COMPONENT FOR VEHICLE INTERIOR

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application claims priority to and incorporates by reference in full the following patent application: U.S. Provisional Patent Application No. 63/210,476 titled “VEHICLE INTERIOR COMPONENT” filed June 14, 2021.

[0002] The present application is related to and incorporates by reference in full the following patent applications: (a) U.S. Patent Application No. 13/595,741 titled “SYSTEM AND METHOD FOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSION FORMING AND INJECTION MOLDING” filed August 27, 2012 (now U.S. Patent No. 8,939,745); (b) U.S. Patent Application No. 13/846,529 titled “SYSTEM AND METHOD FOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSION FORMING AND INJECTION MOLDING” filed March 18, 2013 (now U.S. Patent No. 9,149,961); (c) U.S. Patent Application No.

14/808,938 titled “VEHICLE TRIM COMPONENT” filed July 24, 2015 (now U.S. Patent No. 10,118,325); (d) U.S. Patent Application No. 15/459,894 titled “TRIM COMPONENT FOR VEHICLE INTERIOR” filed March 15, 2017 (now U.S. Patent No. 10,464,280); (e) U.S. Patent Application No. 15/995,621 titled “VEHICLE TRIM COMPONENT” filed June 1, 2018 (now U.S. Patent No. 10,507,609); (f) U.S. Patent Application No. 16/536,395 titled “VEHICLE INTERIOR COMPONENT” filed August 9, 2019 (now U.S. Patent No. 10,507,628); (g) U.S. Patent Application No. 16/654,620 titled “VEHICLE TRIM COMPONENT” filed October 16, 2019 (now U.S. Patent No. 10,807,283); (h) U.S. Patent Application No. 16/671,793 titled “VEHICLE TRIM COMPONENT” filed November 1, 2019 (now U.S. Patent No. 10,807,284); (i) U.S. Patent Application No. 17/021,335 titled “VEHICLE TRIM COMPONENT” filed September 15, 2020; (j) U.S. Patent Application No. 14/424,671 titled “SYSTEM AND METHOD FOR MOUNTING AN AIRBAG CHUTE ASSEMBLY WITHIN A VEHICLE TRIM COMPONENT” filed February 27, 2015 (now U.S. Patent No. 9,481,337); (k) U.S. Patent Application No. 15/331,578 titled “TRIM COMPONENT FOR VEHICLE INTERIOR” filed October 21, 2016 (now U.S. Patent No. 10,093,268); (1) U.S. Patent Application No. 16/220,863 titled “VEHICLE INTERIOR COMPONENT” filed December 14, 2018 (now U.S. Patent No. 10,926,732); (m) U.S. Patent Application No. 16/685,658 titled “VEHICLE TRIM COMPONENT” filed November 15, 2019 (now U.S. Patent No. 10,981,532); (n) U.S. Patent Application No. 17/006,213 titled “VEHICLE TRIM COMPONENT” filed August 28, 2020 (now U.S. Patent No. 11,325,290).

FIELD

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

[0004] The present invention also relates to a component for a vehicle interior configured to comprise an assembly/module configured to deploy an airbag into the vehicle interior.

BACKGROUND

[0005] It is known to provide an airbag module to deploy an airbag into a vehicle interior; it is also known to install an airbag module behind or within a trim component such as an instrument panel in a vehicle interior.

[0006] It would be advantageous to provide an improved component for a vehicle interior configured to comprise an assembly/module configured to deploy an airbag into the vehicle interior.

[0007] It would also be advantageous to provide the improved component comprising a composite structure with a structural substrate and a structure configured for an airbag assembly.

[0008] It would also be advantageous to provide the improved component comprising a composite structure with a structural substrate such as a panel and a structure such as a resin feature configured for an airbag assembly.

[0009] It would also be advantageous to provide the improved component comprising a composite structure with a structural substrate such as a compression-formed fiber panel and a structure such as a molded resin feature configured for an airbag assembly to fit within a pocket/enclosure.

SUMMARY

[0010] The present invention relates to a component for a vehicle interior configured for deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a pocket, and an airbag assembly. The pocket may be configured to support the airbag assembly. The panel may comprise an aperture configured to provide access to the pocket for assembly of the airbag assembly to the pocket. The airbag assembly may comprise an airbag component and an inflator; the inflator may be configured to deploy the airbag component. The pocket may be integrally formed with the panel. The pocket may be injection molded onto the panel. The panel may comprise a fiber panel and the pocket may comprise a thermoplastic molding. The pocket may be coupled to a rear surface of the fiber panel and to an edge of the fiber panel at the aperture. The pocket may extend into the aperture and along a rear surface of the fiber panel. The component may comprise a rib configured to couple the pocket to the fiber panel. The pocket may comprise a rib formed on a rear side of the fiber panel. The rib may comprise a resin material. The component may comprise an airbag door configured to establish an opening for deployment of the airbag.

The airbag door may comprise a tab configured to assemble the airbag door to the pocket.

The tab may be configured to secure the pocket between the airbag door and the fiber panel. The fiber panel may comprise a compression-formed fiber panel. The fiber panel may comprise a plurality of fibers and a resin configured to bind the fibers. The component may comprise an airbag door configured to establish an opening for deployment of the airbag.

The airbag door may be coupled to the pocket. The airbag door may comprise a front surface in planar alignment with a surface of the structural substrate. The airbag door may comprise a front surface; the front surface of the airbag door and a front surface of the structural substrate are configured to provide a smooth exterior surface for the component. The airbag door may comprise a front surface; the front surface of the airbag door and a front surface of the structural substrate are configured to provide a continuous surface. The airbag door may comprise (a) a tab configured for insertion into a slot in the pocket and (b) a retainer configured to snap onto the pocket. The pocket may be configured for assembly to a cross car beam in the vehicle. The pocket may be fastened between the airbag assembly and a cross-car beam. The structural substrate and the airbag assembly may be configured to be attached to a beam structure at the pocket. The component may comprise a cover configured to cover the structural substrate; the cover may be comprised of at least one of (a) woven fabric, (b) non-woven fabric, (c) an applique, vinyl, (e) foam, (f) foil, (g) leather; (h) coverstock. The component may comprise at least one of (a) a component; (b) an instrument panel; (c) a door panel.

[0011] The present invention relates to a component for a vehicle interior configured for deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a pocket, and an airbag assembly. The pocket may be configured to support the airbag assembly. The airbag assembly may be housed between the panel and the pocket. The pocket may comprise an aperture configured to provide access to the pocket for assembly of the airbag assembly. The panel may be configured to cover the aperture of the pocket. The pocket may be configured to be welded to the panel after assembly of the airbag assembly to the pocket.

[0012] The present invention relates to a method of producing an instrument panel assembly configured for an airbag actuated by an inflator comprising the steps of forming a structural substrate for the instrument panel, coupling an inflator to an airbag component to form an airbag assembly, coupling the airbag assembly to the structural substrate, and coupling an airbag door and the structural substrate. The airbag assembly may be housed between the structural substrate and the airbag door. The structural substrate may comprise an aperture configured to provide access to a pocket for assembly of the airbag assembly to the structural substrate. The structural substrate may comprise the pocket for the airbag assembly. The step of forming the structural substrate may comprise integrally forming the pocket with the structural substrate.

[0013] The present invention relates to a method of manufacturing a component for a vehicle interior configured for deployment of an airbag into the vehicle interior and comprising a fiber panel compression formed in a mold cavity comprising forming an aperture in the fiber panel, heating the fiber panel, placing the fiber panel into the mold cavity, compressing the fiber panel in the mold cavity to form a compression formed component providing a structural substrate having a shape, injecting resin into the mold cavity with the structural substrate to form a pocket, assembling an airbag assembly to the pocket, and assembling an airbag door to the pocket. The step of injecting resin into the mold cavity with the structural substrate to form a pocket may comprise coupling the pocket to a rear surface of the fiber panel and to an edge of the fiber panel at the aperture. The step of assembling an airbag door to the pocket may comprise inserting a tab of the airbag door into a slot in the pocket and snapping a retainer of the airbag door to the pocket. The method may comprise the step of injecting resin into the mold cavity to form a rib extending across an interface between the fiber panel and the pocket. The step of assembling an airbag assembly to the pocket may comprise fastening the pocket between the airbag assembly and a cross-car beam. The step of placing the fiber panel into the mold cavity may comprise placing a cover in the mold cavity and placing the fiber panel on the cover; the cover may be comprised of at least one of

(a) woven fabric, (b) non-woven fabric, (c) an applique, vinyl, (e) foam, (f) foil, (g) leather. [0014] The present invention relates to a component for a vehicle interior configured for deployment of an airbag into the vehicle interior and comprising a fiber panel compression formed in a mold cavity prepared by a process comprising the steps of forming an aperture in the fiber panel, heating the fiber panel, placing the fiber panel into the mold cavity, compressing the fiber panel in the mold cavity to form a compression formed component providing a structural substrate having a shape, injecting resin into the mold cavity with the structural substrate to form a pocket, assembling an airbag assembly to the pocket, and assembling an airbag door to the pocket. The process may comprise the step of injecting resin into the mold cavity to form a rib extending across an interface between the fiber panel and the pocket. The step of assembling an airbag assembly to the pocket may comprise fastening the pocket between the airbag assembly and a cross-car beam.

[0015] The present invention relates to a component for an interior of a vehicle configured to be attached to a beam structure in the interior and to contain an airbag assembly to deploy an airbag into the interior comprising a structural substrate comprising a panel with an opening for the airbag assembly. The structural substrate and the airbag assembly may be configured to be attached to the beam structure. A pocket for the airbag assembly may be provided in the opening of the panel. The panel may comprise a compressed fiber panel. The structural substrate may comprise a plastic structure formed on the compressed fiber panel of the structural substrate. The plastic structure may comprise at least one of (a) an injection- molded resin material; (b) a set of ribs; (c) a border for the opening. The plastic structure may comprise a compartment for the airbag assembly. The plastic structure may comprise a base structure and a compartment comprising an enclosure structure to form the pocket for the airbag assembly; the compartment may be at least one of (a) bonded to the base structure;

(b) attached to the base structure. The plastic structure may be configured to attach the structural substrate and the airbag assembly to the beam structure.

[0016] The present invention relates to a component for a vehicle interior configured to support an airbag assembly providing an airbag configured to be deployed through an opening comprising a panel providing a structural substrate with an opening, and a structure provided on the panel. The structure on the panel may comprise a resin material. The panel may comprise a compression-formed fiber panel. The structure may be configured to support the airbag assembly within the opening of the panel. The structure provided on the panel may comprise an injection-molded structure formed from the resin material. The component may comprise a composite structure comprising the structural substrate and the structure; the structure may be formed from resin. The airbag assembly within the opening of the panel may be configured to be mounted to a beam structure of the vehicle interior. The structure on the panel may comprise an enclosure to form a pocket for the airbag assembly. The component may comprise an airbag module comprising the airbag assembly; the airbag module may be mounted within the pocket. The structure may comprise at least one of (a) a frame and an enclosure to form the pocket; (b) a flange and an enclosure to form the pocket. The structure may comprise a border for the opening. The structure may comprise at least one of (a) a frame; (b) a grid; (c) a frame and an enclosure attached to the frame; (d) a frame and an enclosure bonded to the frame; (e) a reinforcement for the panel; (f) a set of ribs for the panel. The component may comprise a cover for the panel comprising a door configured to rotate upon deployment of the airbag to facilitate deployment of the airbag. The door may be configured to open as at least one flap from the structure opened adjacent to a recess. The component may comprise a support coupled to the panel and the structure; the support may be configured to secure the door to the panel during deployment of the airbag. The component may comprise an injection-molded resin feature configured to facilitate deployment of the airbag. The structure may be injection molded onto a side of the panel.

The component may be produced by a method comprising the steps of providing the panel in a mold, compressing the panel in the mold to form the compression-formed fiber panel, and injecting a resin into the mold on the compression-formed fiber panel to form the structure. The structure may be configured to support the airbag assembly and to direct the airbag toward the fiber panel during deployment of the airbag. The step of injecting resin into the mold may comprise forming a resin feature. The resin feature may comprise at least one of (a) an enclosure for the airbag assembly; (b) a set of ribs on the panel; (c) a dimensionally accurate border. The resin feature may comprise at least one of (a) a rib; (b) a ridge; (c) an enclosure to provide a pocket; attachment for a component; (e) a rib configured to reinforce the structural substrate; (f) a rib configured to support the structural substrate; (g) a rib configured to extend across an interface between the fiber panel and the molded feature to enhance the strength of the interface; (h) a resin border; (i) a resin border at the edge of the periphery of the structural substrate; (j) a connector; (k) a connector configured to facilitate coupling at least one of (1) a door frame or (2) an instrument panel or (3) a support structure within the vehicle interior. The resin feature may be configured to secure a door to the panel. The fiber panel and the resin feature may be configured to provide a substantially continuous structure. The resin feature may comprise at least one of (a) an ancillary component; (b) a rib; (c) a connector; a reinforcement for the structural substrate. The fiber panel may comprise structural fibers and a resin; the structural fibers comprise at least one of (a) natural fibers; (b) hemp; (c) wood; flax; (e) kenaf; (f) sisal; (g) synthetic fibers; (h) glass fibers; (i) carbon fibers; (j) polymeric fibers; the resin may comprise at least one of (a) thermoplastic resin; (b) polypropylene; (c) acrylonitrile butadiene styrene; polycarbonate; (e) thermoset resin; (f) epoxy resin; (g) polyimide resin; (h) polyester resin; (i) vinylester resin. The component may comprise an airbag module comprising the airbag assembly. The structure may comprise a flange. The structure may comprise a border for the opening. The component may comprise a cover to provide a surface on the compression-formed fiber panel. The compression-formed fiber panel may comprise a thickness along a periphery; the structure may comprise a border of the structural substrate along the thickness of the periphery of the compression-formed fiber panel; the periphery of the fiber panel may comprise an edge; the structure may be formed on the edge. The fiber panel may comprise a plurality of fibers and a resin configured to bind the fibers. The structure may be bonded to the compression-formed fiber panel. The structure may comprise at least one of (a) an injection- molded resin configured to reinforce the compression- formed fiber panel; (b) a molded feature providing an ancillary component. The structure may comprise at least one molded feature; the at least one molded feature may comprise at least one of (a) a rib; (b) a ridge; (c) a runner; (d) a molded feature configured to support the fiber panel. The component may comprise at least one of (a) a center console; (b) a floor console; (c) a door panel; an instrument panel; (e) a headliner; (f) an overhead console; (g) a sun visor.

[0017] The present invention relates to a component for a vehicle interior configured for installation of an airbag assembly comprising a fiber panel and a structure comprising a resin. The fiber panel may comprise a compression-formed panel. The compression-formed panel may comprise an opening providing a periphery. The compression-formed panel and structure comprise a structural substrate having a shape and a thickness along an edge. The structure may comprise a molded resin feature for the structural substrate. The structure may be formed at the periphery of the opening of the compression-formed panel. The structure may comprise an enclosure for a pocket for the airbag assembly. The component may be formed by a process comprising the steps of heating the fiber panel, placing the fiber panel into a mold cavity, compressing the fiber panel in the mold cavity to form the compression- formed panel comprising an edge along the periphery and to form a structural substrate having a shape and a thickness along the edge, and injecting resin into the mold cavity with the structural substrate. The shape of the structural substrate may be formed in the mold cavity. A border of the structural substrate may be formed along the thickness of the structural substrate by the resin injected into the mold cavity.

[0018] The present invention relates to a component for an interior of a vehicle configured to be attached to a beam structure in the interior and to contain an airbag assembly to deploy an airbag into the interior comprising a structural substrate comprising a panel with an opening for the airbag assembly. The structural substrate and the airbag assembly may be configured to be attached to the beam structure. A pocket for the airbag assembly may be provided in the opening of the panel. The panel may comprise a compressed fiber panel. The structural substrate may comprise a plastic structure. The plastic structure may be formed on the compressed fiber panel of the structural substrate. The plastic structure may comprise an injection- molded resin material. The plastic structure may comprise a set of ribs. The plastic structure may comprise a border for the opening. The plastic structure may comprise a compartment for the airbag assembly. The plastic structure may comprise a base structure and a compartment for the airbag assembly. The compartment may be bonded to the base structure. The compartment may be attached to the base structure. The compartment may comprise an enclosure structure to form the pocket for the airbag assembly. The plastic structure may be configured to attach the structural substrate and the airbag assembly to the beam structure in the interior. The component may comprise a door to enclose the airbag assembly within the structural substrate.

[0019] The present invention relates to a component for a vehicle interior configured to support an airbag assembly providing an airbag configured to be deployed through an opening comprising a panel providing a structural substrate with an opening, and a structure provided on the panel. The structure on the panel may comprise a resin material. The panel may comprise a compression-formed fiber panel. The structure may be configured to support the airbag assembly within the opening of the panel. The structure provided on the panel may comprise an injection-molded structure formed from the resin material. The structure provided on the panel may comprise an injection-molded structure formed from the resin material. The structure provided on the panel may be configured to be mounted to a beam structure of the vehicle interior. The airbag assembly within the opening of the panel may be configured to be mounted to a beam structure of the vehicle interior. The structure on the panel may comprise an enclosure to form a pocket for the airbag assembly. The airbag assembly may comprise an airbag assembly mounted within the pocket. The structure may be configured to reinforce the panel. The structure may comprise a frame. The structure may comprise a grid. The structure may comprise a frame and an enclosure to form the pocket. The structure may comprise a flange and an enclosure to form the pocket. The structure may comprise a frame and an enclosure attached to the frame. The structure may comprise a frame and an enclosure bonded to the frame. The structure may comprise a border for the opening. The structure may comprise a set of ribs for the panel. The component may comprise a cover for the panel comprising a door. The door may be configured to rotate upon deployment of the airbag to facilitate deployment of the airbag. The door may be configured to open as at least one flap from the structure opened adjacent to the recess configured to open upon deployment of the airbag. The door may be hinged to the structure and open at the feature. The component may comprise a support coupled to the panel and the structure; the support may be configured to secure the door to the panel during deployment of the airbag. The door may comprise a resin feature configured to secure the support to the door. The component may comprise an injection-molded resin feature configured to facilitate deployment of the airbag. The structure may be injection molded onto the side of the panel. The component may be produced by a method comprising the steps of providing the panel in a mold, compressing the panel in the mold to form the compression-formed fiber panel, and injecting a resin into the mold on the compression-formed fiber panel to form the structure. The structure may be configured to support the airbag assembly and to direct the airbag toward the fiber panel during deployment of the airbag. The step of injecting resin into the mold may comprise forming a resin feature. The resin feature may comprise an enclosure for the airbag assembly. The resin feature may comprise a set of ribs on the panel. The resin feature may comprise a dimensionally accurate border. The resin feature may comprise at least one of (a) a rib; (b) a ridge; (c) an enclosure to provide a pocket; (d) attachment for a component; (e) a rib configured to reinforce the structural substrate; (f) a rib configured to support the structural substrate; (g) a rib configured to extend across an interface between the fiber panel and the molded feature to enhance the strength of the interface; (h) a resin border; (i) a resin border at the edge of the periphery of the structural substrate; (j) a connector; (k) a connector configured to facilitate coupling at least one of (1) a door frame or (2) an instrument panel or (3) a support structure within the vehicle interior. The resin feature may be configured to reinforce the structural substrate. The resin feature may be configured to secure a door to the panel. The fiber panel and the resin feature may be configured to provide a substantially continuous structure. The resin feature may comprise at least one of (a) an ancillary component; (b) a rib; (c) a connector. The fiber panel may comprise structural fibers and a resin; the structural fibers comprise at least one of (a) natural fibers; (b) hemp;

(c) wood; (d) flax; (e) kenaf; (f) sisal; (g) synthetic fibers; (h) glass fibers; (i) carbon fibers;

(j) polymeric fibers; the resin may comprise at least one of (a) thermoplastic resin; (b) polypropylene; (c) acrylonitrile butadiene styrene; (d) polycarbonate; (e) thermoset resin; (f) epoxy resin; (g) polyimide resin; (h) polyester resin; (i) vinylester resin. The structure may comprise a flange. The structure may comprise a border for the opening. The structure may be configured to enhance the structural rigidity of the compression-formed component. The component may comprise a cover to provide a surface on the compression-formed fiber panel. The compression-formed fiber panel may comprise a thickness along a periphery.

The structure may comprise a border of the structural substrate along the thickness of the periphery of the compression-formed fiber panel. The periphery of the fiber panel may comprise an edge; the structure may be formed on the edge. The fiber panel may comprise a plurality of fibers and a resin configured to bind the fibers. The structure may be bonded to the compression-formed fiber panel. The structure may comprise at least one of (a) an injection- molded resin configured to reinforce the compression- formed fiber panel; (b) a molded feature providing an ancillary component. The structure may comprise at least one molded feature. The at least one molded feature may comprise a molded feature configured to support the fiber panel. The at least one molded feature may comprise at least one of (a) a rib; (b) a ridge; (c) a runner. The component may comprise a cover for the structural substrate. The component may comprise at least one of (a) a center console; (b) a floor console; (c) a door panel; (d) an instrument panel; (e) a headliner; (f) an overhead console;

(g) a sun visor.

[0020] The present invention relates to a component for a vehicle interior configured for installation of an airbag assembly comprising a fiber panel and a structure comprising a resin. The fiber panel may comprise a compression-formed panel. The compression-formed panel may comprise an opening providing a periphery. The compression-formed panel and structure may comprise a structural substrate having a shape and a thickness along an edge. The structure may comprise a molded resin feature for the structural substrate. The structure may be formed in the at least at the periphery of the opening of the compression-formed panel. The structure may comprise an enclosure for a pocket for the airbag assembly. The structure may be formed on the edge. The fiber panel may comprise a plurality of fibers and a resin configured to bind the fibers. The structure may comprise a feature providing an ancillary component; the feature may comprise a molded resin feature. The structure may comprise a feature for attachment of the enclosure for the pocket for the airbag assembly. The structure may be configured to accommodate at least one variation in the edge of the fiber panel. The structure may comprise a rib configured to reinforce the fiber panel. The structure may comprise a molded feature configured to support the fiber panel. The molded feature configured to support the fiber panel may comprise a rib. The rib may comprise at least one of (a) a ridge; (b) a runner. The molded feature may comprise the border coupled to at least a portion of a periphery of the fiber panel. The border of the structural substrate may comprise a resin border about a periphery of the fiber panel. The component may comprise a cover for the compression-formed component. The component may comprise a cover. The cover may comprise at least one of (a) cover stock; (b) a woven fabric; (c) a non-woven fabric; (d) an applique; (e) a vinyl layer; (f) a foam layer; (g) a foil layer; (h) a leather covering. The structure may be bonded to the compression-formed fiber panel. The structure may comprise an injection-molded resin configured to reinforce the compression-formed fiber panel. The structure may comprise a molded feature providing an ancillary component. The structure may comprise a dimensionally accurate border. The component may be formed by a process comprising the steps of heating the fiber panel, placing the fiber panel into a mold cavity, compressing the fiber panel in the mold cavity to form the compression-formed panel comprising an edge along the periphery and to form a structural substrate having a shape and a thickness along the edge, and injecting resin into the mold cavity with the structural substrate. The shape of the structural substrate may be formed in the mold cavity.

A border of the structural substrate may be formed along the thickness of the structural substrate by the resin injected into the mold cavity. A frame for the structural substrate may be formed by the resin injected into the mold cavity. The frame may be formed to extend across an interface between the structural substrate and the border. The compression-formed panel formed from the fiber panel may comprise variations at the edge along the periphery; the border of the structural substrate formed by injected resin may be configured to provide dimensional accuracy at the edge along the periphery. The step of injecting resin into the mold cavity with the structural substrate may comprise forming a frame from injected resin and forming the border from injected resin; the border formed from injected resin may be configured to provide dimensional accuracy along the edge of the structural substrate. The step of injecting resin into the mold cavity with the structural substrate may comprise forming a reinforcing element on the structural substrate. The step of injecting resin into the mold cavity with the structural substrate may comprise forming a resin feature in the at least one void of the structural substrate. The resin feature may comprise a reinforcing element configured to reinforce the structural substrate in the at least one void. The resin feature may be configured to provide a weakened zone in the structural substrate configured to facilitate separation of the reinforcing element from the structural substrate for deployment of an airbag. The resin feature may be formed along at least a portion of a first surface of the structural substrate and along at least a portion of a second surface of the structural substrate to couple the resin feature to the structural substrate. The structural substrate and the resin feature may be configured to provide a substantially continuous structure. The step of injecting resin into the mold cavity with the structural substrate may comprise at least one of: (a) the mold cavity providing dimensional accuracy for injected resin; (b) injecting resin into the at least one void; (c) injecting resin into a gap within the fiber panel; (d) injecting resin into a gap; (e) injecting resin to fill a gap to form a structure from resin; (f) injecting resin to form an element; (g) injecting resin to form a reinforcing element; (h) injecting resin to form an element on a side of the fiber panel; (i) injecting resin to form the shape; (j) injecting resin to form a resin part; (k) injecting resin to form a resin feature; (1) injecting resin to form a resin feature within a void of the fiber panel; (m) injecting resin to form a resin feature formed within a gap of the fiber panel; (n) injecting resin to form a resin feature providing an opening; (o) injecting resin to form a resin feature comprising an ancillary component; (p) injecting resin to form a resin feature comprising a connector; (q) injecting resin to form a resin feature comprising a mount; (r) injecting resin to form a resin feature comprising a substantially smooth texture; (s) injecting resin to form a resin feature comprising a rib; (t) injecting resin to form a resin feature comprising a rib to extend between an interface of the fiber panel and the border; (u) injecting resin to form ribs to extend between the fiber panel and the border. The component may comprise a cover configured to cover the structural substrate; the cover may be comprised of at least one of (a) woven fabric, (b) non-woven fabric, (c) an applique, (d) vinyl, (e) foam, (f) foil, (g) leather; (h) coverstock.

[0021] The present invention relates to a component for an interior of a vehicle configured to be attached to a beam structure in the interior and to contain an airbag module to deploy an airbag into the interior comprising a structural substrate comprising a panel with an opening for the airbag module. The structural substrate and the airbag module may be configured to be attached to the beam structure. A pocket for the airbag module may be provided in the opening of the panel. The panel may comprise a compressed fiber panel. The structural substrate may comprise a plastic structure. The plastic structure may be formed on the compressed fiber panel of the structural substrate. The plastic structure may comprise an injection- molded resin material. The plastic structure may comprise a set of ribs. The plastic structure may comprise a border for the opening. The plastic structure may comprise a compartment for the airbag module. The plastic structure may comprise a base structure and a compartment for the airbag module. The compartment may be bonded to the base structure. The compartment may be attached to the base structure. The compartment may comprise an enclosure structure to form the pocket for the airbag module. The plastic structure may be configured to attach the structural substrate and the airbag module to the beam structure in the interior. The component may comprise a door to enclose the airbag module within the structural substrate. The airbag module may comprise an airbag assembly.

FIGURES

[0022] FIGURE 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0023] FIGURE IB is a schematic perspective cut-away view of a vehicle showing a vehicle interior according to an exemplary embodiment.

[0024] FIGURE 2A is a schematic perspective view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0025] FIGURES 2B through 2D are schematic perspective detail views of an airbag deployment according to an exemplary embodiment.

[0026] FIGURE 3A is a schematic partial exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0027] FIGURE 3B is a schematic exploded perspective view of a subassembly of a component for a vehicle interior according to an exemplary embodiment.

[0028] FIGURES 4A and 4B are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.

[0029] FIGURES 5A through 5E are schematic perspective views of a process to form a structural substrate from a fiber mat/panel according to an exemplary embodiment.

[0030] FIGURE 5F is a schematic partial section view of a structural substrate of a component for a vehicle interior according to an exemplary embodiment.

[0031] FIGURE 5G is a schematic perspective cut-away view of a structural substrate of a component for a vehicle interior according to an exemplary embodiment.

[0032] FIGURE 6A is a schematic exploded section perspective view of a structural substrate of a component for a vehicle interior according to an exemplary embodiment.

[0033] FIGURES 6B and 6C are schematic partial section perspective views of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0034] FIGURES 7 A through 7D are schematic partial section views of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0035] FIGURE 8A is a schematic exploded section perspective view of a structural substrate of a component for a vehicle interior according to an exemplary embodiment.

[0036] FIGURES 8B and 8C are schematic partial section perspective views of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0037] FIGURES 9A through 9D are schematic partial section views of a method for forming a component for a vehicle interior according to an exemplary embodiment. [0038] FIGURE 10A is a schematic exploded section perspective view of a structural substrate of a component for a vehicle interior according to an exemplary embodiment. [0039] FIGURES 10B and IOC are schematic partial section perspective views of a method for forming a component for a vehicle interior according to an exemplary embodiment. [0040] FIGURES 11 A and 1 IB are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.

[0041] FIGURES 12A and 12B are schematic partial section perspective views of a method for forming a component for a vehicle interior according to an exemplary embodiment. [0042] FIGURES 13A through 13D are schematic partial section views of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0043] FIGURES 14A and 14B are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.

[0044] FIGURES 15A through 15C are schematic section views of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0045] FIGURES 16A through 16C are schematic section views of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0046] FIGURES 17A and 17B are schematic flow diagrams of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0047] FIGURES 18A and 18B are schematic flow diagrams of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0048] FIGURE 19 is a schematic flow diagram of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0049] FIGURE 20 is a schematic flow diagram of a method for forming a component for a vehicle interior according to an exemplary embodiment.

[0050] FIGURES 21 A and 2 IB are schematic flow diagrams of a method for forming a component for a vehicle interior according to an exemplary embodiment.

DESCRIPTION

[0051] Referring to FIGURES 1A and IB, a vehicle V is shown including an interior I with vehicle interior components such as an instrument panel IP, a door/door panel D and a floor console FC (e.g. trim component/panels comprised of materials such as fiber and plastic). According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, trim components such as instrument panel IP may provide at least one airbag AB configured to deploy into the interior of the vehicle through a door ABD (e.g. from door and/or weakened area behind visible surface of trim component). See also FIGURES 3A-3B, 4A-4B, 11A-11B and 14A-14B.

[0052] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B and 4A-4B, the component C may comprise a composite structure CS with a structural substrate SB and a structure SR configured for an airbag assembly AA comprising an airbag component AC and an inflator IN; component C may comprise composite structure CS with structural substrate SB such as a panel PA/FP and structure SR such as a resin feature/structure configured for airbag assembly AA; component C may comprise composite structure CS with structural substrate SB such as a compression- formed fiber panel PA/FP and a structure SR such as a molded resin feature/structure configured for airbag assembly AA to fit within a pocket/enclosure PT ; component C shown as composite structure CS with panel PA and structure SR comprising structural substrate SB providing airbag assembly AA may be mounted to a structure of the vehicle interior such as a member CCB (e.g. frame/member of cross-car beam); airbag assembly AA may comprise an airbag module ABM with a housing AC attached within component C/CS and at member CCB. See also FIGURES 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B, 13A-13D, 14A- 14B, 15A-15C and 16A-16C.

[0053] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B and 4A-4B, component C/CS may comprise an airbag door ABD and a cover CV; component C/CS may be configured for a knee airbag to deploy into the interior of the vehicle from a trim panel shown as instrument panel IP; airbag door ABD (e.g. shown a door panel as configured for a knee airbag) may comprise tabs TB and retainer RT configured to fit within corresponding slots SL for an enclosure providing pocket PT for airbag assembly AA within an enclosure provided by structure SR and/or behind panel PA for component C/CS. See also FIGURES 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B, 13A-13D, 14A-14B, 15A-15C and 16A-16C. According to an exemplary embodiment, the airbag door may be formed from a thermoplastic olefin (TPO) material; the airbag door may comprise a stop such as a strap, web (e.g. nylon strap, integrated webbing, etc.) to withstand deployment load.

[0054] As indicated schematically according to an exemplary embodiment in FIGURES 5A- 5G, panel PA for component/composite structure C/CS may be formed from a mat MA pressed and pre-formed/shaped into a pre-form PF shown as providing aperture/opening AP and heated in an oven OV and placed into a mold M with mold top MT and mold bottom MB for forming and/or attachment of a structure SR as by injection molding of a resin/plastic material to form composite structure CS comprising a structural substrate SB and molded/attached features of structure SR such frame/ribs RB on panel PA. See also FIGURES 6A-6C, 8A-8C, 10A-10C and 12A-12B.

[0055] As shown schematically according to an exemplary embodiment in FIGURES 6A-6C and 7A-7D, the component/composite structure C/CS may comprise structure/reinforcement shown as plastic structure SR with a frame of ribs RB and an enclosure over an aperture AP for panel shown as fiber panel PA/FP to comprise structural substrate SB with pocket PT for installation of airbag assembly AA to be installed to the vehicle interior as mounted to a beam/member shown as member CCB and enclosed with/behind airbag door ABD. See also FIGURES 2A-2D, 3A and 5F.

[0056] As shown schematically according to an exemplary embodiment in FIGURES 8A-8C and 9A-9D, component/composite structure C/CS may comprise structure shown as plastic structure SR comprising a flange providing ribs RB and an enclosure over an aperture AP for attachment on panel shown as fiber panel PA/FP to comprise structural substrate SB with pocket PT for installation of airbag assembly AA to be installed to the vehicle interior as mounted to a beam/member shown as member CCB and enclosed with/behind airbag door ABD. See also FIGURES 2A-2D, 3A and 5F.

[0057] As shown schematically according to an exemplary embodiment in FIGURES 10A- 10C and 11A-11B, component/composite structure C/CS may comprise structure/reinforcement shown as plastic structure SR with a frame of ribs RB and a separate enclosure attachable to a frame over an aperture AP for panel shown as fiber panel PA/FP to comprise structural substrate SB with pocket PT for installation of airbag assembly AA to be installed to the vehicle interior as mounted to a beam/member shown as member CCB and enclosed with/behind airbag door ABD as to facilitate deployment of airbag AB into the vehicle interior. See also FIGURES 2A-2D, 3A and 5F.

[0058] As shown schematically according to an exemplary embodiment in FIGURES 12A- 12B and 13A-13D, component/composite structure C/CS may comprise structure shown as plastic structure SR with frame/ribs and an enclosure providing pocket PT for installation of airbag assembly AA on panel PA to be installed to the vehicle interior as mounted to a beam/member shown as member CCB and enclosed with/behind airbag door ABD. See also FIGURES 2A-2D, 3A and 5F.

[0059] According to an exemplary embodiment as shown schematically in FIGURES 14A- 14B, 15A-15C and 16A-16C, component C/CS may comprise a structure SR attached on a panel PA providing the enclosure/pocket PT for attachment of airbag assembly AA with inflator IN and airbag AB for deployment through airbag door ABD.

Exemplary Embodiments - A

[0060] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B, 4A-4B, 5A-5G, 6A-6C and 7A-7D, a component C for a vehicle interior configured for deployment of an airbag into the vehicle interior may comprise a structural substrate SB comprising a panel PA and a pocket PT, and an airbag assembly AA. The pocket may be configured to support the airbag assembly. The panel may comprise an aperture AP configured to provide access to the pocket for assembly of the airbag assembly to the pocket. The airbag assembly may comprise an airbag component AC and an inflator IN; the inflator may be configured to deploy the airbag component. The pocket may be integrally formed with the panel. The pocket may be injection molded onto the panel. The pocket may be coupled to a rear surface of the fiber panel and to an edge of the fiber panel at the aperture. The pocket may extend into the aperture and along a rear surface of the fiber panel. The component may comprise a rib RB configured to couple the pocket to the fiber panel. The pocket may comprise a rib RB formed on a rear side of the fiber panel. The rib may comprise a resin material. The panel may comprise a fiber panel and the pocket may comprise a thermoplastic molding. The component may comprise an airbag door ABD configured to establish an opening for deployment of the airbag. The airbag door may comprise a tab TB configured to assemble the airbag door to the pocket. The tab may be configured to secure the pocket between the airbag door and the fiber panel. The fiber panel may comprise a compression-formed fiber panel. The fiber panel may comprise a plurality of fibers and a resin configured to bind the fibers. The component may comprise an airbag door ABD configured to establish an opening for deployment of the airbag. The airbag door may be coupled to the pocket. The airbag door may comprise a front surface in planar alignment with a surface of the structural substrate. The airbag door may comprise a front surface; the front surface of the airbag door and a front surface of the structural substrate may be configured to provide a smooth exterior surface for the component. The airbag door may comprise a front surface; the front surface of the airbag door and a front surface of the structural substrate may be configured to provide a continuous surface. The airbag door may comprise (a) a tab TB configured for insertion into a slot SL in the pocket and (b) a retainer RT configured to snap onto the pocket. The pocket may be configured for assembly to a cross-car beam CCB in the vehicle. The pocket may be fastened between the airbag assembly and a cross-car beam CCB. The structural substrate and the airbag assembly may be configured to be attached to a beam structure shown as cross-car beam CCB at the pocket. The component may comprise a cover configured to cover the structural substrate; the cover may be comprised of at least one of (a) woven fabric, (b) non-woven fabric, (c) an applique, (d) vinyl, (e) foam, (f) foil, (g) leather; (h) coverstock. The component may comprise at least one of (a) a component; (b) an instrument panel; (c) a door panel.

[0061] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B, 5A-5E, 5G, 8A-8C, 9A-9D and 10A-10C, a component C for a vehicle interior configured for deployment of an airbag into the vehicle interior may comprise a structural substrate SB comprising a panel PA and a pocket PT, and an airbag assembly AA. The pocket may be configured to support the airbag assembly. The panel may comprise an aperture AP configured to provide access to the pocket for assembly of the airbag assembly to the pocket. The airbag assembly may comprise an airbag component AC and an inflator IN; the inflator may be configured to deploy the airbag component. The panel may comprise a fiber panel and the pocket may comprise a thermoplastic molding. The component may comprise an airbag door ABD configured to establish an opening for deployment of the airbag. The airbag door may comprise a tab TB configured to assemble the airbag door to the pocket. The tab may be configured to secure the pocket between the airbag door and the fiber panel. The fiber panel may comprise a compression-formed fiber panel. The fiber panel may comprise a plurality of fibers and a resin configured to bind the fibers. The component may comprise an airbag door ABD configured to establish an opening for deployment of the airbag. The airbag door may be coupled to the pocket. The airbag door may comprise a front surface in planar alignment with a surface of the structural substrate. The airbag door may comprise a front surface; the front surface of the airbag door and a front surface of the structural substrate may be configured to provide a smooth exterior surface for the component. The airbag door may comprise a front surface; the front surface of the airbag door and a front surface of the structural substrate may be configured to provide a continuous surface. The airbag door may comprise (a) a tab TB configured for insertion into a slot SL in the pocket and (b) a retainer RT configured to snap onto the pocket. The pocket may be configured for assembly to a cross-car beam CCB in the vehicle. The pocket may be fastened between the airbag assembly and a cross-car beam CCB. The structural substrate and the airbag assembly may be configured to be attached to a beam structure shown as cross-car beam CCB at the pocket. The component may comprise a cover configured to cover the structural substrate; the cover may be comprised of at least one of (a) woven fabric, (b) non- woven fabric, (c) an applique, (d) vinyl, (e) foam, (f) foil, (g) leather; (h) coverstock. The component may comprise at least one of (a) a component; (b) an instrument panel; (c) a door panel.

[0062] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B, 11A-11B, 12A-12B and 13A-13D, a component C for a vehicle interior configured for deployment of an airbag into the vehicle interior may comprise a structural substrate SB comprising a panel PA and a pocket PT, and an airbag assembly AA. The pocket may be configured to support the airbag assembly. The panel may comprise an aperture AP configured to provide access to the pocket for assembly of the airbag assembly to the pocket. The airbag assembly may comprise an airbag component AC and an inflator IN; the inflator may be configured to deploy the airbag component. The pocket may be integrally formed with the panel. The component may comprise an airbag door ABD configured to establish an opening for deployment of the airbag. The airbag door may be coupled to the pocket. The airbag door may comprise a front surface in planar alignment with a surface of the structural substrate. The airbag door may comprise a front surface; the front surface of the airbag door and a front surface of the structural substrate may be configured to provide a smooth exterior surface for the component. The airbag door may comprise a front surface; the front surface of the airbag door and a front surface of the structural substrate may be configured to provide a continuous surface. The airbag door may comprise (a) a tab TB configured for insertion into a slot SL in the pocket and (b) a retainer RT configured to snap onto the pocket. The pocket may be configured for assembly to a cross-car beam CCB in the vehicle. The pocket may be fastened between the airbag assembly and a cross-car beam CCB. The structural substrate and the airbag assembly may be configured to be attached to a beam structure shown as cross-car beam CCB at the pocket. The component may comprise at least one of (a) a component; (b) an instrument panel; (c) a door panel.

[0063] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 14A-14B 15A-15C, and 16A-16C, a component C for a vehicle interior configured for deployment of an airbag into the vehicle interior may comprise a structural substrate comprising a panel PA and a pocket PT, and an airbag assembly AA. The pocket may be configured to support the airbag assembly. The airbag assembly may be housed between the panel and the pocket. The pocket may comprise an aperture AP configured to provide access to the pocket for assembly of the airbag assembly. The panel may be configured to cover the aperture of the pocket. The pocket may be configured to be welded to the panel after assembly of the airbag assembly to the pocket. The pocket may be configured for assembly to a cross-car beam CCB in the vehicle. The pocket may be fastened between the airbag assembly and a cross-car beam CCB. The structural substrate and the airbag assembly may be configured to be attached to a beam structure shown as cross-car beam CCB at the pocket. [0064] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B, 4A-4B, 5A-5G, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B and 13A-13D, a method of producing a component C shown as an instrument panel assembly configured for an airbag actuated by an inflator IN may comprise the steps of forming a structural substrate SB for the instrument panel, coupling an inflator IN to an airbag component AC to form an airbag assembly AA, coupling the airbag assembly to the structural substrate, and coupling an airbag door ABD and the structural substrate. The airbag assembly may be housed between the structural substrate and the airbag door. The structural substrate may comprise an aperture AP configured to provide access to a pocket for assembly of the airbag assembly to the structural substrate. The structural substrate may comprise the pocket for the airbag assembly. According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B, 4A-4B, 5A-5G, 6A-6C, 7A-7D, 11A-11B, 12A- 12B and 13A-13D, the step of forming the structural substrate may comprise integrally forming the pocket with the structural substrate.

[0065] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B, 4A-4B, 5A-5G, 6A-6C and 7A-7D, a method of manufacturing a component C for a vehicle interior configured for deployment of an airbag into the vehicle interior and comprising a fiber panel PA compression formed in a mold cavity M may comprise forming an aperture AP in the fiber panel, heating the fiber panel, placing the fiber panel into the mold cavity, compressing the fiber panel in the mold cavity to form a compression formed component providing a structural substrate SB having a shape, injecting resin into the mold cavity with the structural substrate to form a pocket PT, assembling an airbag assembly AA to the pocket, and assembling an airbag door ABD to the pocket. The step of injecting resin into the mold cavity with the structural substrate to form a pocket may comprise coupling the pocket to a rear surface of the fiber panel and to an edge of the fiber panel at the aperture. The step of assembling an airbag door to the pocket may comprise inserting a tab TB of the airbag door into a slot SL in the pocket and snapping a retainer RT of the airbag door to the pocket. The method may comprise the step of injecting resin into the mold cavity to form a rib RB extending across an interface between the fiber panel and the pocket. The step of assembling an airbag assembly to the pocket may comprise fastening the pocket between the airbag assembly and a cross-car beam CCB. The step of placing the fiber panel into the mold cavity may comprise placing a cover in the mold cavity and placing the fiber panel on the cover. The cover may be comprised of at least one of (a) woven fabric, (b) non- woven fabric, (c) an applique, (d) vinyl, (e) foam, (f) foil, (g) leather.

[0066] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A-3B, 4A-4B, 5A-5G, 6A-6C and 7A-7D, a component C for a vehicle interior configured for deployment of an airbag into the vehicle interior and comprising a fiber panel PA compression formed in a mold cavity M may be prepared by a process comprising the steps of forming an aperture AP in the fiber panel, heating the fiber panel, placing the fiber panel into the mold cavity, compressing the fiber panel in the mold cavity to form a compression formed component providing a structural substrate SB having a shape, injecting resin into the mold cavity with the structural substrate to form a pocket PT, assembling an airbag assembly to the pocket, and assembling an airbag door ABD to the pocket. The process may comprise the step of injecting resin into the mold cavity to form a rib RB extending across an interface between the fiber panel and the pocket. The step of assembling an airbag assembly to the pocket may comprise fastening the pocket between the airbag assembly and a cross-car beam CCB.

Exemplary Embodiments - B

[0067] According to an exemplary embodiment as shown schematically in FIGURES 3A-3B, 4A-4B, 5A-5G, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B and 13A- 13D, a component C/CS for an interior of a vehicle configured to be attached to a structure/member CCB in the interior and to contain airbag assembly AA to deploy an airbag AB into the interior may comprise a structural substrate SB comprising a panel PA with an opening for airbag assembly AA; structural substrate SB and airbag assembly AA may be configured to be attached to structure/member CCB. A pocket PT for airbag assembly AA may be provided in the opening of the panel PA. As indicated schematically in FIGURES 5A-5G, panel PA may comprise a compressed fiber panel FP. Structural substrate SB may comprise a plastic structure SR; plastic structure SR may be formed on compressed fiber panel PA/FP of structural substrate SB; plastic structure SR may comprise an injection- molded resin material; plastic structure SR may comprise a set of ribs RB; plastic structure SR may comprise a border/structure for the opening; plastic structure SR may comprise a compartment for airbag assembly AA; plastic structure SR may comprise a base structure of structural substrate and a compartment for airbag assembly AA. See FIGURES 6A-6C, 8A- 8C, 10A-10C and 12A-12B. The compartment may be bonded to the base structure of structural substrate; the compartment may be attached to the base structure of structural substrate; the compartment may comprise an enclosure structure SR to form pocket PT for airbag assembly AA; plastic structure SR may be configured to attach structural substrate SB and airbag assembly AA to structure/member CCB in the interior. Component C/CS may comprise a door ABD to enclose airbag assembly AA within structural substrate SB.

[0068] According to an exemplary embodiment as shown schematically in FIGURES 3A-3B, 4A-4B, 5F-5G, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B and 13A-13D, a component C/CS for a vehicle interior configured to support an airbag assembly AA providing an airbag AB configured to be deployed through an opening may comprise a panel FP providing a structural substrate SB with an opening, and a structure SR provided on panel PA. Structure SR on the panel PA may comprise a resin material; panel PA may comprise a compression-formed fiber panel FP. See FIGURES 5A-5G. Structure SR may be configured to support airbag assembly AA within the opening of panel PA; structure SR provided on panel PA may comprise an injection- molded structure SR formed from the resin material; structure SR provided on panel PA may comprise an injection-molded structure SR formed from the resin material. Structure SR provided on panel PA may be configured to be mounted to a structure/member CCB of the vehicle interior; airbag assembly AA within the opening of panel PA/FP may be configured to be mounted to structure/member CCB of the vehicle interior. See FIGURES 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A- 12B and 13A-13D.

[0069] According to an exemplary embodiment as shown schematically in FIGURES 4A-4B, 5F-5G, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B and 13A-13D, structure SR may be configured to reinforce panel PA/FP; component C with composite structure CS may comprise structure SR such as a frame; structure SR may comprise a grid; structure SR may comprise a frame and an enclosure to form pocket PT; structure SR may comprise a flange and an enclosure to form pocket PT ; structure SR may comprise a frame and an enclosure attached to the frame; structure SR may comprise a frame and an enclosure bonded to the frame; structure SR may comprise a border/structure for the opening; structure SR may comprise a set of ribs RB for panel PA/FP; structure SR on panel PA/FP may comprise an enclosure to form a pocket PT for airbag assembly AA; airbag assembly AA may be mounted within pocket PT. See also FIGURES 2A-2D and 3A.

[0070] According to an exemplary embodiment as shown schematically in FIGURES 3A-3B, 4A-4B, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B and 13A-13D, component C/CS may comprise a cover CV for panel PA and an airbag door ABD; airbag door ABD may be configured to rotate upon deployment of the airbag AB to facilitate deployment of airbag AB ; airbag door ABD may be configured to open as at least one flap from structure SR opened adjacent to the recess configured to open upon deployment of the airbag AB; airbag door ABD may be hinged to structure SR and open at the feature. The component C/CS may comprise a support for panel PA and structure SR; the support may be configured to secure airbag door ABD to panel PA during deployment of airbag AB. Airbag door ABD may comprise a resin feature/structure configured to secure the support. Component C/CS may comprise an injection-molded resin feature/structure configured to facilitate deployment of airbag AB. Structure SR may be injection molded onto the side of panel PA/FP.

[0071] According to an exemplary embodiment as shown schematically in FIGURES 5A-5G, 17A-17B, 18A-18B, 19, 20 and 21A-21B, component C/CS may be produced by a method comprising the steps of providing a mat MA as a pre-form PF for the panel, compressing the mat/pre-form for the panel in the mold M to form the compression-formed fiber panel FP, and injecting a resin into the mold M on the compression-formed fiber panel FP to form structure SR for structural substrate SB. See also FIGURES 6A-6C, 8A-8C, 10A-10C and 12A-12B. Structure SR may be configured to support airbag assembly AA and to direct the airbag AB toward the fiber panel PA/FP during deployment of the airbag AB. According to an exemplary embodiment as shown schematically in FIGURES 5F-5G, 17A-17B, 18A-18B, 19, 20 and 21A-21B, the step of injecting resin into the mold M may comprise forming a resin feature/structure; the resin feature/structure may comprise an enclosure for airbag assembly AA; the resin feature/structure may comprise a set of ribs RB on the panel PA; the resin feature/structure may comprise a dimensionally accurate border/structure; the resin feature/structure may comprise at least one of (a) a rib RB; (b) a ridge; (c) an enclosure to provide a pocket PT; (d) attachment for a component C/CS; (e) a rib RB configured to reinforce structural substrate SB; (f) a rib RB configured to support structural substrate SB; (g) a rib RB configured to extend across an interface between the fiber panel PA/FP and the molded feature to enhance the strength of the interface; (h) a resin border/structure; (i) a resin border/structure at the edge of the periphery of structural substrate SB; (j) a connector; (k) a connector configured to facilitate coupling at least one of (1) a door ABD frame or (2) an instrument panel PA/FP or (3) a support structure SR within the vehicle interior. See also FIGURES 5F-5G, 6A-6C, 8A-8C, 10A-10C and 12A-12B. Resin feature/structure may be configured to reinforce structural substrate SB with panel PA; resin feature/structure may be configured to secure airbag door ABD to panel PA/FP. The fiber panel PA/FP and resin feature/structure may be configured to provide a substantially continuous structure. Resin feature/structure may comprise at least one of (a) an ancillary component; (b) a rib RB; (c) a connector. See FIGURES 5F-5G, 6A-6C, 8A-8C, 10A-10C and 12A-12B. The fiber panel PA/FP may comprise structural fibers and a resin; the structural fibers comprise at least one of (a) natural fibers; (b) hemp; (c) wood; (d) flax; (e) kenaf; (f) sisal; (g) synthetic fibers; (h) glass fibers; (i) carbon fibers; (j) polymeric fibers; the resin may comprise at least one of (a) thermoplastic resin; (b) polypropylene; (c) acrylonitrile butadiene styrene; (d) polycarbonate; (e) thermoset resin; (f) epoxy resin; (g) polyimide resin; (h) polyester resin; (i) vinylester resin.

[0072] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A, 5F-5G, 4A-4B, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B and 13A- 13D, structure SR may comprise a flange; structure SR may comprise a border/structure for the opening; structure SR may be configured to enhance the structural rigidity of compression- formed component C/CS; compression- formed fiber panel PA/FP may comprise a thickness along a periphery; structure SR may comprise a border/structure of structural substrate SB along the thickness of the periphery of the compression-formed fiber panel PA/FP; the periphery of the fiber panel PA/FP may comprise an edge; structure SR may be formed on the edge; fiber panel PA/FP may comprise a plurality of fibers and a resin configured to bind the fibers; structure SR may be bonded to compression-formed fiber panel PA/FP; structure SR may comprise at least one of (a) an injection-molded resin configured to reinforce the compression- formed fiber panel PA/FP; (b) a molded feature providing an ancillary component. Structure SR may comprise at least one molded feature; molded feature/structure SR may comprise a feature configured to support the fiber panel PA/FP; the molded feature may comprise (a) a rib RB; (b) a ridge; (c) a runner.

[0073] According to an exemplary embodiment as shown schematically in FIGURES 3 A, 4A-4B, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B, component C/CS may comprise a cover CV for component C/CS; the cover may comprise at least one of (a) cover stock; (b) a woven fabric; (c) a non-woven fabric; (d) an applique; (e) a vinyl layer; (f) a foam layer; (g) a foil layer; (h) a leather covering. Structure SR may be bonded to the compression-formed fiber panel PA/FP. Structure SR may comprise an injection-molded resin configured to reinforce compression-formed fiber panel PA/FP. Structure SR may comprise a molded feature providing an ancillary component; structure SR may comprise a dimensionally accurate border/structure.

[0074] According to an exemplary embodiment as shown schematically in FIGURES 5A-5G, component C/CS may be formed by a process comprising the steps of heating the fiber panel PA/FP, placing the fiber panel PA/FP into a cavity of mold M, compressing the fiber panel PA/FP in the cavity of mold M to form the compression-formed panel PA/FP comprising an edge along the periphery and to form a structural substrate SB having a shape and a thickness along the edge, and injecting resin into the cavity of mold M with structural substrate SB; the shape of structural substrate SB may be formed in the cavity of mold M; a border/structure of structural substrate SB may be formed along the thickness of structural substrate by the resin injected into the cavity of mold M; a frame/structure for structural substrate SB may be formed by the resin injected into the cavity of mold M; the frame may be formed to extend across an interface between structural substrate SB and the border/structure. See also FIGURES 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B, 17A-17B, 18A- 18B, 19, 20 and 21A-21B. The compression-formed panel PA/FP formed from the fiber panel/mat MA may comprise variations at the edge along the periphery; the border/structure of structural substrate SB formed by injected resin may be configured to provide dimensional accuracy at the edge along the periphery. According to an exemplary embodiment as shown schematically in FIGURES 5F-5G, 17A-17B, 18A-18B, 19, 20 and 21A-21B, the step of injecting resin into the cavity of mold M with structural substrate SB may comprise forming a frame from injected resin and forming the border/structure from injected resin; the border/structure formed from injected resin may be configured to provide dimensional accuracy along the edge of structural substrate SB; the step of injecting resin into the cavity of mold M with structural substrate SB may comprise forming a reinforcing element on structural substrate; the step of injecting resin into the cavity of mold M with structural substrate SB may comprise forming a resin feature/structure in the at least one void of structural substrate SB. See also FIGURES 3A, 4A-4B, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B and 12A-12B.

[0075] According to an exemplary embodiment as shown schematically in FIGURES 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B, the resin feature/structure may comprise a reinforcing element configured to reinforce structural substrate SB in the at least one void. See also FIGURES 5F-5G. The resin feature/structure may be configured to provide a weakened zone in structural substrate SB configured to facilitate separation of the reinforcing element from structural substrate SB for deployment of an airbag AB. The resin feature/structure may be formed along at least a portion of a first surface of structural substrate SB and along at least a portion of a second surface of structural substrate SB to couple the resin feature/structure to structural substrate SB. The structural substrate SB and the resin feature/structure SR may be configured to provide a substantially continuous structure. According to an exemplary embodiment as indicated schematically in FIGURES 5A-5G, 17A-17B, 18A-18B, 19, 20 and 21A-21B, the step of injecting resin into the cavity of mold M with structural substrate SB may comprise at least one of: (a) the cavity of mold M providing dimensional accuracy for injected resin; (b) injecting resin into the at least one void; (c) injecting resin into a gap within the fiber panel PA/FP; (d) injecting resin into a gap; (e) injecting resin to fill a gap to form a structure SR from resin; (f) injecting resin to form an element; (g) injecting resin to form a reinforcing element; (h) injecting resin to form an element on a side of the fiber panel PA/FP; (i) injecting resin to form the shape; (j) injecting resin to form a resin part; (k) injecting resin to form a resin feature/structure; (1) injecting resin to form a resin feature/structure within a void of the fiber panel PA/FP; (m) injecting resin to form a resin feature/structure formed within a gap of the fiber panel PA/FP; (n) injecting resin to form a resin feature/structure providing an opening; (o) injecting resin to form a resin feature/structure comprising an ancillary component; (p) injecting resin to form a resin feature/structure comprising a connector; (q) injecting resin to form a resin feature/structure comprising a mount; (r) injecting resin to form a resin feature/structure comprising a substantially smooth texture; (s) injecting resin to form a resin feature/structure comprising a rib RB; (t) injecting resin to form a resin feature/structure comprising a rib RB to extend between an interface of the fiber panel PA/FP and the border/structure; (u) injecting resin to form ribs RB to extend between the fiber panel PA/FP and the border/structure. See also FIGURES 3A, 4A-4B, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B and 12A- 12B.

[0076] According to an exemplary embodiment as shown schematically in FIGURES 2A-2D, 3A, 4A-4B, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B and 13A-13D, component C/CS may comprise a cover CV to provide a surface on the compression-formed fiber panel PA/FP. The component C/CS may comprise a cover for structural substrate SB. The component C/CS may comprise at least one of (a) a center console; (b) a floor console;

(c) a door ABD panel PA/FP; (d) an instrument panel PA/FP; (e) a headliner; (f) an overhead console; (g) a sun visor. The component C/CS may comprise a cover configured to cover structural substrate SB; the cover may be comprised of at least one of (a) woven fabric, (b) non-woven fabric, (c) an applique, (d) vinyl, (e) foam, (f) foil, (g) leather; (h) coverstock. [0077] According to an exemplary embodiment as shown schematically in FIGURES 4A-4B, 5A-5G, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B, 12A-12B, a component C/CS for a vehicle interior configured for installation of airbag assembly AA may comprise a fiber panel PA/FP and a structure SR comprising a resin; the panel PA may comprise a compression-formed fiber panel FP. The compression-formed panel PA/FP may comprise an opening providing a periphery; the compression-formed panel PA/FP and structure SR may comprise a structural substrate SB having a shape and a thickness along an edge. Structure SR may comprise a molded resin feature/structure for structural substrate SB ; structure SR may be formed in the at least at the periphery of the opening of the compression-formed panel PA/FP; structure SR may comprise an enclosure for a pocket PT for airbag assembly AA; structure SR may be formed on the edge. The fiber panel may comprise a plurality of fibers and a resin configured to bind the fibers; structure SR may comprise a feature providing an ancillary component; the feature may comprise a molded resin feature/structure; structure SR may comprise a feature for attachment of the enclosure for the pocket PT for airbag assembly AA; structure SR may be configured to accommodate variation in the edge of the fiber panel; structure SR may comprise a rib RB configured to reinforce the fiber panel; structure SR may comprise a molded feature configured to support the fiber panel PA/FP. The molded feature configured to support the fiber panel may comprise a rib RB ; the rib RB may comprise at least one of (a) a ridge; (b) a runner. The molded feature may comprise the border/structure coupled to at least a portion of a periphery of the fiber panel; the border/structure of structural substrate SB may comprise a resin border/structure about a periphery of the fiber panel.

[0078] According to an exemplary embodiment as shown schematically in FIGURES 4A-4B, 6A-6C, 7A-7D, 8A-8C, 9A-9D, 10A-10C, 11A-11B and 12A-12B, a component C/CS for an interior of a vehicle configured to be attached to a structure/member CCB in the interior and to contain airbag assembly/module AA/ABM to deploy an airbag AB into the interior may comprise a structural substrate SB comprising a panel PA with an opening for the airbag assembly /module AA/ABM ; structural substrate SB and the airbag assembly/module AA/ABM may be configured to be attached to the structure/member CCB. A pocket PT for the airbag assembly /module AA/ABM may be provided in the opening of the panel PA. The panel PA may comprise a compressed fiber panel FP. The structural substrate SB may comprise a plastic structure SR; the plastic structure SR may be formed on the compressed fiber panel FP of structural substrate SB; the plastic structure SR may comprise an injection- molded resin material; the plastic structure SR may comprise a set of ribs RB; plastic structure SR may comprise a border/structure for the opening; the plastic structure SR may comprise a compartment for the airbag module ABM; the plastic structure SR may comprise a base structure and a compartment for the airbag module ABM. The compartment may be bonded to the base structure of structural substrate; the compartment may be attached to the base structure of structural substrate; the compartment may comprise an enclosure structure SR to form the pocket PT for the airbag assembly/module AA/ABM; plastic structure SR may be configured to attach structural substrate SB and the airbag module ABM to the structure/member CCB in the interior; the component C/CS may comprise a door ABD to enclose the airbag assembly /module AA/ABM within structural substrate SB. Airbag module ABM may comprise airbag assembly AA. See FIGURE 3B.

Exemplary Embodiments - C

[0079] According to an exemplary embodiment as shown schematically in FIGURES 15A- 15C and 16A-16C, a component for a vehicle interior configured for deployment of an airbag into the vehicle interior may comprise a structural substrate, an airbag assembly and a structure and/or cover. The structural substrate may provide a structure/pocket or housing for the airbag assembly. The airbag assembly may comprise an airbag component and an inflator; the inflator may be configured to deploy the airbag component. The airbag assembly may comprise a bracket configured to at least one of (a) couple the inflator to the structural substrate; (b) couple the inflator to the airbag component. The structural substrate may comprise a structure/housing for the airbag assembly. The structure/housing may be integrally formed with the structural substrate. The structure/housing may be welded to the cover. The structure/housing may be fastened to the cover. The structure/housing may be coupled to the cover; the cover may be configured to decouple from the housing during deployment of an airbag component of the airbag assembly. The component may comprise at least one of (a) a trim component; (b) an instrument panel; (c) a door panel.

[0080] According to an exemplary embodiment as shown schematically in FIGURES 15A- 15C and 16A-16C, a method of producing an instrument panel assembly configured for an airbag actuated by an inflator may comprise the steps of forming a structural substrate for the instrument panel, coupling an inflator to an airbag component to form an airbag assembly, coupling the airbag assembly to the structural substrate and coupling a cover and the structural substrate so that the airbag assembly is housed between the structural substrate and the cover. The structural substrate may comprise a structure/housing for the airbag assembly. The step of forming the structural substrate may comprise integrally forming the structure/housing with the structural substrate.

Exemplary Embodiments - D

[0081] According to an exemplary embodiment as shown schematically in FIGURE 17A, a method of producing a component for a vehicle interior may comprise the steps of providing a fiber mat as a base for a pre-form, forming the pre-form (e.g. consolidating, compressing, merging/fusing, heating/melting, shaping, cutting/sizing, etc.), pre-treating/heating the pre form, forming a structural substrate (e.g. compressing/molding the pre-form), molding a pocket on the structural substrate, assembling an airbag assembly to the structural substrate, assembling an airbag door to the structural substrate, and finishing/providing the component. [0082] According to an exemplary embodiment as shown schematically in FIGURE 17B, a method of producing a component for a vehicle interior may comprise the steps of providing a fiber mat as a base for a pre-form, forming the pre-form (e.g. consolidating, compressing, merging/fusing, heating/melting, shaping, cutting/sizing, etc.), pre-treating/heating the pre form, forming a structural substrate (e.g. compressing/molding the pre-form), welding a pocket to the structural substrate, assembling an airbag assembly to the structural substrate, assembling an airbag door to the structural substrate, and finishing/providing the component. [0083] According to an exemplary embodiment as shown schematically in FIGURE 18 A, a method of producing a component for a vehicle interior may comprise the steps of providing a substrate layer (e.g. fiber mat, etc.) as a base for a pre-form substrate, forming the pre-form substrate (e.g. consolidating, compressing, merging/fusing, heating/melting, shaping, cutting/sizing, etc.), pre-treating/heating the pre-form substrate, forming a structural substrate (e.g. compressing/molding the pre-form substrate), assembling a pocket to the structural substrate, applying a cover to the structural substrate, assembling an airbag assembly to the structural substrate, assembling an airbag door to the structural substrate, and finishing/providing a panel assembly (with the cover on the structure/substrate).

[0084] According to an exemplary embodiment as shown schematically in FIGURE 18B, a method of producing a component for a vehicle interior may comprise the steps of providing a substrate layer (e.g. fiber mat, etc.) as a base for a pre-form substrate, forming the pre-form substrate (e.g. consolidating, compressing, merging/fusing, heating/melting, shaping, cutting/sizing, etc.), pre-treating/heating the pre-form substrate, forming a structural substrate (e.g. compressing/molding the pre-form substrate), injection molding a pocket on the structural substrate, applying a cover to the structural substrate, assembling an airbag assembly to the structural substrate and a cross-car beam, assembling an airbag door to the structural substrate, and finishing/providing a panel assembly (with the cover on the structure/substrate).

[0085] According to an exemplary embodiment as shown schematically in FIGURE 19, a method of producing a component for a vehicle interior may comprise the steps of providing an airbag component (e.g. cut and sew fabric), providing an inflator, assembling the inflator to the airbag component to form an airbag assembly, providing a pocket (e.g. molding a pocket), providing a structural substrate (e.g. molding or forming a panel), assembling the pocket to the structural substrate (e.g. molding the pocket on the structural substrate or fastening the pocket to the structural substrate), assembling the airbag assembly to the pocket, providing an airbag door (e.g. molding an airbag door), assembling the airbag door to the structural substrate with the airbag assembly, and finishing/providing the component.

[0086] According to an exemplary embodiment as shown schematically in FIGURE 20, a method of producing a component for a vehicle interior may comprise the steps of providing an airbag component (e.g. cut and sew fabric), providing an inflator, assembling the inflator to the airbag component to form an airbag assembly, providing a structural substrate with a pocket (e.g. molding a structural substrate with an integrally formed pocket or welding a pocket to a structural substrate), assembling the airbag assembly to the structural substrate/pocket, providing an airbag door (e.g. molding an airbag door), assembling the airbag door to the structural substrate with the airbag assembly, and finishing/providing the component.

[0087] According to an exemplary embodiment as shown schematically in FIGURE 21 A, a method of producing a component for a vehicle interior may comprise the steps of forming (pressing, compressing, fitting, etc.) a pre-form (panel), forming (molding, etc.) a structure (resin, plastic, etc.) on the pre-form panel to form a structural substrate (composite structure), attaching (welding, bonding, coupling, connecting, snap-fitting, molding, etc.) an enclosure (pocket) for an airbag assembly, and installing the airbag assembly into the composite structure.

[0088] According to an exemplary embodiment as shown schematically in FIGURE 2 IB, a method of producing a component for a vehicle interior may comprise the steps of forming (pressing, compressing, fitting, etc.) a pre-form (fiber panel), forming (molding, etc.) a structure with a feature (resin, plastic, etc.) on the pre-form panel to form a structural substrate (composite structure), attaching (welding, bonding, coupling, connecting, snap fitting, molding, etc.) an enclosure (pocket) for an airbag assembly, installing the airbag assembly into the composite structure (component), and attaching a cover.

* * *

[0089] It is important to note that the present inventions (e.g. inventive concepts, etc.) have been described in the specification and/or illustrated in the FIGURES of the present patent document according to exemplary embodiments; the embodiments of the present inventions are presented by way of example only and are not intended as a limitation on the scope of the present inventions. The construction and/or arrangement of the elements of the inventive concepts embodied in the present inventions as described in the specification and/or illustrated in the FIGURES is illustrative only. Although exemplary embodiments of the present inventions have been described in detail in the present patent document, a person of ordinary skill in the art will readily appreciate that equivalents, modifications, variations, etc. of the subject matter of the exemplary embodiments and alternative embodiments are possible and contemplated as being within the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. It should also be noted that various/other modifications, variations, substitutions, equivalents, changes, omissions, etc. may be made in the configuration and/or arrangement of the exemplary embodiments (e.g. in concept, design, structure, apparatus, form, assembly, construction, means, function, system, process/method, steps, sequence of process/method steps, operation, operating conditions, performance, materials, composition, combination, etc.) without departing from the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. The scope of the present inventions is not intended to be limited to the subject matter (e.g. details, structure, functions, materials, acts, steps, sequence, system, result, etc.) described in the specification and/or illustrated in the FIGURES of the present patent document. It is contemplated that the claims of the present patent document will be construed properly to cover the complete scope of the subject matter of the present inventions (e.g. including any and all such modifications, variations, embodiments, combinations, equivalents, etc.); it is to be understood that the terminology used in the present patent document is for the purpose of providing a description of the subject matter of the exemplary embodiments rather than as a limitation on the scope of the present inventions.

[0090] It is also important to note that according to exemplary embodiments the present inventions may comprise conventional technology (e.g. as implemented and/or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or may comprise any other applicable technology (present and/or future) with suitability and/or capability to perform the functions and processes/operations described in the specification and/or illustrated in the FIGURES. All such technology (e.g. as implemented in embodiments, modifications, variations, combinations, equivalents, etc.) is considered to be within the scope of the present inventions of the present patent document.