CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and incorporates by reference in full the following patent applications: U.S. Provisional Patent Application No. 63/320,468 titled “COMPONENT FOR VEHICLE INTERIOR” filed March 16, 2022.

FIELD

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

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

BACKGROUND

[0004] It is known to provide a component for a vehicle interior configured for deployment of an airbag through an opening into the vehicle interior.

[0005] It would be advantageous to provide an improved component configured to facilitate deployment of an airbag into the vehicle interior.

[0006] It would be advantageous to provide an improved component configured to facilitate deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a structure comprising a structural feature.

[0007] It would be advantageous to provide an improved component configured to facilitate deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a structure comprising a door structure configured to facilitate formation of an airbag door at an opening at a separation area in the structural substrate during airbag deployment.

[0008] It would be advantageous to provide an improved component configured to facilitate deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a structure comprising a structural feature and/or profile configured to facilitate formation of an initial opening area for the opening in the separation area of the structural substrate during airbag deployment.

SUMMARY [0009] The present invention relates to a component for an interior of a vehicle configured to facilitate deployment of an airbag comprising a structural substrate comprising a panel and a structure comprising a structural feature. The structural feature may be configured to facilitate formation of an airbag door at an opening at a separation area in the structural substrate during deployment of the airbag. The panel may comprise a fiber panel; the structure may be provided on the fiber panel. The fiber panel may comprise a compressed fiber panel. The panel may comprise a formed panel. The panel may comprise a formed resin panel. The component may comprise a cover on the panel. The structure may comprise an airbag chute. The structure may comprise a door structure configured to facilitate formation of an initial opening area for the opening during deployment of the airbag. The structure may comprise a door structure configured to facilitate formation of an initial opening area at an edge of the door for the opening during deployment of the airbag. The door structure may comprise a profile providing a contact area for the airbag configured to facilitate formation of the initial opening area at the edge of the door for the opening during deployment of the airbag; the profile may comprise at least one of (a) raised height within the profile and/or (b) varying shape along the profile. The profile may comprise a raised height across the profile. The structural feature of the door structure may be configured to facilitate formation of the initial opening area at a stress concentration at the edge of the door and then lateral opening segments for the opening during deployment of the airbag; the structural feature may comprise a contact area for the airbag during deployment of the airbag. The panel may comprise the separation area configured to provide an initial opening area for formation of the opening for the airbag; the opening may be configured to comprise the initial opening area and then lateral segments along the separation area. The panel may comprise the separation area for formation of the opening for the airbag with an initial opening area at an edge of the airbag chute. The panel may comprise the separation area for formation of the opening for the airbag; the opening may be configured to form at an edge of the airbag door adjacent the edge of the airbag chute. The separation area may comprise a tear line. The structure may comprise a door structure comprising the structural feature within the airbag chute; the structural feature may comprise a contact area provided by a profile. The structural feature may comprise a rib structure transverse to the separation area. The structural feature may comprise a set of projections; the profile may comprise a raised profile comprising the set of projections. The set of projections may comprise as a set of walls of varying height across the profile. The opening may comprise a U-shaped opening; the separation area may be configured to produce the U-shaped opening. The structural substrate may comprise a notch configured to establish the opening for deployment of the airbag through the opening. The structural feature may comprise a rib adjacent the notch. The rib may be transverse to the notch. The notch may comprise a recess or a depression in the structural substrate. The rib may comprise a wall generally perpendicular to the recess or depression. The separation area may comprise a tear line; the rib may be transverse to the tear line. The rib may comprise a wall generally perpendicular to the tear line. The rib may comprise a wall; the wall may comprise a height extending from the structural substrate. The height may comprise a first height and a second height greater than the first height. The height may increase from a first end of the wall to a second end of the wall. The second end of the wall may be adjacent a tear line for the opening for deployment of the airbag. The height of the wall may decrease as the wall extends away from a tear line for the opening for deployment of the airbag. The tear line may be provided at a separation area. The structure may comprise a molded structure. The structure may comprise a formed resin structure. The structure may comprise the structural feature formed on the panel. The structure may comprise a door structure. The door structure may comprise a frame structure. The door structure may comprise a grid structure. The door structure may comprise a backing structure. The door structure may comprise a web structure. The door structure may comprise a cell structure. The door structure may comprise a honeycomb structure. The door structure may comprise a two-section structure. The door structure may comprise a reinforcement section and a rigidification section. The door structure may comprise a reinforcement section and the structural feature. The door structure may comprise a rigidification section. The rigidification section may comprise the structural feature. The structure may comprise an airbag chute. The airbag chute may comprise a frame. The frame may be configured for the airbag door. The structure may comprise an airbag chute and a door structure configured to form an airbag door. The panel may comprise a separation area configured for formation of the airbag door. The separation area may be provided at the airbag chute. The separation area may comprise a separation line within the airbag chute. The separation area may be between an edge of the airbag door and a frame of the airbag chute. The separation area may be provided within the airbag chute. The airbag door may be configured to be formed at the separation area within the airbag chute. The airbag door may be configured to be formed at the separation area within a frame of the airbag chute. The frame of airbag chute may comprise sidewalls. The door structure may comprise the structural feature. The structural feature may comprise a rib structure. The rib structure may comprise at least one rib. The door structure may comprise a rigidification section. The structural feature may comprise the rigidification section. The rigidification section may comprise a rib structure. The rigidification section may comprise a profile. The door structure may comprise a profile. The door structure may comprise a structural feature; the structural feature may comprise a shape. The door structure may comprise a contour shape. The door structure may comprise a varying depth and/or a varying depth. The door structure may comprise a set of projections. The door structure may comprise a wall structure. The wall structure may comprise a set of walls. The set of walls may comprise walls of a varying form. The set of walls may comprise walls of a varying shape. The set of walls may comprise walls of a varying height. The set of walls may comprise walls of a varying depth. The set of walls may comprise a high point. The high point may comprise a contact area for the airbag at deployment of the airbag. The door structure may comprise a plate coupled to the set of walls configured for contact from the airbag during deployment of the airbag. The plate may be welded to the set of walls. The door structure may comprise a set of connectors coupled to the set of walls. The door structure may comprise a contact area configured for contact by the airbag during deployment of the airbag. The contact area may comprise an initial contact area for the airbag during deployment of the airbag. The contact area may be configured to create an initial opening area for the opening for the airbag during deployment of the airbag. The initial opening area may be configured to comprise a tear. The initial opening area may be configured to comprise a rupture in the panel. The initial opening area may be configured to comprise a break point in the panel. The component may comprise a cover; the initial opening area may be configured to comprise a shear tear in the cover at a separation area. Contact of the airbag at the contact area may create a stress concentration at the initial opening area of the separation area. The door structure may comprise a profile. The profile may be configured to provide the contact area. The profile may comprise a uniform profile. The profile may comprise a non-uniform profile. The profile may comprise a contoured profile. The door structure may comprise a set of flanges. The door structure may comprise a web structure. The door structure may comprise a frame section. The door structure may comprise a contact section. The structural feature may comprise a contact surface. The contact surface may be configured to be in contact with the airbag to facilitate formation of the airbag door. The contact surface may comprise a contact area for the airbag during deployment of the airbag. The structural feature may comprise an end. The end may comprise a front edge. The end may comprise a nose; the nose may comprise a compliant section. The opening for the airbag door may be formed in a separation area. An edge of the airbag door may be formed at the separation area. The edge of the airbag door may be formed by a shear tear. The separation area may comprise a notch. The edge of the airbag door may be formed at the notch. The notch provides an initial opening area during formation of the opening. The notch may provide the initial opening area at an edge of the airbag door during deployment of the airbag. The panel may comprise the edge of the airbag door. The panel may comprise a hinge area for the airbag door. The airbag door may comprise an edge and a hinge area. The edge may be formed at a tear line in the separation area. The tear line may be configured to form the opening in the panel. The separation area may be configured to form the opening in the panel. The separation area may be configured to form the opening in the panel by facilitating formation of the airbag door by shear force at an initial opening area at a contact area of the structural feature with the airbag during deployment of the airbag. The door structure may comprise the structural feature. The structural feature of the door structure may be configured to direct force to the separation area during formation of the airbag door. A profile of the door structure may be configured to direct force to the separation area during formation of the airbag door. The structural feature of the door structure may be configured to direct force to the separation area to create an initial opening area during formation of the airbag door. The structural feature of the door structure may be configured to direct force to the separation area to create a stress concentration during formation of the airbag door. The structural feature of the door structure may be configured to direct force to the separation area to provide a shear force during formation of the airbag door. The structural feature of the door structure may be configured to direct force to the separation area to create a stress concentration to provide a shear force during formation of the airbag door. The structural feature of the door structure may comprise a contact area for the airbag during deployment of the airbag to create the stress concentration. The structural feature may comprise a projection on the door structure. The separation area may comprise a notch; the separation area may comprise a tear line for formation of the opening for deployment of the airbag; the structural feature may be configured to direct establishment of the tear line. The tear line may comprise at least one of (a) a weakening line or (b) a weakened segment. The tear line may comprise a U-shaped line. The opening for the airbag may be configured to be formed at a separation area; the separation area may comprise a tear line comprising an opening segment configured to create an initial opening area at a contact area of the airbag during deployment of the airbag. The tear line may comprise an opening segment and lateral segments transverse to the opening segment. The structural feature may be configured to create an initial opening area at the opening segment of the tear line. The opening segment of the tear line may be configured to extend to form lateral segments of the tear line. The opening segment of the tear line may be configured to establish lateral segments of the tear line. The opening may be formed at the tear line comprising the opening segment and the lateral segments. The panel may comprise fibers. The panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The cover may comprise at least one of (a) a resin; (b) TPO; (c) leather; (d) synthetic leather; (e) fabric. The structural feature may be formed on the panel; the structural feature may comprise resin. The component may comprise an airbag chute. The airbag chute may comprise the structural feature. The airbag chute may comprise a structural feature. The structural feature on the airbag chute may comprise a set of walls. The structural feature on the airbag chute may comprise a frame. The structural feature on the airbag chute may comprise a frame for the airbag door. The structural substrate may comprise a notch configured to establish the opening for deployment of the airbag through the opening. The structural feature may be adjacent the notch. The structural feature may be transverse to the notch. The notch may comprise a recess in the structural substrate. The structural feature may comprise a wall generally perpendicular to the recess. The structural feature may comprise a wall; the wall may comprise a height extending from the structural substrate. The height may comprise a first height and a second height greater than the first height. The height may increase from a first end of the wall to a second end of the wall. The second end of the wall may be adjacent a tear line for the opening for deployment of the airbag. The height of the wall may decrease as the wall extends away from a tear line for the opening for deployment of the airbag. The structural substrate may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat. The structural feature may comprise a rib. The separation area for the airbag door may comprise a notch; the notch may comprise a formed notch. The airbag door may comprise a set of airbag doors. The component may comprise at least one of (a) an instrument panel; (b) a door panel; (c) a trim panel; (d) a trim component.

[0010] The present invention relates to a component for an interior of a vehicle configured to facilitate deployment of an airbag through an opening into the interior comprising a structural substrate configured to provide the opening by formation of an airbag door at a separation area during deployment of the airbag; and a structure comprising a structural feature provided on the structural substrate. The structural feature may be configured to facilitate formation of the airbag door and an initial opening area for the opening in the structural substrate during deployment of the airbag. The structural substrate may comprise a panel; the panel may comprise the structure. The structural substrate may comprise a fiber panel; the structure may be provided on the fiber panel. The separation area may be configured to form the opening in the panel. The separation area may be configured to form the opening in the panel by facilitating formation of the initial opening area in the airbag door by shear force. The structure may comprise a door structure comprising the structural feature. The structural feature of the door structure may be configured to direct force to the separation area to create the initial opening area during formation of the airbag door. A profile of the door structure may be configured to direct force to the separation area to create the initial opening area during formation of the airbag door. A raised section of the profile of the door structure may be configured to direct force to the separation area to create the initial opening area during formation of the airbag door. The structural feature of the door structure may be configured to direct force to the separation area to create a stress concentration to create the initial opening area during formation of the airbag door. The structural feature of the door structure may be configured to direct force to the separation area to provide a shear force to create the initial opening area during formation of the airbag door. The structure may be formed on the panel. The structure may comprise an airbag chute. The structure may comprise a molded structure. The structural substrate may comprise a compressed fiber panel. The structural substrate may comprise a formed resin panel. The structure may comprise a formed resin structure. The component may comprise a cover. The structural substrate may comprise an airbag door section; the airbag door may be configured to be formed at the airbag door section of the structural substrate. The structural feature may be provided at the airbag door section of the panel. The airbag chute may comprise a frame; the structural feature may be provided at the airbag door section of the panel; the airbag door may be configured to be formed within the frame of the airbag chute.

[0011] The present invention relates to a component for a vehicle interior configured for deployment of an airbag through an opening into the vehicle interior comprising a structural substrate providing at least one door established upon deployment of the airbag to facilitate deployment of the airbag through the opening; and a rib. The rib may be configured to direct establishment of the door upon deployment of the airbag.

[0012] The present invention relates to a component for an interior of a vehicle configured to facilitate deployment of an airbag through an opening into the interior comprising a panel configured to provide the opening by formation of an airbag door during deployment of the airbag; and a structure comprising a structural feature provided on the panel. The structural feature may be configured to facilitate formation of the airbag door and the opening of the panel during deployment of the airbag. The panel may comprise a structural substrate; the structural substrate may comprise the structure. The panel may comprise a plastic panel; the plastic panel may comprise the structure.

[0013] The present invention relates to a component for a vehicle interior configured for deployment of an airbag through an opening into the vehicle interior produced in a mold comprising a first surface and a second surface by a process comprising placing a pre-form substrate onto the first surface of the mold; forming a compression-formed structure from the pre- form substrate by compressing the pre- form substrate between the first surface of the mold and the second surface of the mold; and injecting resin into the mold after the compression-formed structure is formed to form a rib. The rib may be configured to direct establishment of a door upon deployment of the airbag to facilitate deployment of the airbag through the opening. The pre- form substrate may comprise a fiber panel. The step of forming the compression-formed structure may comprise forming the pre-form substrate into a generally rigid form. The compression-formed structure may comprise a first contour provided by the first surface of the mold and a second contour provided by the second surface of the mold. The pre-form substrate may comprise a resin; the process may comprise the step of heating the pre-formed substrate and the pre-formed substrate may be compressed as the pre-formed substrate cools.

[0014] The present invention relates to a component for a vehicle interior configured for deployment of an airbag through an opening into the vehicle interior comprising a structural substrate providing at least one door established upon deployment of the airbag to facilitate deployment of the airbag through the opening, and a rib. The rib may be configured to direct establishment of the door upon deployment of the airbag. The structural substrate may be configured to provide a tear line for the opening for deployment of the airbag; the rib may be configured to direct establishment of the tear line. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The tear line may comprise a U-shaped line. The tear line may comprise an opening section and a lateral section transverse to the opening section. The rib may be configured to direct establishment of the opening section of the tear line. The opening section of the tear line may be configured to establish the lateral section of the tear line. The opening may be formed at the tear line comprising the opening section and the lateral section. The structural substrate may comprise a panel comprised at least partially of fibers. The panel further may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The rib may be formed on the panel; the rib may comprise resin. The component may comprise an airbag chute; the airbag chute may comprise the rib. The structural substrate may comprise a notch configured to establish the opening for deployment of the airbag through the opening. The rib may be adjacent the notch. The rib may be transverse to the notch. The notch may comprise a depression in the structural substrate. The rib may comprise a wall generally perpendicular to the depression. The rib may comprise a wall; the wall may comprise a height extending from the structural substrate. The height may comprise a first height and a second height greater than the first height. The height may increase from a first end of the wall to a second end of the wall. The second end of the wall may be adjacent a tear line for the opening for deployment of the airbag. The height of the wall may decrease as the wall extends away from a tear line for the opening for deployment of the airbag. The structural substrate may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat.

[0015] The present invention relates to a component for a vehicle interior configured for deployment of an airbag through an opening into the vehicle interior produced in a mold comprising a first surface and a second surface by a process comprising placing a pre-form substrate onto the first surface of the mold, forming a compression-formed structure from the pre- form substrate by compressing the pre- form substrate between the first surface of the mold and the second surface of the mold, and injecting resin into the mold after the compression-formed structure is formed to form a rib. The rib may be configured to direct establishment of a door upon deployment of the airbag to facilitate deployment of the airbag through the opening. The pre-form substrate may comprise a fiber panel. The step of forming the compression-formed structure may comprise forming the pre-form substrate into a generally rigid form. The compression-formed structure may comprise a first contour provided by the first surface of the mold and a second contour provided by the second surface of the mold. The pre-form substrate may comprise a resin; the process may comprise the step of heating the pre-formed substrate and the pre-formed substrate may be compressed as the pre-formed substrate cools.

FIGURES

[0016] FIGURE 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.

[0017] FIGURE IB is a schematic perspective cut-away view of a vehicle showing a vehicle interior according to an exemplary embodiment.

[0018] FIGURE 2A is a schematic perspective view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0019] FIGURES 2B through 2C are schematic perspective views of a deployment of an airbag from a vehicle interior component according to an exemplary embodiment.

[0020] FIGURES 3 A through 3F are schematic perspective views of a deployment of an airbag from a vehicle interior component according to an exemplary embodiment.

[0021] FIGURES 4A through 4F are schematic partial perspective views of a deployment of an airbag from a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0022] FIGURES 5A through 5G are schematic perspective views of a process to form a structural substrate of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0023] FIGURE 5H is a schematic partial perspective view of a structural substrate of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

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

[0025] FIGURE 7 is a schematic partial exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0026] FIGURE 8 is a schematic partial exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0027] FIGURE 9 is a schematic partial exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0028] FIGURE 10A is a schematic partial exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0029] FIGURE 10B is a schematic partial exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0030] FIGURE 11A is a schematic perspective view of a structural substrate for a component for a vehicle interior according to an exemplary embodiment. [0031] FIGURE 1 IB is a schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0032] FIGURE 11C is a schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0033] FIGURE 12 is a schematic partial exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.

[0034] FIGURE 13A is a schematic partial exploded section view of a component for a vehicle interior according to an exemplary embodiment.

[0035] FIGURE 13B is a schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.

[0036] FIGURES 14A to 14C are schematic partial section views of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment.

[0037] FIGURE 15A is a schematic partial perspective view of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment.

[0038] FIGURE 15B is a schematic partial section view of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment.

[0039] FIGURES 15C and 15D are schematic cutaway section views of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment. [0040] FIGURES 16A and 16B are schematic partial perspective views of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0041] FIGURES 17A and 17B are schematic partial perspective views of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0042] FIGURES 18A and 18B are schematic partial perspective views of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0043] FIGURE 19A is a schematic partial section view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0044] FIGURE 19B is a schematic partial side view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0045] FIGURE 19C is a schematic partial section view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.

[0046] FIGURES 20A to 20C are schematic partial section views of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment.

[0047] FIGURES 21A and 2 IB are schematic partial perspective views of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment. [0048] FIGURES 22A through 22C are schematic partial perspective views of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment. [0049] FIGURES 23A and 23C are schematic partial section views of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment.

[0050] FIGURES 24A and 24C are schematic partial section views of an airbag deployment from a component for a vehicle interior according to an exemplary embodiment.

[0051] FIGURE 25A is a schematic partial exploded section view of a component for a vehicle interior according to an exemplary embodiment.

[0052] FIGURE 25B is a schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.

DESCRIPTION

[0053] Referring to FIGURES 1A and IB, a vehicle V is shown including an interior I with an instrument panel IP and doors DL. According to an exemplary embodiment, components of vehicle V such as instrument panel IP and doors DL may include trim panels. According to an exemplary embodiment, components such as instrument panel IP and doors DL (and other trim components) may provide visible surfaces in the vehicle interior of vehicle V. According to an exemplary embodiment, instrument panel IP and/or doors DL may provide at least one airbag (configured to deploy from an airbag module) that is installed behind/within interior components such as instrument panel IP and/or doors DL. See FIGURES 2A-2C, 3A-3C and 4A-4F.

[0054] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, a component C such as instrument panel IP may be configured to provide an area to provide an opening/door ABD for deployment of an airbag AB such as from an airbag system/module ABS/ABM. See also FIGURES 3A-3C and 4A-4F.

[0055] As indicated schematically according to an exemplary embodiment in FIGURES 3A- 3F, the component may comprise a separation area PR shown as weakened line/area (e.g. such as a seam/tear line) to facilitate formation of the opening/door shown as airbag door ABD through which the airbag AB will deploy (e.g. where the airbag will break through the component during airbag deployment as intended). As indicated schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A- 15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A-25B, the component such as instrument panel C/IP may provide a separation area PR such as seam/tear line through which airbag AB will progressively develop an opening comprising an initial opening area/opening segment OS with lateral segments LS to form the airbag door ABD and through which opening airbag AB may deploy into the vehicle interior; the component C may comprise a panel PN configured to provide a structural substrate SB with a structure SR such as an airbag chute CH and a door structure DS with a structural feature SF configured to facilitate formation of the airbag door ABD at a separation area PR providing a tear line TR upon deployment of the airbag AB through the component C from the airbag system ABS/ABM; component C may comprise a cover/top surface CV/TX which may deform and provide a stretch area PR/TN at deployment of the airbag AB that ruptures during formation of the airbag door ABD. See FIGURES 14A-14C, 15A-15D, 20A-20C, 23A-23C and 24A-24C. [0056] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the component C may be configured to facilitate deployment of an airbag into the vehicle interior comprising a structural substrate SB comprising a panel PN and a structure SR such as airbag chute CH and/or door structure DS comprising a structural feature SF such as rib RB.

[0057] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the component may be configured to facilitate deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a structure comprising a door structure configured to facilitate formation of an airbag door at an opening at a separation area in the structural substrate during airbag deployment.

[0058] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the component may be configured to facilitate deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a structure comprising a structural feature and/or profde configured to facilitate formation of an initial opening area for the opening in the separation area of the structural substrate during airbag deployment; the panel may comprise a fiber panel FP, plastic/resin panel PL, etc.

[0059] As indicated schematically in FIGURES 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 21A-21B and 22A-22C, door structure DS may comprise a structural feature SF providing a profile such as a flat form or contour form or cover/surface at a section shown as contact/rigidification section CS configured to provide a contact surface CT for airbag at deployment to create a force/stress concentration at the edge ND of the air bag door ABD to provide the initial opening area OS ; door structure DS may also comprise a reinforcing section RS configured to facilitate formation of the hinge at hinge area HG during deployment of the airbag through the opening at the airbag door. Exemplary Embodiments - A

[0060] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, a component C for an interior I of a vehicle V configured to facilitate deployment of an airbag AB may comprise a structural substrate SB comprising a panel PN and a structure SR comprising a structural feature SF; the structural feature may be configured to facilitate formation of an airbag door at an opening at a separation area PR in the structural substrate during deployment of the airbag, See also FIGURES 14A-14C, 15A- 15D, 20A-20C, 23A-23C and 24A-24C.

[0061] As indicated schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the panel may comprise a fiber panel; the structure may be provided on the fiber panel; the fiber panel may comprise a compressed fiber panel. The panel may comprise a formed panel; the panel may comprise a formed resin panel. As indicated schematically, the component may comprise a cover on the panel.

[0062] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A- 25B, the structure may comprise an airbag chute; the structure may comprise a door structure DS configured to facilitate formation of an initial opening area for the opening during deployment of the airbag. As indicated schematically, the structure may comprise a door structure configured to facilitate formation of an initial opening area at an edge of the door for the opening during deployment of the airbag; the door structure DS may comprise a profile providing a contact area CT for the airbag configured to facilitate formation of the initial opening area OS at the edge ND of the door for the opening during deployment of the airbag; the profile may comprise at least one of (a) raised height within the profile and/or (b) varying shape along the profile. As indicated schematically, the profile may comprise a raised height across the profile. As indicated schematically, the structural feature of the door structure may be configured to facilitate formation of the initial opening area at a stress concentration at the edge of the door and then lateral opening segments for the opening during deployment of the airbag; the structural feature may comprise a contact area for the airbag during deployment of the airbag. As indicated schematically, the panel may comprise the separation area configured to provide an initial opening area for formation of the opening for the airbag; the opening may be configured to comprise the initial opening area and then lateral segments along the separation area; the panel may comprise the separation area for formation of the opening for the airbag with an initial opening area at an edge of the airbag chute; the panel may comprise the separation area for formation of the opening for the airbag; the opening may be configured to form at an edge of the airbag door adjacent the edge of the airbag chute. As indicated schematically, the separation area may comprise a tear line. As indicated schematically, the structure may comprise a door structure comprising the structural feature within the airbag chute; the structural feature may comprise a contact area provided by a profile; the structural feature may comprise a rib structure transverse to the separation area. As indicated schematically, the structural feature may comprise a set of projections; the profile may comprise a raised profile comprising the set of projections; the set of projections may comprise as a set of walls of varying height across the profile. As indicated schematically, the opening may comprise a U-shaped opening; the separation area may be configured to produce the U-shaped opening.

[0063] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the structural substrate may comprise a notch configured to establish the opening for deployment of the airbag through the opening. The structural feature may comprise a rib adjacent the notch; the rib may be transverse to the notch. The notch may comprise a recess or a depression in the structural substrate. As indicated schematically, the rib may comprise a wall generally perpendicular to the recess or depression; the separation area may comprise a tear line; the rib may be transverse to the tear line; the rib may comprise a wall generally perpendicular to the tear line; the rib may comprise a wall; the wall may comprise a height extending from the structural substrate; the height may comprise a first height and a second height greater than the first height; the height may increase from a first end of the wall to a second end of the wall; the second end of the wall may be adjacent a tear line for the opening for deployment of the airbag; the height of the wall may decrease as the wall extends away from a tear line for the opening for deployment of the airbag. As indicated schematically, the tear line may be provided at a separation area. As indicated schematically, the structure may comprise a molded structure; the structure may comprise a formed resin structure; the structure may comprise the structural feature formed on the panel.

[0064] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A- 25B, the structure SR may comprise a door structure DS. As indicated schematically, the door structure may comprise a frame structure; the door structure may comprise a grid structure; the door structure may comprise a backing structure; the door structure may comprise a web structure; the door structure may comprise a cell structure; the door structure may comprise a honeycomb structure. As indicated schematically, the door structure may comprise a two- section structure.

[0065] As indicated schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, I IA-IIC, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A- 19C, 20A-20C, 21 A-21B, 22A-22C, 24A-24C and 25A-25B, the door structure DS may comprise a reinforcement section RS and a contact/rigidification section CS; the door structure may comprise a reinforcement section and the structural feature; the door structure may comprise a rigidification section; the rigidification section may comprise the structural feature; the structure may comprise an airbag chute; the airbag chute may comprise a frame; the frame may be configured for the airbag door; the structure may comprise an airbag chute and a door structure configured to form an airbag door; the panel may comprise a separation area configured for formation of the airbag door; the separation area may be provided at the airbag chute; the separation area may comprise a separation line within the airbag chute; the separation area may be between an edge of the airbag door and a frame of the airbag chute; the separation area may be provided within the airbag chute; the airbag door may be configured to be formed at the separation area within the airbag chute; the airbag door may be configured to be formed at the separation area within a frame of the airbag chute; the frame of airbag chute may comprise sidewalls; the door structure may comprise the structural feature; the structural feature may comprise a rib structure; the rib structure may comprise at least one rib; the door structure may comprise a rigidification section; the structural feature may comprise the rigidification section; the rigidification section may comprise a rib structure; the rigidification section may comprise a profile; the door structure may comprise a profile; the door structure may comprise a structural feature; the structural feature may comprise a shape; the door structure may comprise a contour shape; the door structure may comprise a varying depth and/or a varying depth; the door structure may comprise a set of projections; the door structure may comprise a wall structure; the wall structure may comprise a set of walls; the set of walls may comprise walls of a varying form; the set of walls may comprise walls of a varying shape; the set of walls may comprise walls of a varying height; the set of walls may comprise walls of a varying depth; the set of walls may comprise a high point; the high point may comprise a contact area for the airbag at deployment of the airbag; the door structure may comprise a contact area configured for contact by the airbag during deployment of the airbag; the contact area may comprise an initial contact area for the airbag during deployment of the airbag; the contact area may be configured to create an initial opening area for the opening for the airbag during deployment of the airbag; the initial opening area may be configured to comprise a tear; the initial opening area may be configured to comprise a rupture in the panel; the initial opening area may be configured to comprise a break point in the panel; the component may comprise a cover; the initial opening area may be configured to comprise a shear tear in the cover at a separation area. See FIGURES 14A-14C, 15A-15D, 20A-20C, 23A-23C and 24A-24C. The door structure may comprise a plate coupled to the set of walls configured for contact from the airbag during deployment of the airbag. The plate may be welded to the set of walls. See FIGURES 10A, 10B and 22A-22C. The door structure may comprise a set of connectors coupled to the set of walls.

[0066] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A- 25B, contact of the airbag at the contact area may create a stress concentration at the initial opening area of the separation area; the door structure may comprise a profile; the profile may be configured to provide the contact area; the profile may comprise a uniform profile; the profile may comprise a non-uniform profile; the profile may comprise a contoured profile; the door structure may comprise a set of flanges; the door structure may comprise a web structure; the door structure may comprise a frame section; the door structure may comprise a contact section; the structural feature may comprise a contact surface; the contact surface may be configured to be in contact with the airbag to facilitate formation of the airbag door; the contact surface may comprise a contact area for the airbag during deployment of the airbag; the structural feature may comprise an end; the end may comprise a front edge FN; the end may comprise a nose; the nose may comprise a compliant section; the opening for the airbag door may be formed in a separation area. As indicated schematically in FIGURES 15A-15D, the edge of the airbag door may be configured to deform upon contact with an obstruction such as a windshield WS (e.g. to reduce the likelihood of breakage/damage). An edge of the airbag door may be formed at the separation area; the edge of the airbag door may be formed by a shear tear; the separation area may comprise a notch; the edge of the airbag door may be formed at the notch; the notch provides an initial opening area during formation of the opening; the notch may provide the initial opening area at an edge of the airbag door during deployment of the airbag; the panel may comprise the edge of the airbag door; the panel may comprise a hinge area HG for the airbag door; the airbag door ABD may comprise an edge ND and a hinge area HG; the edge may be formed at a tear line in the separation area; the tear line may be configured to form the opening in the panel; the separation area may be configured to form the opening in the panel; the separation area may be configured to form the opening in the panel by facilitating formation of the airbag door by shear force at an initial opening area at a contact area of the structural feature with the airbag during deployment of the airbag. See FIGURES 14A-14C, 15A-15D, 20A-20C, 23A-23C and 24A- 24C.

[0067] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A- 25B, the door structure may comprise the structural feature; the structural feature of the door structure may be configured to direct force to the separation area during formation of the airbag door. A profile of the door structure may be configured to direct force to the separation area during formation of the airbag door; the structural feature of the door structure may be configured to direct force to the separation area to create an initial opening area during formation of the airbag door; the structural feature of the door structure may be configured to direct force to the separation area to create a stress concentration during formation of the airbag door; the structural feature of the door structure may be configured to direct force to the separation area to provide a shear force during formation of the airbag door; the structural feature of the door structure may be configured to direct force to the separation area to create a stress concentration to provide a shear force during formation of the airbag door; the structural feature of the door structure may comprise a contact area for the airbag during deployment of the airbag to create the stress concentration; the structural feature may comprise a projection on the door structure.

[0068] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the separation area may comprise a notch; the separation area may comprise a tear line for formation of the opening for deployment of the airbag; the structural feature may be configured to direct establishment of the tear line; the tear line may comprise at least one of (a) a weakening line or (b) a weakened segment. The tear line may comprise a U-shaped line. The opening for the airbag may be configured to be formed at a separation area; the separation area may comprise a tear line comprising an opening segment configured to create an initial opening area at a contact area of the airbag during deployment of the airbag. The tear line may comprise an opening segment and lateral segments transverse to the opening segment; the structural feature may be configured to create an initial opening area at the opening segment of the tear line; the opening segment of the tear line may be configured to extend to form lateral segments of the tear line; the opening segment of the tear line may be configured to establish lateral segments of the tear line; the opening may be formed at the tear line comprising the opening segment and the lateral segments. . See FIGURES 14A-14C, 15A-15D, 20A-20C, 23A-23C and 24A-24C.

[0069] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the panel may comprise fibers. The panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The cover may comprise at least one of (a) a resin; (b) TPO; (c) leather; (d) synthetic leather; (e) fabric. The structural feature may be formed on the panel; the structural feature may comprise resin.

As indicated schematically according to an exemplary embodiment in FIGURES 2A-2C, 3A- 3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A- 16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A-25B, the component may comprise an airbag chute. The airbag chute may comprise the structural feature. The airbag chute may comprise a structural feature. The structural feature on the airbag chute may comprise a set of walls. The structural feature on the airbag chute may comprise a frame. The structural feature on the airbag chute may comprise a frame for the airbag door. The structural substrate may comprise a notch configured to establish the opening for deployment of the airbag through the opening. The structural feature may be adjacent the notch. The structural feature may be transverse to the notch. The notch may comprise a recess in the structural substrate. The structural feature may comprise a wall generally perpendicular to the recess. The structural feature may comprise a wall; the wall may comprise a height extending from the structural substrate. The height may comprise a first height and a second height greater than the first height. The height may increase from a first end of the wall to a second end of the wall. The second end of the wall may be adjacent a tear line for the opening for deployment of the airbag. The height of the wall may decrease as the wall extends away from a tear line for the opening for deployment of the airbag.

[0070] As indicated schematically according to an exemplary embodiment in FIGURES 2A- 2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the structural substrate may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat. The structural feature may comprise a rib. The separation area for the airbag door may comprise a notch; the notch may comprise a formed notch.

[0071] As indicated schematically according to an exemplary embodiment in the FIGURES, the airbag door may comprise a set of airbag doors. The component may comprise at least one of (a) an instrument panel; (b) a door panel; (c) a trim panel; (d) a trim component. See FIGURES IA-IB and 2A-2C.

[0072] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A- 25 B, a component for an interior of a vehicle configured to facilitate deployment of an airbag through an opening into the interior may comprise a structural substrate configured to provide the opening by formation of an airbag door at a separation area during deployment of the airbag; and a structure comprising a structural feature provided on the structural substrate. The structural feature may be configured to facilitate formation of the airbag door and an initial opening area for the opening in the structural substrate during deployment of the airbag. The structural substrate may comprise a panel; the panel may comprise the structure. The structural substrate may comprise a fiber panel; the structure may be provided on the fiber panel. The separation area may be configured to form the opening in the panel. The separation area may be configured to form the opening in the panel by facilitating formation of the initial opening area in the airbag door by shear force. The structure may comprise a door structure comprising the structural feature. The structural feature of the door structure may be configured to direct force to the separation area to create the initial opening area during formation of the airbag door. A profile of the door structure may be configured to direct force to the separation area to create the initial opening area during formation of the airbag door. A raised section of the profile of the door structure may be configured to direct force to the separation area to create the initial opening area during formation of the airbag door. The structural feature of the door structure may be configured to direct force to the separation area to create a stress concentration to create the initial opening area during formation of the airbag door. The structural feature of the door structure may be configured to direct force to the separation area to provide a shear force to create the initial opening area during formation of the airbag door. The structure may be formed on the panel. The structure may comprise an airbag chute. The structure may comprise a molded structure.

The structural substrate may comprise a compressed fiber panel. The structural substrate may comprise a formed resin panel. The structure may comprise a formed resin structure. The component may comprise a cover. The structural substrate may comprise an airbag door section; the airbag door may be configured to be formed at the airbag door section of the structural substrate. The structural feature may be provided at the airbag door section of the panel. The airbag chute may comprise a frame; the structural feature may be provided at the airbag door section of the panel; the airbag door may be configured to be formed within the frame of the airbag chute.

[0073] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, a component for a vehicle interior configured for deployment of an airbag through an opening into the vehicle interior may comprise a structural substrate providing at least one door established upon deployment of the airbag to facilitate deployment of the airbag through the opening; and a rib. The rib may be configured to direct establishment of the door upon deployment of the airbag.

[0074] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, a component for an interior of a vehicle configured to facilitate deployment of an airbag through an opening into the interior may comprise a panel configured to provide the opening by formation of an airbag door during deployment of the airbag; and a structure comprising a structural feature provided on the panel. The structural feature may be configured to facilitate formation of the airbag door and the opening of the panel during deployment of the airbag. The panel may comprise a structural substrate; the structural substrate may comprise the structure. The panel may comprise a plastic panel; the plastic panel may comprise the structure.

[0075] According to an exemplary embodiment as shown schematically in FIGURES 5A-5H, a component for a vehicle interior configured for deployment of an airbag through an opening into the vehicle interior may be produced in a mold M comprising a first surface/top MT and a second surface/bottom MB by a process comprising placing a pre-form substrate shown as a fiber mat FM onto the first surface of the mold (after fiber mat may be pre-heated such as in an oven OV); forming a compression-formed structure from the pre-form substrate by compressing the pre-form substrate between the first surface of the mold and the second surface of the mold to provide a panel PN for the compression-formed structure/structural substrate SB; and injecting resin into the mold to form the compression- formed structure/structural substrate SB with structure SR such as an airbag chute CH and a door structure DS comprising a structural feature shown as rib. See also FIGURES 2A-2C, 3A- 3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A- 24C and 25A-25B. The structural feature shown as rib may be configured to direct establishment of a door upon deployment of the airbag to facilitate deployment of the airbag through the opening; the pre-form substrate may comprise a fiber panel; the step of forming the compression-formed structure may comprise forming the pre-form substrate into a generally rigid form; the compression- formed structure may comprise a first contour provided by the first surface of the mold and a second contour provided by the second surface of the mold; the pre-form substrate may comprise a resin; the process may comprise the step of heating the pre-formed substrate and the pre-formed substrate may be compressed as the pre-formed substrate cools. See FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A- 10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B.

[0076] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the component may be configured to facilitate deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a structure comprising a structural feature. See FIGURES 14A-14C, 15A-15D, 20A-20C, 23A-23C and 24A-24C.

[0077] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the component may be configured to facilitate deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a structure comprising a door structure configured to facilitate formation of an airbag door at an opening at a separation area in the structural substrate during airbag deployment. See FIGURES 14A-14C, 15A-15D, 20A-20C, 23A-23C and 24A-24C.

[0078] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 12, 13A-13B, 14A-14C, 15A-15D, 20A-20C, 24A-24C and 25A-25B, the component may be configured to facilitated deployment of an airbag into the vehicle interior comprising a structural substrate comprising a panel and a structure comprising a structural feature and/or profile configured to facilitate formation of an initial opening area for the opening in the separation area of the structural substrate during airbag deployment. See FIGURES 14A-14C, 15A-15D, 20A-20C, 23A-23C and 24A-24C. [0079] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A- 25B, a component for a vehicle interior may comprise a structural substrate comprising a panel and a structure comprising a structural feature; the structural feature may facilitate formation of an airbag door at an opening at a separation area in the structural substrate during deployment of an airbag. The panel may comprise a fiber panel; the structure may be provided on the fiber panel. The structure may comprise a door structure to facilitate formation of an initial opening area for the opening during airbag deployment. The door structure may comprise a profile providing a contact area for the airbag to facilitate formation of the initial opening area at an edge of the door during airbag; the profile may comprise a raised height within the profile and/or varying shape along the profile.

Exemplary Embodiments - B

[0080] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5F-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A- 25 B, a component C for a vehicle interior configured for deployment of an airbag AB through an opening into the vehicle interior may comprise a structural substrate SB providing at least one door ABD established upon deployment of the airbag to facilitate deployment of the airbag through the opening, and a rib RB. The rib may be configured to direct establishment of the door upon deployment of the airbag. The structural substrate may be configured to provide a tear line TR for the opening for deployment of the airbag; the rib may be configured to direct establishment of the tear line. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The tear line may comprise a U-shaped line. The tear line may comprise an opening section and a lateral section transverse to the opening section. The rib may be configured to direct establishment of the opening section of the tear line. The opening section of the tear line may be configured to establish the lateral section of the tear line. The opening may be formed at the tear line comprising the opening section and the lateral section. The structural substrate may comprise a panel comprised at least partially of fibers. The panel further may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The rib may be formed on the panel; the rib may comprise resin. The component may comprise an airbag chute CH; the airbag chute may comprise the rib. The structural substrate may comprise a notch NR configured to establish the opening for deployment of the airbag through the opening. The rib may be adjacent the notch. The rib may be transverse to the notch. The notch may comprise a depression in the structural substrate. The rib may comprise a wall generally perpendicular to the depression. The rib may comprise a wall; the wall may comprise a height extending from the structural substrate. The height may comprise a first height and a second height greater than the first height. The height may increase from a first end of the wall to a second end of the wall. The second end of the wall may be adjacent a tear line for the opening for deployment of the airbag. The height of the wall may decrease as the wall extends away from a tear line for the opening for deployment of the airbag. The structural substrate may comprise at least one of (a) a compression-formed component; (b) a generally rigid fiber mat.

[0081] According to an exemplary embodiment as shown schematically in FIGURES 2A-2C, 3A-3F, 4A-4F, 5A-5H, 6, 7, 8, 9, 10A-10B, 11A-11C, 12, 13A-13B, 14A-14C, 15A-15D, 16A-16B, 17A-17B, 18A-18B, 19A-19C, 20A-20C, 21A-21B, 22A-22C, 24A-24C and 25A- 25B, a component for a vehicle interior configured for deployment of an airbag through an opening into the vehicle interior may be produced in a mold comprising a first surface and a second surface by a process comprising placing a pre-form substrate onto the first surface of the mold, forming a compression-formed structure from the pre- form substrate by compressing the pre-form substrate between the first surface of the mold and the second surface of the mold, and injecting resin into the mold after the compression-formed structure is formed to form a rib. The rib may be configured to direct establishment of a door upon deployment of the airbag to facilitate deployment of the airbag through the opening. The preform substrate may comprise a fiber panel. The step of forming the compression-formed structure may comprise forming the pre-form substrate into a generally rigid form. The compression-formed structure may comprise a first contour provided by the first surface of the mold and a second contour provided by the second surface of the mold. The pre-form substrate may comprise a resin; the process may comprise the step of heating the pre- formed substrate and the pre-formed substrate is compressed as the pre-formed substrate cools.

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[0082] 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 exemplar)' embodiments rather than as a limitation on the scope of the present inventions.

[0083] 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.