WO2016077773A1

WO2016077773A1 - Vehicle trim component having cover and method for such manufacturing vehicle trim component via compression forming and injection molding

Info

Publication number: WO2016077773A1
Application number: PCT/US2015/060710
Authority: WO
Inventors: Bart W. Fox
Original assignee: Yangfeng Us Automotive Interior Systems I Llc
Priority date: 2014-11-14
Filing date: 2015-11-13
Publication date: 2016-05-19

Abstract

A vehicle trim component includes a fiber panel and a cover pressure coupled to the fiber panel. The vehicle trim component also includes resin coupled to at least one of the cover and the fiber panel. A method of forming a vehicle trim component includes disposing the cover and fiber panel between a first surface of a mold and a second surface of a mold, compressing them to form a compression formed component having a shape that corresponds to a first contour of the first surface and a second contour of the second surface, and injecting resin into the mold to fill at least one first void disposed adjacent to at least one of a peripheral side surface and an interior side surface of at least one of the cover and the fiber panel.

Description

VEHICLE TRIM COMPONENT HAVING COVER AND METHOD FOR SUCH MANUFACTURING VEHICLE TRIM COMPONENT VIA COMPRESSION FORMING AND INJECTION MOLDING CROSS-REFERENCE TO RELATED PATENT APPLICATIONS [0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No.62/079,932, filed on November 14, 2014, the entire disclosure of which is hereby incorporated by reference. FIELD [0002] This application relates generally to a vehicle trim component and method for manufacturing a vehicle trim component via compression forming and injection molding. BACKGROUND [0003] Certain vehicle trim components are produced by compression forming a fiber panel into a desired shape. For example, certain fiber panels include a combination of structural fibers and thermoplastic resin. To form a trim component from such a fiber panel, the panel is heated to induce the thermoplastic resin to liquefy. The fiber panel is then placed into a low- temperature mold, and compression molded into a desired shape. As the fiber panel cools, the thermoplastic solidifies, thereby establishing a substantially rigid composite panel in the shape of the mold. Alternative fiber panels include a combination of structural fibers and a thermoset resin. To form a trim component from such a fiber panel, the panel is compressed within a heated mold to form the panel into the desired shape, and to induce curing of the resin. Once the thermoset resin cures, a substantially rigid composite panel is formed. [0004] Once the molding process is complete, the composite panel is removed from the mold, and the edges are trimmed to the desired dimensions. The composite panel is then placed within a second mold to form ancillary components, such as support ribs and/or connectors. For example, the second mold may include a primary cavity configured to receive the trim component, and secondary cavities corresponding to the shape of each ancillary component. In such configurations, liquid resin is injected into each of the additional cavities to form the desired ancillary components. As the resin hardens, the ancillary components bond to the surface of the composite panel, thereby forming a completed trim component. Alternatively, components may be attached to the panel with adhesives and/or mechanical connectors, or rigid components may be pressed into the fiber panel during the compression forming process. [0005] Moreover, a cover may be adhered to the compressed fiber panel. For example, the compressed fiber panel may be removed from the mold cavity and trimmed and the cover may be adhered to the surface of the trim component and further trimmed to form a desired surface of the trim component. [0006] The process of trimming the composite panel to establish the dimensionally accurate edges is time consuming and generates a significant amount of offal (i.e., excess material). In addition, transferring the trim component from the first mold to the second mold increases the duration of the manufacturing process. Furthermore, the design and manufacturing costs associated with producing two separate molds increases the setup expenses for the trim component manufacturing process. Additionally, the duration of the manufacturing process may be increased because the cover is bonded to the trim component in a separate processing step. Moreover, the additional trimming steps to trim the cover further increases the duration of the manufacturing process, and may also increase the cost of manufacturing the trim component. Furthermore, wrapping the cover around the trim component to cover the visible surface and provide a secure bond may waste cover by covering areas that may not be visible after installation. [0007] It has been considered to apply the cover during compression molding. However, conventional techniques have not recognized advantageous approaches to coupling resin to the cover and compressed fiber panel. SUMMARY [0008] One aspect relates to a vehicle trim component prepared by a process that includes disposing a cover onto a first surface of a mold, disposing a fiber panel onto the cover, and compressing the fiber panel and the cover between the first surface and a second surface of the mold to couple the fiber panel and the cover and form the fiber panel into a compression formed component having a shape. The shape corresponds to a first contour of the first surface and a second contour of the second surface. Resin is injected into the mold after the compression formed component is formed to fill at least one first void, and the vehicle trim component is removed from the mold. [0009] Another aspect relates to a vehicle trim component including a fiber panel, a cover coupled to the fiber panel, and resin coupled to at least one of the cover and the fiber panel.’ [0010] Another aspect relates to a method of forming a vehicle trim component. The method includes disposing a cover and a fiber panel relative to one another at respective lateral faces and between a first surface of a mold and a second surface of a mold, and compressing the fiber panel and the cover between the first surface and the second surface of the mold to couple the fiber panel and the cover and form a compression formed component having a shape. The shape corresponds to a first contour of the first surface and a second contour of the second surface. The method further includes injecting resin into the mold after the compression formed component is formed to fill at least one first void disposed adjacent to at least one of a peripheral side surface and an interior side surface of at least one of the cover and the fiber panel, and removing the vehicle trim component from the mold. BRIEF DESCRIPTION OF THE DRAWINGS [0011] FIG.1A is a schematic perspective view of an exemplary embodiment of a vehicle containing an embodiment of the invention. [0012] FIG.1B is a schematic perspective view of the vehicle shown in FIG.1A, cut away to show and exemplary embodiment of the interior of the vehicle. [0013] FIG.2A is a schematic perspective view of an exemplary embodiment of a floor console with an exemplary embodiment of a vehicle trim component according to the present invention. [0014] FIG.2B is a schematic perspective view of the floor console shown in FIG.2A with the vehicle trim component removed. [0015] FIG.2C is a schematic perspective view of vehicle trim component shown in FIG. 2A, removed from the floor console. [0016] FIG.2D is a schematic perspective view of an exemplary embodiment of a floor console with an exemplary embodiment of a vehicle trim component according to the present invention. [0017] FIG.2E is a schematic perspective view of the floor console shown in FIG.2D with the vehicle trim component removed. [0018] FIG.2F is a schematic perspective view of vehicle trim component shown in FIG. 2D, removed from the floor console. [0019] FIG.3A is a schematic perspective view of an exemplary embodiment of a floor console with an exemplary embodiment of a vehicle trim component according to the present invention. [0020] FIG.3B is a schematic perspective, partial sectional view of a portion of the vehicle trim component shown in FIG.3A. [0021] FIG.3C is a schematic perspective view of the vehicle trim component shown in FIG.3A removed from the floor console. [0022] FIG.3D is a schematic perspective view of vehicle trim component shown in FIG. 3A, removed from the floor console. [0023] FIG.3E is a schematic cross-sectional view of the floor console and vehicle trim component shown in FIG.3A. [0024] FIG.4A is a schematic perspective view of an exemplary embodiment of a floor console with an exemplary embodiment of a vehicle trim component according to the present invention. [0025] FIG.4B is a schematic perspective, partial sectional view of a portion of the vehicle trim component shown in FIG.4A. [0026] FIG.4C is a schematic perspective view of the vehicle trim component shown in FIG.4A removed from the floor console. [0027] FIG.4D is a schematic perspective view of vehicle trim component shown in FIG. 4A, removed from the floor console. [0028] FIG.4E is a schematic cross-sectional view of the floor console and vehicle trim component shown in FIG.4A. [0029] FIG.5A is a schematic perspective view of an exemplary embodiment of a floor console with an exemplary embodiment of a vehicle trim component according to the present invention. [0030] FIG.5B is a schematic perspective, partial sectional view of a portion of the vehicle trim component shown in FIG.5A. [0031] FIG.5C is a schematic perspective view of the vehicle trim component shown in FIG.5A removed from the floor console. [0032] FIG.5D is a schematic perspective view of vehicle trim component shown in FIG. 5A, removed from the floor console. [0033] FIG.5E is a schematic cross-sectional view of the floor console and vehicle trim component shown in FIG.5A. [0034] FIG.6A is a schematic perspective view of an exemplary embodiment of a floor console with an exemplary embodiment of a vehicle trim component according to the present invention. [0035] FIG.6B is a schematic perspective, partial sectional view of a portion of the vehicle trim component shown in FIG.6A. [0036] FIG.6C is a schematic perspective view of the vehicle trim component shown in FIG.6A removed from the floor console. [0037] FIG.6D is a schematic perspective view of vehicle trim component shown in FIG. 6A, removed from the floor console. [0038] FIG.6E is a schematic cross-sectional view of the floor console and vehicle trim component shown in FIG.6A. [0039] FIG.7A is a schematic cross-sectional view of an exemplary embodiment of a mold for forming an exemplary embodiment of a vehicle component, showing an exemplary embodiment of a fiber panel and a cover, where the mold is in an open position. [0040] FIG.7B is a schematic cross-sectional view of the mold shown in FIG.7A, where the mold is in a partially closed position before compressing the fiber panel. [0041] FIG.7C is a schematic cross-sectional view of the mold shown in FIG.7A, where the mold is in a fully closed position after compressing the fiber panel. [0042] FIG.7D is a schematic cross-sectional view of the mold shown in FIG.7A, where the mold is in a fully closed position and resin is being injected. [0043] FIG.7E is a schematic cross-sectional view of the mold shown in FIG.7A, where the mold is in a fully closed position and after injection of the resin. [0044] FIG.7F is a schematic cross-sectional view of the mold shown in FIG.7A, where the mold is in an open position and the vehicle trim component is being removed. [0045] FIG.8A is a schematic, cross-sectional view of an exemplary embodiment of a vehicle trim component according to the present invention. [0046] FIG.8B is a schematic, cross-sectional view of an exemplary embodiment of a vehicle trim component according to the present invention. [0047] FIG.8C is a schematic, cross-sectional view of an exemplary embodiment of a vehicle trim component according to the present invention. [0048] FIG.8D is a schematic, cross-sectional view of an exemplary embodiment of a vehicle trim component according to the present invention. [0049] FIG.8E is a schematic, cross-sectional view of an exemplary embodiment of a vehicle trim component according to the present invention. [0050] FIG.8F is a schematic, cross-sectional view of an exemplary embodiment of a vehicle trim component according to the present invention. [0051] FIG.8G is a schematic, cross-sectional view of an exemplary embodiment of a vehicle trim component according to the present invention. DETAILED DESCRIPTION [0052] Referring generally to the figures, this application discloses various embodiments of vehicle trim components for use in vehicles and methods for producing the vehicle trim components. [0053] Exemplary Vehicle Trim Components [0054] FIG.1 is a perspective view of an exemplary embodiment of a vehicle V that may include a trim component according to the present invention. According to an exemplary embodiment, the vehicle V includes an interior I having an instrument panel IP, a seat ST, a floor console FC, and door D. Certain trim components of the instrument panel IP, seat ST, floor console FC, door D, and/or other areas within the interior I may be manufactured in accordance with the present invention. [0055] Exemplary embodiments of vehicle trim components 10, 11, 12, 13, 14, 15, 16 are shown in the schematic views of FIGS.8A-8G. According to exemplary embodiments, the vehicle trim component may include a compression formed component including a cover (or coverstock) C that is pressure coupled to a fiber panel P. According to exemplary embodiments, the cover C can be pressure coupled to the compressed fiber panel P along respective lateral faces, i.e., lateral face 20 of cover P and lateral face 22 of fiber panel P. The term pressure coupling is intended to encompass not only coupling that is facilitated by use of pressure, but also coupling aided by adhesive or other means that is subjected to compression of the cover P toward the fiber panel P. [0056] The cover C of the vehicle trim component be provided on at least a portion of the fiber panel P to provide a desired appearance on the A surface, i.e., the surface intended to be visible to the occupant of the vehicle V. For example, the cover C may establish a show surface (e.g., a visible surface) that matches the vehicle interior I, thereby enhancing the appearance of the trim component. According to exemplary embodiments, the cover C may extend over just a portion of the fiber panel P (FIG.8A), may be coextensive with the fiber panel P (FIGS.8C, 8D), or may extend beyond the ends of fiber panel P (FIGS.8B, 8E, 8F, 8G). According to exemplary embodiments, the cover C may include or may consist of a woven fabric, a non-woven fabric, an appliqué, vinyl, foam, foil, leather, or a combination thereof. [0057] The fiber panel P of the vehicle trim component may be used to provide a form and a desired level of structural rigidity for the vehicle trim component. In exemplary embodiments, the fiber panel P includes a combination of structural fibers and resin.

According to exemplary embodiments, the structural fibers may include natural fibers, such as hemp, wood, flax, kenaf, and sisal, and/or synthetic fibers, such as glass fibers, carbon fibers, and polymeric fibers. According to an exemplary embodiment, the fiber panel P may be constructed from about 50 percent natural fibers and about 50 percent PP. According to an exemplary embodiment, the resin of the fiber panel P may include a thermoplastic resin such as, for example, polypropylene (PP), acrylonitrile butadiene styrene (ABS), and/or polycarbonate (PC) binders. According to an exemplary embodiment, the resin of the fiber panel P may include a thermoset resin such as, for example, epoxy resin, polyimide resin, polyester resin, and/or vinylester resin. [0058] According to exemplary embodiments, the vehicle trim component may include resin Ra, Rb that has been coupled via injection molding to the cover C and/or the fiber panel P. According to exemplary embodiments, the resin Ra, Rb may include a thermoplastic material, such as polypropylene (PP), acrylonitrile butadiene styrene (ABS), or polycarbonate (PC). As another alternative, the resin may include a thermoset material, such as epoxy resin, polyimide resin, polyester resin, or vinylester resin. [0059] According to exemplary embodiments, the resin Ra may be coupled to at least one of a peripheral side surface 30, 32 and an interior side surface 34 of at least one of the cover C and the compressed fiber panel P. According to exemplary embodiments, the resin Ra may provide a full or partial frame or border for the vehicle trim component. The resin Ra can be efficiently placed for desired structure, rigidity, appearance, and/or other desired features. According to exemplary embodiments, the resin Ra also may be used to form other features, such as attachment or alignment features. According to exemplary embodiments, these other features may be provided on or an integral part of the border. [0060] According to exemplary embodiments, the vehicle trim component may also include injection-molded resin Rb to provide an ancillary component. According to exemplary embodiments, the ancillary component may be a rib, honeycomb, or other strengthening structure. The strengthening structure, according to exemplary embodiments, can be configured to support the fiber panel P, thereby providing a stronger trim component, and/or reducing the weight of the trim component by facilitating a reduction in fiber panel thickness. In certain embodiments, the strengthening structure may extend across the interface between the fiber panel P and the border formed by resin Ra, to thereby enhance the strength of the panel/border interface. According to exemplary embodiments, the strengthening structure may be arranged or configured (e.g., oriented perpendicular to a desired collapse direction) to facilitate a desired degree or direction of energy absorption. [0061] According to exemplary embodiments, the ancillary component instead or in addition may be other features, such as connector, attachment, or alignment features (such as holes, pins, mounts, etc.). The connectors, attachment or alignment features can be configured to facilitate coupling between the trim component and another surface (e.g., door frame, instrument panel support structure, etc.) within the interior I of the vehicle V. The resin Rb may have a composition that is the same as or different from resin Ra. The resin Rb can be efficiently placed for desired structure, rigidity, appearance, and/or other desired features. [0062] Schematic and exemplary embodiments of vehicle trim components are illustrated in FIGS.8A-8G. According to exemplary embodiments, resin Ra may be coupled to the peripheral side surface 30 of the cover C (FIGS.8A, 8C, 8F), the resin Ra may be coupled to the peripheral side surface 32 of the compressed fiber panel P (FIGS.8A, 8B, 8E), and/or the resin Ra may be coupled to (and, for example, across) the peripheral side surfaces 30, 32 of both the cover C and the compressed fiber panel P (FIGS.8D). According to exemplary embodiments, the resin Ra may be coupled to an interior side surface 34 of at least one of the cover C and the compressed fiber panel P. Only an interior side surface 34 of the compressed fiber panel P is illustrated in FIG.8G, but it is understood that a similar interior side surface could be provided on the cover C alone or on both the cover C and the compressed fiber panel P. In exemplary embodiments, the cover C can be sized to substantially cover or not cover the resin Ra, as desired for the particular envisaged or desired usage. In FIGS.8A-8G, the injection-molded resin Rb, which provides the ancillary component, is shown coupled to a lateral face of the fiber panel P. However, such ancillary components could be provided at other locations, such as coupled to the cover C or as part of the resin Ra that is coupled to the peripheral or interior side surfaces 30, 32, 34. [0063] While the description has related to resins Ra and Rb, it is understood that the resins Ra and Rb may be the same or different resins and may be formed at the same or different times on the cover C and/fiber panel P. [0064] Exemplary Methods of Forming Vehicle Trim Components [0065] According to exemplary embodiments, a process for manufacturing a trim component by a compression forming and injection molding, and the trim component formed by that process. According to exemplary embodiments, the process may include disposing the cover and the fiber panel relative to one another at respective lateral faces and between a first surface of a mold and a second surface of a mold. It further includes compressing the fiber panel and the cover between the first surface and the second surface of the mold to couple the fiber panel and the cover and form a compression formed component having a shape. The shape corresponds to a first contour of the first surface and a second contour of the second surface. The method further includes injecting resin into the mold after the compression formed component is formed to fill at least one first void disposed adjacent to compression formed component, such as adjacent to at least one of the cover and the fiber panel. The vehicle trim component can then be removed from the mold. [0066] The compression forming and injection molding process may facilitate formation of a trim component having dimensionally accurate edges, thereby obviating the post-molding trimming process. Due to the dimensional accuracy of the mold cavity, each edge of the resultant trim component substantially corresponds to the desired dimensions. As a result, the process of trimming the edges of the component after formation may be obviated, thereby decreasing the duration of the manufacturing process and reducing the quantity of offal that may otherwise be deposited in a landfill. In addition, by bonding the cover on the fiber panel during the molding process, adhesion between the cover and fiber may be improved as compared to bonding the cover to the fiber panel via adhesives in a separate process step, thereby obviating the“wrap around” process, which saves material and reduces the duration of the manufacturing process. Moreover, by forming the fiber panel and molding certain ancillary components within a single mold cavity, the duration of the manufacturing process may be substantially reduced, as compared to processes that include a first compression mold and a second injection mold. [0067] According to an exemplary embodiment shown in FIGS.7A-7F, the mold may include first (e.g., top) mold element MT and a second (e.g., bottom) mold element MB. The first mold element MT includes a first surface Sa defining a first portion of a mold cavity, and the second mold element MB includes a second surface Sb defining a second portion of the mold cavity. The first surface Sa is configured to receive the fiber panel P, and the second surface Sb is configured to receive the cover C. The first mold element MT and the second mold element MB can be moved from an open position (FIG.7A) to a closed position (FIG. 7C) to compress the fiber panel P and the cover C against the first surface Sa and the second surface Sb to form the fiber panel P and the cover C into a compression formed component having a desired shape. According to exemplary embodiments, the mold cavity formed by the first mold element MT and the second mold element MB can include first and second voids Va, Vb into which resin Ra, Rb can be injected to form features of the vehicle trim component. [0068] According to exemplary embodiments, the cover C and fiber panel P are trimmed or cut to desired size(s) and shape(s) for the vehicle trim component to establish the visible surface of the final trim component. Because the cover C is trimmed to substantially conform to the desired end size, the material used to form the visible surface may be reduced while also reducing or eliminating additional cover trimming steps after formation of the trim component. Because the fiber panel P is trimmed prior to the compression forming process, the offal (i.e., excess material) may be recycled. In contrast, recycling post-formation offal may be more difficult or impossible because the resin within the fiber panel has

cured/hardened, and/or the resin has bonded to the structural fibers. [0069] While the first mold element MT and the second mold element MB are in the open position (FIG.7A), the fiber panel P and the cover C can be disposed relative to one another at their respective lateral faces and between the first surface Sa and the second surface Sb. According to exemplary embodiments, the cover C can be disposed on the second surface Sb of the second mold element MB, and the fiber panel P can be disposed on the cover C. [0070] According to exemplary embodiments, when the fiber panel P includes a thermoplastic resin, the fiber panel P can be heated (e.g., to about 200 degrees Celsius) before it is disposed in the mold to induce the thermoplastic resin to liquefy. The fiber panel P is then disposed onto the cover C, and they are disposed between the first surface Sa and the second surface Sb. The mold is then moved from the open position (FIG. 7A) to a closed position (FIG.7C) to compress the fiber panel P and cover C between the first surface Sa and the second surface Sb and pressure couple the fiber panel P and cover C. As the fiber panel P cools within the mold, the thermoplastic resin solidifies, thereby bonding the cover C to the fiber panel P and forming a substantially rigid compression formed component that conforms to the shape of the mold cavity, e.g., the shape corresponds to a first contour of the first surface Sa and a second contour of the second surface Sb. Consequently, the shape of the compression formed component is different than the original shape of the fiber panel P. [0071] According to other exemplary embodiments, when the fiber panel P includes a thermoset resin, the fiber panel P and cover C can be disposed between the first surface Sa and the second surface Sb. The mold is then moved from the open position (FIG.7A) to a closed position (FIG.7C) to compress the fiber panel P and cover C between the first surface Sa and the second surface Sb and pressure couple the fiber panel P and cover C. During the compression process, the panel P is heated, such as by conventional mechanisms (not shown) for heating the first mold element MT and/or the second mold element MB, to induce inducing the thermoset resin to cure and adhere to the cover C. Consequently, a substantially rigid compression formed component that conforms to the shape of the mold cavity is formed, e.g., the shape corresponds to a first contour of the first surface Sa and a second contour of the second surface Sb. Consequently, the shape of the compression formed component is different than the original shape of the fiber panel P. [0072] Bonding the cover C to the fiber panel P in the mold may reduce the duration of the manufacturing process by eliminating a second processing step. The compression formed component may have greater durability than bonding the cover C to the fiber panel P with an adhesive. Additionally, the quantity of the cover C used may be reduced by bonding the cover C to the fiber panel P in the mold. For example, the cover C may be cut to a shape substantially corresponding to a visible surface of the trim component before being placed in the mold. Accordingly, a quantity of material utilized to from the cover C may be reduced, as compared to processes in which the cover C is adhered to the trim component after forming. For example, in conventional techniques where the cover is applied after the fiber panel is formed in the mold, the cover may be wrapped substantially around a visible surface of the fiber panel to a back side (e.g., non-visible surface) of the trim component. The cover on the back side of the fiber panel may not be visible after installation of the trim component within the vehicle V. As a result, larger quantities of cover material are utilized in embodiments in which the cover is placed on the fiber panel after the compression forming and injection molding processes are complete. Moreover, wrapping the cover around the fiber panel may block or cover connectors disposed on the fiber panel, thereby potentially adding additional trimming steps to remove the blockages. [0073] According to exemplary embodiments, a scrim layer (not shown) may be positioned on the non-visible side of the cover C (e.g., between the cover C and the fiber panel P). The scrim layer may block penetration of resin from the fiber panel P into a surface layer of the cover C. The scrim layer may also substantially insulate the surface layer from the heat of the fiber panel P. In certain embodiments, the scrim layer may be a polyurethane layer configured to provide heat and/or acoustic insulation between the cover C and the fiber panel P. [0074] According to exemplary embodiments, the method of forming the vehicle trim component further includes injecting resin into the mold after the compression formed component is formed to fill at least one first void disposed adjacent to the compression formed component. According to exemplary embodiments, the at least one void can be disposed adjacent at least one of a peripheral side surface and an interior side surface of at least one of the cover and the fiber panel. However, the at least one void can bid disposed adjacent other portions of the compression formed component. [0075] According to exemplary embodiments, resin Ra is injected into the mold cavity (e.g., via a port PTa) to fill at least one first void Va. According to exemplary embodiments, the at least one first void Va may be implemented in a variety of configurations, based on desired result. For example, according to exemplary embodiments, the at least one first void Va can be disposed between the first surface Sa and the second surface Sb adjacent to the compression formed component. According to exemplary embodiments, the at least one first void Va may be disposed between the compression formed component and only one of the first surface Sa and the second surface Sb. According to exemplary embodiments, the at least one first void Va may include a void adjacent to the cover and/or the fiber panel. According to exemplary embodiments, the at least one first void Va may include a void or gap within the fiber panel P, and the gap is enclosed by material of the fiber panel P. In certain exemplary embodiments, the first void Va extends at least partly along at least one of a peripheral side surface 30, 32 and an interior side surface 34 of at least one of the cover C and the compressed fiber panel P. According to exemplary embodiments, the at least one first void Va may extends about at least a portion of a periphery of the cover C and/or fiber panel P such that injecting resin into the mold forms a border disposed about the at least a portion of the periphery of the cover C and/or fiber panel P, as applicable. According to exemplary embodiments, the border may be configured for attaching the vehicle trim component to the vehicle and/or a second vehicle trim component. [0076] In such embodiments, the injected resin Ra fills the first void Va and establishes a a border, component, element, feature, etc., as the resin hardens and/or cures. In the case of forming a border, due to the dimensional accuracy of the mold cavity, each edge of the resultant trim component will substantially corresponds to the desired dimensions. As a result, the process of trimming the edges of the component after formation may be obviated, thereby decreasing the duration of the manufacturing process and reducing the quantity of offal that may otherwise be deposited in a landfill. [0077] In certain exemplary embodiments, resin is injected into the mold after the compression formed component is formed to fill at least one second void Vb between the compression formed component and the first surface Sa and/or second surface Sb to form an ancillary component of the vehicle trim component. According to exemplary embodiments, resin Rb is injected via a port PTb into at least one second void Vb between the fiber panel P and the first surface Sa to form an ancillary component of the vehicle trim component. For example, the mold cavity may include multiple second voids Vb configured to establish ribs along a surface of the fiber panel P. The ribs are configured to support the vehicle trim component, thereby providing a stronger component, and/or reducing the weight of the component by facilitating a reduction in fiber panel thickness. In other exemplary embodiments, the ancillary components can be attachment mechanisms configured to attach the vehicle trim component to the vehicle or to other vehicle trim components. Because the fiber panel P and the ancillary components are formed within a single mold cavity, the process of transferring the part between a compression mold and an injection mold is obviated, thereby reducing the duration of the manufacturing process. In addition, employing a single mold reduces design and manufacturing costs, as compared to producing a first mold for the compression forming process and a second mold for the injection molding process. [0078] After the resin Ra and/or Rb has been injected and cured, the first mold element MT and the second mold element MB can be moved to the open position (FIG.7F) and the vehicle trim component can be removed from the mold. [0079] While the description has related to resins Ra and Rb injected through different ports PTa and PTb to fill the first and second voids Va and Vb, it is understood that the same resin Ra may be injected through a single port to fill both the first and second voids Va and Vb. [0080] Exemplary Embodiments of Vehicle Trim Components [0081] Various exemplary embodiments of the vehicle trim component can be formed, just some of which are disclosed in FIGS.2A-2F, 3A-3E, 4A-4E, 5A-5E, and 6A-6E. [0082] According to one exemplary embodiment, the vehicle trim component 120 can be part of a floor console 100, as shown in FIGS.2A-2C. The main body 110 of the floor console 100 can have an inner surface configured to receive the vehicle trim component 120. In this embodiment, the vehicle trim component 120 can have ancillary components 132 formed by the resin Ra coupled to the compression formed component. These ancillary components 132 may be connectors used to attach or align the vehicle trim component 120 to or relative to the main body 110. For example, the ancillary components 132 may have apertures A that receive a screw or a projection from the main body 110. In this embodiment, the ancillary components 132 are disposed such that they will not be seen by a vehicle occupant when the vehicle trim component is mounted to the main body 110. [0083] According to another exemplary embodiment, the vehicle trim component 220 can be part of a floor console 200, as shown in FIGS.2D-2F. The main body 210 of the floor console 200 can be configured to receive the vehicle trim component 120 and to have connectors 212 to attach or align the vehicle trim component 220 to or relative to the main body 210. In this embodiment, those connectors 212 may interact with the cover, fiber panel, or resin Ra to attach or align the vehicle trim component 220. [0084] According to another exemplary embodiment, the vehicle trim component 130 can be part of a floor console 100, as shown in FIGS. 3A-3E. The main body 110 of the floor console 100 can have an inner surface configured to receive the vehicle trim component 130. In this embodiment, the vehicle trim component 130 can have ancillary components 132 formed by the resin Ra that also forms a border 133 and is coupled to the cover 131. These ancillary components 132 may be connectors used to attach or align the vehicle trim component 130 to or relative to the main body 110. For example, the ancillary components 132 may have apertures A that receive a screw or a projection from the main body 110. In this embodiment, the ancillary components 132 are disposed such that they will not be seen by a vehicle occupant when the vehicle trim component is mounted to the main body 110. In this exemplary embodiment, the vehicle trim component 130 may have ancillary components 134 that are ribs arranged in a honeycomb pattern and provided on the fiber panel 135 to enhance strength. [0085] According to another exemplary embodiment, the vehicle trim component 140 can be part of a floor console 100, as shown in FIGS.4A-4E. The main body 110 of the floor console 100 can have an inner surface configured to receive the vehicle trim component 140. In this embodiment, the fiber panel 135 can project outward from the cover 141 such that a portion 142 is visible before mounting the vehicle trim component 140 to the main body 110. The vehicle trim component 140 can have ancillary components 143 formed by the resin Ra coupled to one or more peripheral side surfaces of the fiber panel 135. These ancillary components 143 may be connectors used to attach or align the vehicle trim component 140 to or relative to the main body 110. For example, the ancillary components 143 may have apertures A that receive a screw or a projection from the main body 110. In this embodiment, the ancillary components 143 are disposed such that they will not be seen by a vehicle occupant when the vehicle trim component is mounted to the main body 110. In this exemplary embodiment, the vehicle trim component 140 may also include ancillary components 144 that may be arranged in a honeycomb pattern and provided on the fiber panel 145 to enhance strength. [0086] According to another exemplary embodiment, the vehicle trim component 150 can be part of a floor console 100, as shown in FIGS.5A-5E. The main body 110 of the floor console 100 can have an inner surface configured to receive the vehicle trim component 150. In this embodiment, the cover 151 can project outward from the fiber panel 154. The vehicle trim component 150 can have ancillary components 152 formed by the resin Ra coupled to the fiber panel 154 along a partial or complete border 153 that is formed by the resin Ra and is coupled to one or more peripheral side surfaces of fiber panel 154. These ancillary components 152 may be connectors used to attach or align the vehicle trim component 150 to or relative to the main body 110. For example, the ancillary components 152 may have apertures A that receive a screw or a projection from the main body 110. In this embodiment, the ancillary components 152 are disposed such that they will not be seen by a vehicle occupant when the vehicle trim component is mounted to the main body 110. [0087] According to another exemplary embodiment, the vehicle trim component 260 can be part of a floor console 200, as shown in FIGS.6A-6E. The main body 210 of the floor console 200 can have an outer surface configured to receive the vehicle trim component 260. In this embodiment, the cover 261 can project outward from the fiber panel 266. A partial or complete border 265 can be formed by the resin Ra. The vehicle trim component 260 can have ancillary components 263 formed by the resin Rb coupled to the fiber panel 266. These ancillary components 263 may be connectors used to attach or align the vehicle trim component 260 to or relative to the main body 210. For example, the ancillary components 263 may have projections 268 that project into apertures A in the main body 210. In this embodiment, the ancillary components 263 are disposed such that they will not be seen by a vehicle occupant when the vehicle trim component is mounted to the main body 210. In this exemplary embodiment, the vehicle trim component 260 may also include ancillary components 264 that may be arranged in a honeycomb pattern and provided on the fiber panel 266 to enhance strength. [0088] The invention is not limited to the embodiments as described, they are rather to be understood as being examples. Modifications and amendments of individual features will be familiar to the person skilled in the art. Besides those embodiments depicted in the figures and described in the above description, other embodiments of the present invention are also contemplated. For example, any single feature of one embodiment of the present invention may be used in any other embodiment of the present invention. Given the disclosure of the present invention, one versed in the art would appreciate that there may be other

embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present invention within the scope and spirit of the present invention are to be included as further embodiments of the present invention. [0089] As utilized herein, the terms“approximately,”“about,”“substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims. [0090] The terms“coupled,”“connected,” and the like, as used herein, mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. [0091] References herein to the positions of elements (e.g.,“top,”“bottom,”“above,” “below,” etc.) are merely used to describe the orientation of various elements in the figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. [0092] The construction and arrangement of the elements of the panels, molded bodies, tooling, etc. as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. [0093] Additionally, the word“exemplary” is used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as“exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). Rather, use of the word“exemplary” is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims. [0094] Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. For example, any element (e.g., panel, molded body, tooling part, etc.) disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Also, for example, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative

embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims. [0095] According to exemplary and alternative embodiments, the methods and systems can be used to produce a wide variety of component forms and provide a wide variety of effects, for example, enhanced strength/material properties (e.g. by material selection, fiber selection/orientation, etc.), reduced weight/mass properties (e.g. by forming with composite or layered material, with voids, etc.), visual/decorative effects (e.g. color, color gradations, differing or multi-color fibers/additives, variations in surface effect, translucence, simulated stitching, simulated effects, etc.), environmental-friendly composition (e.g. use of scrap and/or recycled materials/fibers), alternative geometries/shapes (e.g. with

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

Claims

WHAT IS CLAIMED IS:

1. A vehicle trim component prepared by a process comprising:

disposing a cover onto a first surface of a mold;

disposing a fiber panel onto the cover;

compressing the fiber panel and the cover between the first surface and a second surface of the mold to couple the fiber panel and the cover and form the fiber panel into a compression formed component having a shape wherein the shape corresponds to a first contour of the first surface and a second contour of the second surface;

injecting resin into the mold after the compression formed component is formed to fill at least one first void; and

removing the vehicle trim component from the mold.

2. The vehicle trim component of Claim 1 wherein the at least one first void comprises a void between the first surface and the second surface adjacent to the cover.

3. The vehicle trim component of Claim 2 wherein the at least one first void extends about at least a portion of a periphery of the cover such that injecting resin into the mold forms a border disposed about the at least the portion of the periphery of the cover.

4. The vehicle trim component of Claim 3 wherein the border is configured for attaching the vehicle trim component to a second vehicle trim component.

5. The vehicle trim component of Claim 2 wherein the process further comprises injecting resin into the mold after the compression formed component is formed to fill at least one second void between the compression formed component and the second surface to form an ancillary component of the vehicle trim component.

6. The vehicle trim component of Claim 1 wherein the at least one first void comprises a void between the first surface and the second surface adjacent to the compression formed component.

7. The vehicle trim component of Claim 6 wherein the at least one first void extends about at least a portion of a periphery of the compression formed component such that injecting resin into the mold forms a border disposed about the at least the portion of the periphery of the compression formed component.

8. The vehicle trim component of Claim 7 wherein the border is configured for attaching the vehicle trim component to a second vehicle trim component.

9. The vehicle trim component of Claim 6 wherein the process further comprises injecting resin into the mold after the compression formed component is formed to fill at least one second void between the compression formed component and the second surface to form an ancillary component of the vehicle trim component.

10. The vehicle trim component of Claim 1 wherein the at least one first void comprises a void between the second surface and the cover adjacent to the compression formed component.

11. The vehicle trim component of Claim 10 wherein the at least one first void extends about at least a portion of a periphery of the compression formed component such that injecting resin into the mold forms a border disposed about the at least the portion of the periphery of the compression formed component.

12. The vehicle trim component of Claim 11 wherein the border is configured for attaching the vehicle trim component to a second vehicle trim component.

13. The vehicle trim component of Claim 10 wherein the process further comprises injecting resin into the mold after the compression formed component is formed to fill at least one second void between the compression formed component and the second surface to form an ancillary component of the vehicle trim component.

14. The vehicle trim component of Claim 1 wherein the at least one first void corresponds to a gap within the fiber panel and the gap is enclosed by material of the fiber panel.

15. The vehicle trim component of Claim 1 wherein the fiber panel comprises a plurality of fibers and a thermoplastic resin.

16. The vehicle trim component of Claim 15 wherein the fiber panel is heated to a temperature to at least partially liquefy the thermoplastic resin, the fiber panel is disposed into the mold after the fiber panel is heated; the fiber panel is cooled in the mold to solidify the thermoplastic resin and to form the fiber panel into the compression formed component.

17. The vehicle trim component of Claim 1 wherein the fiber panel comprises a plurality of fibers and a thermoset resin.

18. The vehicle trim component of Claim 17 wherein the mold is heated to cure the thermoset resin and to form the fiber panel into the compression formed component.

19. The vehicle trim component of Claim 1 wherein the shape of the compression formed component is different than an original shape of the fiber panel.

20. The vehicle trim component of Claim 1 wherein coupling the fiber panel and the cover comprises bonding the fiber panel and the cover.

21. The vehicle trim component of Claim 1 wherein the cover is comprised of at least one of (a) woven fabric, (b) non-woven fabric, (c) an applique, (d) vinyl, (e) foam, (f) foil, and (g) leather.

22. A vehicle trim component comprising:

a fiber panel;

a cover coupled to the fiber panel; and

resin coupled to at least one of the cover and the fiber panel.

23. The vehicle trim component of claim 22 wherein the cover is pressure coupled to the fiber panel along respective lateral faces to provide a compression formed component.

24. The vehicle trim component of Claim 23 wherein the resin is coupled to at least one of a peripheral side surface and an interior side surface of at least one of the cover and the fiber panel.

25. The vehicle trim component of Claim 23 wherein the resin is coupled to the cover.

26. The vehicle trim component of Claim 23 wherein the resin is coupled to the fiber panel.

27. The vehicle trim component of Claim 26 wherein the resin is coupled to the fiber panel in a gap within the fiber panel.

28. The vehicle trim component of Claim 23 wherein the resin forms a border disposed about at least a portion of the periphery of the at least one of the fiber panel and the cover to which the resin is coupled.

29. The vehicle trim component of Claim 28 wherein the border is configured for attaching the vehicle trim component to a second vehicle trim component.

30. The vehicle trim component of Claim 23 further comprising an ancillary component coupled to the compression formed component.

31. A method of forming a vehicle trim component comprising: disposing a cover and a fiber panel relative to one another at respective lateral faces and between a first surface of a mold and a second surface of a mold;

compressing the fiber panel and the cover between the first surface and the second surface of the mold to couple the fiber panel and the cover and form a compression formed component having a shape, wherein the shape corresponds to a first contour of the first surface and a second contour of the second surface;

injecting resin into the mold after the compression formed component is formed to fill at least one first void disposed adjacent to at least one of a peripheral side surface and an interior side surface of at least one of the cover and the fiber panel; and

removing the vehicle trim component from the mold.