an exemplary embodiment, skin 22 may be made of a variety of materials (e.g. fabric, textiles, leather, composite materials, layered material, composite materials such as layer of leather applied to a polymeric material layer, etc.). Skin 22 may have a thickness of between approximately 0.1 and 2.0 mm, and most preferably a substantially uniform thickness of less than 0.7 mm. As shown schematically in FIGURE 3A, skin 22 may have a design (e.g. size, shape and configuration) adapted or configured to provide a stmcture component formed with a rigid support layer 20.

[0027] According to exemplary embodiments, skin 22 may be manufactured or produced by a conventional process; according to an exemplary embodiment, the skin 22 (e.g. a TPO sheet) may be thermoformed (e.g. vacuum formed, pressure formed, etc.) and trimmed to a desired shape or configuration. In a vacuum molding process, a pre-cut or formed sheet of polymeric material may be provided in a mold and heated to soften the material; a vacuum may be applied to the mold, which draws the softened polymeric material toward walls of the mold; the polymeric material then cools and maintains a shape defined by the mold walls, the formed sheet may be trimmed for a desired size.

[0028] According to an exemplar}- embodiment, skin 22 may also be formed by a slush molding process; thermoplastic material in a liquid or powdered form may be introduced into a temperature-controlled mold to form a viscous skin adjacent to the mold walls; once the skin is formed, the excess material may be removed from the mold and the skin is allowed to cure and cool, after which the skin may be removed from the moid.

[0029] According to an exemplar}' embodiment, skin 22 may further be formed in an injection molding process, an extrusion process, a casting process (e.g. gravity casting) or any other suitable processes for forming a polymeric skin. According to an exemplary embodiment, the skin may be made of a polymeric material and have a thickness between approximately 0.1 and 2.0 mm, and most preferably a generally uniform thickness of less than 0.7 mm.

[0030] As shown schematically in FIGURE 3 A, a bi-laminate cover 10 is shown for a vehicle interior component according to an exemplary embodiment. As shown schematically in FIGURE 3 A, cover 10 may comprise a support layer 20 applied or coupled (e.g. bonded, fused, adhered, fastened, attached, etc.) to skin 22, Support layer 20 may be made from a compressible material, such as for example, a polymeric material such as a foam material (e.g. urethane foam, closed cell foam, open cell foam, etc.). Support layer 20 may have a density between 3 and 7 pounds per cubic foot and a thickness in a range between 1 and 4 mm. According to exemplary embodiments, the support layer 20 may be applied to skin 22 through a laminating process using heat and pressure which bonds support layer 20 to skin 22 to provide a bi-laminate cover 10 as shown schematically in FIGURES 3A and 4A.

[0031] As shown schematically in FIGURES 3 A and 3B, skin 22 may serve as a decorative cover for the finished interior component (e.g. visible for a passenger in the passenger compartment of a vehicle V); behind skin 22 the support/backing layer provides a firmer, more rigid structure or backing (e.g. made of compressible material). Support layer 20 may prevent deformation of skin 22 from stretching or elongating when force is applied to the cover 10 and may additionally be useful to facilitate its handli ng during manufacture of the interior component. For example, in using a bi-laminated cover 10, it may be more readily transferred to a mold without the exterior skin tearing or deforming. In addition, support layer 20 may further prevent the skin 22 from wrinkling or bunching when stitching is applied to the skin. [0032] As shown schematically in FIGURE 3C, a thread may be stitched to the skin 22 and the support layer 20. According to an exemplar}' embodiment the stitching S may be applied by any technique (e.g. hand sewn, machine sewn, etc.); the stitching S (e.g. thread) may be made from any conventional material (e.g. fabric, textile (e.g. cotton), polymer (e.g. nylon, etc) or other materials (including fiber/thread materials that may melt or may not melt/liquefy upon application of heat). As shown schematically in FIGURE 3C, applying stitching S to skin 22 and support layer 20 is intended to create a visible stitch appearance (e.g. thread through recess) on the cover 10 of a vehicle interior component.

[0033] As shown schematically in FIGURE 3D, an adhesive (A) such as glue may be applied to support layer 20 of the bi-laminate cover 10 across stitching S. According to an exemplary embodiment as shown in FIGURE 3D, adhesive (A) may be applied in order to seal holes formed in the skin 22 and the bi-laminate foam adhesive during the stitching operation. As shown schematically (compare to FIGURE 3C), adhesive (A) may applied to support layer 20 on the opposite side of skin 22 and across stitch S (e.g. where holes may be formed in the skin 22, cover 20 and bi-laminated foam layer). According to an exemplary embodiment, the adhesive (A) may be any of a variety of web, spray and/or liquid adhesives and may be applied in a process using an applicator such as a glue or spray gun (e.g. for glue material) and/or application of a segment of adhesive tape (e.g. for tape material).

[0034] As shown schematically in FIGURE 3E, a more preferred stitch sealing process for a cover is shown which includes application of a foam sealant FS to support layer 20 across stitching S. According to an exemplar}- embodiment, foam sealant FS may be at least one of (a) a thermoset material, (b) polyurethane, (c) reactive polyurethane, (d) an adhesive and/or (e) a hot melt polyurethane reactive (HMPUR) adhesive which has been shown to exhibit longer open times when exposed to air/curing. An additional advantage of HMPUR adhesives is that they demonstrate excellent temperature and environmental resistance when cured which can resists melting better than thermoplastic polymers,

[0035] As shown schematically in FIGURE 3E, foam sealant FS may be applied along support layer 20 on the opposite side of skin 22 and in an area across stitch S (e.g. where holes may be formed in the skin 22, cover 20 and bi-laminated foam layer). According to the embodiment shown in FIGURE 3E, foam sealant FS may be applied as a thin film across support layer 20 by a hot melt process using a extruder die head (e.g. Apex Precision Coat Slot Die Applicator) which uses air to control the spread of the film. Such a process may lay down the film in a uniform thickness and better controls the width of the film on support layer 20 over processes where glue is sprayed across the support layer 20. Such a process has further been found to be an improvement over spray glue adhesives in that it better encapsulates the threads, as opposed to simply plugging the holes caused by stitching S. Such encapsulation resists pulling or compression of the stitching S when a cover is bound to a backing substrate. In addition, use of HMPUR adhesives as a foam sealant FS have additionally demonstrated better stabilizing properties with foams used to bind the cover 10 to a substrate,

[0036] Referring to FIGURES 4A to 4F, a method for manufacturing a vehicle interior trim component 70 from the bi-iaminate cover 10 in a moid apparatus M is shown according to an exemplar}' embodiment. As shown schematically in FIGURE 4A, mold M may include a mold bottom section MB and mold top section MT; bi-laminate cover (e.g. the skin 22 and support layer 20 with stitch S) may be provided in mold M between the top MT and bottom MB sections. As shown schematically in FIGURE 4A, a base layer or substrate 30 may also be provided in the mold to be formed to the bi-laminate cover 10 to produce trim component 70. See FIGURES 4A through 4F.

[0037] According to an exemplary embodiment, the substrate 30 may be made of any suitable material, including any natural fiber, and/or any polymer (e.g. polypropylene, polyethylene, copolymers, compressed fibers, TPO, filled plastics, polycarbonate, ABS blends, ABS, or any of a variety of other materials). Substrate 30 may be formed in any shape, size, and configuration, and may include other features (e.g. apertures for door locks and handles, molded-in designs, etc.). Substrate 30 may be formed by any methods, including injection molding, thermoforming, etc. Substrate 30 (e.g. fiber panel) may be manufactured from material used or available for use in manufacture of components for vehicle interiors or other components.

[0038] According to exemplary embodiments, substrate 30 may be prepared by a process including disposing a fiber panel onto a first surface of a mold cavity and compressing the fiber panel between the first surface and a second surface of the mold cavity to form the fiber panel into a desired shape. Resin may be injected into the moid cavity to fill a void between the first surface and the second surface adjacent to the fiber panel. According to an exemplary embodiment, the void may extend about at least a portion of the periphery of the fiber panel. The injected resin may fill the void and establish a resin border about at least a portion of the periphery of the fiber panel as the resin hardens and/or cures. Due to the dimensional accuracy of the mold cavity, each edge of the resultant substrate 30 may correspond to the desired dimensions. The process of trimming the edges of substrate 30 after formation may be obviated, decreasing the duration of the manufacturing process and reducing the quantity of offal.

[0039] Resin may also be injected into at least one secondary void between the fiber panel and the second surface of the mold to form structural reinforcement components of a vehicle trim component/substrate 30. According to exemplar}- embodiments, the substrate 30 may be comprised of a fiber panel and a resin structure configured to reinforce the fiber panel in a gap in the panel. For example, a mold cavity may include multiple secondary voids configured to establish ribs along a surface of the fiber panel. The ribs may be contigured to reinforce the fiber panel for providing a stronger component and/or reduce the weight of the component by facilitating a reduction in fiber panel thickness. Because the fiber panel and the resin structural components may be formed within a single mold cavity, the process of transferri ng the part between a compression mold and an injection mold is obviated, reducing the duration of the manufacturing process. Employing a single moid reduces design and manufacturing costs, as compared to producing a first moid for the compression forming process and a second mold for the injection molding process.

[0040] According to exemplary embodiments, substrate 30 may be comprised of a combination of structural fibers and thermoplastic resin. The structural fibers may include natural fibers (e.g. hemp, wood, flax, kenaf and sisal) and/or synthetic fibers (e.g. glass fibers, carbon fibers and polymeric fibers). The thermoplastic resin may include polypropylene (PP), acrylonitrile butadiene styrene (ABS) and/or polycarbonate (PC) binders. According to an exemplar}' embodiment, a fiber panel may be constaicted from about 50 percent natural fibers and about 50 percent polypropylene. To facilitate compression forming, the fiber panel may be heated (e.g. to about 200 degrees Celsius) to induce the thermoplastic resin to liquefy. The fiber panel may then disposed onto a first surface of a cavity and compressed between the first surface and a second surface as a second moid element is driven toward the first mold element in the direction to the second moid element. As the fiber panel cools within the mold assembly, the thermoplastic solidifies, establishing a rigid composite panel that conforms to the shape of the moid cavity.

[0041] According to exemplary embodiments, substrate 30 may be comprised a combination of structural fibers and a thermoset resin. The structural fibers may include natural fibers (e.g. hemp, wood, flax, kenaf and sisal) and/or synthetic fibers (e.g. glass fibers, carbon fibers and polymeric fibers). The thermoset resin may include epoxy resin, polyimide resin, polyester resin and/or vinyl ester resin. To facilitate compression forming, the fiber panel/base layer 30 may be disposed onto a first surface of a molding cavity and compressed between the first surface and the second surface as the second mold element is driven toward the first mold element. During the compression process the panel is heated (e.g. via a heated mold assembly) causing the thermoset resin to cure. A rigid composite panel that conforms to the shape of the mold cavity is formed.

[0042] As shown schematically in FIGURES 4A and 4B, substrate 30 may be provided as a preformed layer in the mold M, such as for example adjacent the mold top section MT. According to the exemplary embodiment shown in FIGURES 4A and 4B, a stitched bi-laminate cover layer 10 (as shown schematically in FIGURES 3D and 3E) may be provided in the mold, such as for example along the mold bottom section MB. As shown schematically, in FIGURES 4A and 4B, the pre-formed bi-laminate cover 10 may comprise the skin 22 with the support layer 20 and the stitching S covered by foam sealant FS (or another type of adhesive (A)),

[0043] As shown schematically in FIGURE 4C, at a closed state of the mold M, the mold top section MT and the moid bottom section MB may be movable to each other and define a moid cavity C. As shown schematically in FIGURE 4C, in the closed state of the moid, moid cavity C is defined as a gap between the bi-laminate cover 10 and the substrate 30 (see FIGURES 4E and 4F).

[0044] As shown schematically in FIGURES 4D and 4E, thermoplastic material 40, such as a thermoset foam material (e.g. thermoplastic olefin (TPO), polyurethane or polypropylene polymers) is shown as being injected (e.g. through parts not shown in mold apparatus M in FIGURES 4 A to 4F) into the gap of mold cavity C according to an exemplary embodiment. Foam material 40 may solidify to attach the cover (and specifically the support layer 20) to the substrate 30. According to an exemplary embodiment as shown schematically in FIGURES 4D and 4E, thermoset material (e.g. foam material) 40 is shown as being introduced into the mold cavity C and may fill the gap between the pre-formed substrate 30 and the pre-formed bi- laminate cover 10. Foam material 40 can solidify and cool to comprise a core layer configured to attach the cover to the substrate 30, Thus, the core layer may comprise a foam layer formed from a thermoset foam material applied as a liquid and configured to attach the cover to the substrate 30 upon the foam material solidifying. According to exemplary embodiments, the foam material may solidify by hardening or curing. According to exemplary embodiments, the foam layer may be comprised of foam material provided in a thickness in a range between 3 and 15 mm.

[0045] According to exemplar}' embodiments, a seal formed by foam sealant FS (or glue) at stitch S prevents the foam material 40 from exiting through cover 10. Thus, foam sealant FS applied previously to support layer side 20 of the bi-laminate cover 10 may block the holes formed during stitching to prevent the foam material 40 from migrating through the holes (e.g. holes formed during stitching) towards skin 22. [0046] As shown schematically in FIGURE 4F, after the forming process has completed, the mold top section MT and the mold bottom section MB of the mold apparatus M may be separated and a vehicle trim component 70 for a vehicle interior may be removed from the mold M. As shown schematically in FIGURE 4F, the trim component is comprised of the skin 22, support layer 20, core layer 40 (comprised of the foam layer) and substrate 30, with the core layer being configured to attach the cover to substrate 30 and substrate 30 providing a backing or support for the trim component.

[0047] 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 shown schematically in the figures are 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.

[0048] 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.