WO2017053313A1

WO2017053313A1 - Trim component for vehicle interior

Info

Publication number: WO2017053313A1
Application number: PCT/US2016/052691
Authority: WO
Inventors: Heather Rae Springer; Bart Fox; Tony M. Pokorzynski; Angelle J. REIDER; Michael Edward PHILLIPS; Glenn Cowelchuk
Original assignee: Shanghai Yanfeng Jinqiao Automotive Trim Systems Co. Ltd
Priority date: 2015-09-22
Filing date: 2016-09-20
Publication date: 2017-03-30

Abstract

A trim component for vehicle interior is disclosed. A method for forming the trim component is also disclosed. The trim component comprises a cover, a base, and a first foam layer. The cover is adjacent to the first foam layer; the first foam layer is adjacent to the base. The base is formed from substantially fibers. The cover is stitched to the base through the first foam layer. The method for forming the trim component comprises the steps of: (1) providing a material on a first layer to form a cover; (2) placing the cover in a mold; (3) placing a third layer (e.g. the base) in the second mold; (4) injecting foam between the cover and the third layer to provide a foamed trim component. The third layer is prepared in a first mold from a fiber panel. The third layer comprises a first portion and a second portion.

Description

PATENT APPLICATION

TRIM COMPONENT FOR VEHICLE INTERIOR

FIELD

[0001] The present invention relates to a vehicle interior component. The present invention also relates to a trim component for a vehicle interior. The present invention further relates to a trim component for a vehicle interior such as used with a cover for an armrest, an instrument panel, a door panel, a console panel, etc.

CROSS REFERENCE TO RELATED APPLICATIONS

[0002] The present application claims priority from and the benefit of and incorporates by reference in entirety of the following application: U.S. Provisional Patent Application No. 62/222,189 titled "COMPONENT FOR VEHICLE INTERIOR AND METHOD OF

MANUFACTURE" filed September 22, 2015.

BACKGROUND

[0003] It is known to provide a trim component for vehicle interior. It is also known to provide a cover for the trim component. It is also known to provide a foam material underneath the cover. It is also known to provide seams or stitches on the cover of the trim component.

[0004] It would be advantageous to provide an improved trim component. It would also be advantageous to provide an improved method for forming the improved trim component. SUMMARY

[0005] The present invention relates to a component for a vehicle interior. The component comprises a base formed from fibers, a foam layer adjacent the base and a cover adjacent the first foam layer. The cover may be stitched to the base through the foam layer.

[0006] The present invention also relates to a component for a vehicle interior. The component comprises a base formed from fibers, a foam layer adjacent the base and a cover adjacent the first foam layer. The cover may be stitched to the base through the foam layer.

[0007] The present invention also relates to a vehicle interior component. The component comprises a base comprising a material formed from fibers, a cover comprising a cover material, a layer comprising a material applied between the base and the cover and a stitch applied in or adjacent to a feature in the base. The feature may comprise at least one of a stitch location, a groove, a channel, a ridge, a seam, a track, a rim, a line, a bead, a pair of ridges and/or an indentation. The base may comprise fibers in a base density; the base may comprise lofted section; the base may comprise a high-density section. The base may comprise a compressed section; the compressed section may comprise fibers in a localized greater density in the base. The lofted section may comprise fibers in a localized less density in the base; the base may comprise a compressed fiber panel; the base may comprise a fiber panel. The lofted section may be relatively uncompressed relative to the compression section; the layer may comprise a first layer and a second layer.

[0008] The present invention also relates to a method of manufacturing a component for a vehicle interior using an apparatus. The method comprises the steps of providing a base, providing a cover and injecting a material between the cover and the base. The base is prepared by providing a fiber panel, compressing the fiber panel to form a compression-formed component having a shape and injecting resin into the compression-formed component. The base may be formed with a feature for a stitch. The cover may comprise a thermoplastic olefin. The shape may comprise a first contour and a second contour. The material may comprise foam and the material is laminated to the cover. The resin enters voids in the compression-formed component. The fiber panel may be formed from substantially natural fibers. The base may comprise a first portion with a first density and a second portion with a second density; the cover is stitched to the second portion of the base. The base may comprise a first portion with a first thickness and a second portion with a second thickness; the cover is stitched to the second portion of the base. The first portion may be compressed and the second portion is relatively uncompressed relative to the first portion. The second portion may be lofted. The feature comprises at least one of a stitch location, a groove, a channel, a ridge, a seam, a track, a rim, a line, a bead, a pair of ridges and/or an indentation.

[0009] The present invention also relates to a method of manufacturing a component for a vehicle interior. The method comprises the steps of providing a first layer, providing a material on the first layer to form a cover, placing the cover in a second mold, placing a third layer in the second mold and injecting foam between the cover and the third layer to provide a foamed component. The third layer may be prepared by a process comprising the steps of providing a fiber panel onto a first surface of a first mold, compressing the fiber panel between the first surface and a second surface of the first mold to 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 first mold after the compression formed component is formed to fill at least one void and removing the third layer from the first mold. FIGURES

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

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

[0003] FIGURE 1C is a schematic perspective view of the vehicle interior according to an exemplary embodiment.

[0004] FIGURES 2A and 2B are schematic perspective detail views of the vehicle interior according to an exemplary embodiment.

[0005] FIGURES 3 A to 3F are schematic cross-section views of a method for forming a trim component according to an exemplary embodiment.

[0006] FIGURE 4A is a schematic perspective view of the trim component according to an exemplary embodiment.

[0007] FIGURE 4B is a schematic cross-section view of the trim component according to an exemplary embodiment.

[0008] FIGURES 5A to 5C are schematic cross-section detail views of a method for forming a base layer of a trim component according to an exemplary embodiment.

[0009] FIGURES 6A to 6H are schematic cross-section views of stitch applied to trim components according to an exemplary embodiment.

[0010] FIGURES 7A to 7H are schematic perspective views of stitch applied to the trim components according to an exemplary embodiment.

[0011] FIGURES 8 A to 8F are schematic cross-section views of a method for forming a trim component according to an exemplary embodiment. [0012] FIGURE 9A is a schematic cross-section view of the trim component according to an exemplary embodiment.

[0013] FIGURES 10A to 10E are schematic cross-section views of stitch applied to trim components according to an exemplary embodiment.

[0014] FIGURE 11 is a schematic flow diagram of a method for forming a trim component according to an exemplary embodiment.

[0015] FIGURE 12 is a schematic flow diagram of a method for forming a trim component according to an exemplary embodiment.

DESCRIPTION

[0010] Referring to FIGURES 1 A, IB and 1C, a vehicle V is shown including an interior I with an instrument panel IP and a floor console FC; vehicle V also provides doors D and seats ST. Interior components of vehicle V such as instrument panel IP, floor console FC, doors D and seats ST may include components such as panels made from plastic materials (e.g. plastics, thermoplastics components, foamed thermoplastic parts, etc.). According to an exemplary embodiment, components may include panels such as trim panels comprising a base or substrate of a plastic material (e.g. structure) and a cover material (e.g. polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), leather, imitation leather, film, cloth, etc.) to provide a visible exterior surface.

[0011] As shown schematically in FIGURES 1C, 2A and 2B according to an exemplary embodiment, components such as trim panels may comprise a base and a cover shown as a cover layer with seams/stitches S. Interior components or trim parts may provide visible surfaces in the vehicle. See FIGURES IB, 1C, 2A and 2B. As shown schematically in FIGURES 2A and 2B according to an exemplary embodiment, seams S provided on a trim panel may provide a visual appearance or effect (as well as other mechanical effects).

[0012] As shown schematically in FIGURES 2A and 2B, the vehicle trim component may be provided in a form configured to provide cushioning at various sections; according to an exemplary embodiment, the visual characteristics of the trim component (e.g. color, form, etc.) as well as texture or feel may be provided by selected materials (e.g. leather, PVC, etc.). As shown schematically in FIGURES 2A and 2B, the trim component may be configured to display seams/stitches S to provide an intended visual effect. [0013] Referring to FIGURES 3 A to 3F, a method for manufacturing a vehicle interior component in a mold apparatus M is shown according to an exemplary embodiment. As shown schematically in FIGURES 3 A to 3F, mold M comprises a top part shown as a mold top MT and a bottom part shown as a mold bottom MB.

[0014] As shown schematically in FIGURES 3 A to 3F according to an exemplary embodiment, base layer 30 provides base or support for a cover layer 20. According to an exemplary embodiment, the base layer may be made of any suitable material, including any natural fiber and/or any polymer (e.g. polypropylene, polyethylene, copolymers, compressed fibers, thermoplastic olefin (TPO), filled plastics, polycarbonate, ABS blends, ABS, or any of a variety of other materials); the base layer may be formed in any shape, size and configuration and may include other features (e.g. apertures for door locks and handles, molded-in designs, etc.).

(According to an exemplary embodiment, the base layer may be formed by conventional or known methods including injection molding, thermoforming, etc.)

[0015] As shown schematically in FIGURES 3 A and 3B according to an exemplary

embodiment, base layer 30 is shown as a fiber panel 30 prepared (e.g. pre-formed) prior to the molding process; base layer 30 is placed (e.g. attached or fixed) to mold top MT. Cover layer 20 is provided in mold bottom MB of mold M. See also FIGURES 4J to 4L.

[0016] As shown schematically in FIGURE 3C, mold M is at a closed position; a gap is defined between cover layer 20 and base layer 30. As shown schematically in FIGURE 3D, a foam material 40f is injected into gap G to fill gap G between the surfaces of cover layer 20 and fiber panel 30 in mold M.

[0017] As shown schematically in FIGURES 3D and 3E according to an exemplary

embodiment, foam material 40f fills gap G (e.g. void) and bonds to cover layer 20 and fiber panel 30 as foam material 40f solidifies and/or cools to form a structure/base shown as a foam layer 40. According to an exemplary embodiment, foam material 40f may be injected in mold cavity G through a nozzle from the side of mold M.

[0018] As shown schematically in FIGURE 3F, mold top MT and mold bottom MB of mold M are separated after the forming process has completed; a trim component 100 for a vehicle interior is removed from mold M.

[0019] As shown schematically in FIGURES 4A and 4B, trim component 100 comprises a cover layer 20, a foam layer 40 and a base layer 30.

[0020] As shown schematically in FIGURES 5A to 5C, a method for forming a base layer is shown. As shown schematically in FIGURE 5A, a base layer 30 comprises an uncompressed fiber panel 30u; mold M2 is in an open position. As shown schematically in FIGURE 5B, mold M2 is in a closed position; uncompressed fiber panel 30u is compressed between mold top MT2 and mold bottom MB2; fiber panel 30u is compressed into a shape for base layer 30. As shown schematically in FIGURE 5C, mold top MT2 and mold bottom MB2 are separated; base layer 30 is formed; base layer 30 comprises a feature or a portion 37. According to an exemplary embodiment, feature 37 of base layer 30 is not fully compressed; feature 37 has a lower density than the remainder of base layer 30.

[0021] As shown schematically in FIGURES 6A to 6H and 7A to 7H, a stitch 50 can be sewn or stitched into the trim component. FIGURES 4B through 41 show schematically configurations for facilitating the application of stitching on the component according to an exemplary embodiment.

[0022] As shown schematically in FIGURE 6A and 7A, a stitch 50 is sewn or stitched into the trim component according to an exemplary embodiment. [0023] As shown schematically in FIGURE 6B and 7B, base layer 30 comprises multiple sections or portions such as a portion 32 and a portion 34. According to an exemplary embodiment, portion 32 has a lower density than portion 34; stitch 50 is applied (e.g. sewn) through portion 32 (i.e. with lower density) of base layer 30.

[0024] As shown schematically in FIGURE 6C and 7C, base layer 30 comprises a feature or a portion 31 such as a groove or a channel with reduced thickness; stitch 50 is applied (e.g. sewn) through feature 31 of base layer 30. According to an exemplary embodiment, the base layer may provide a feature or a portion such as a groove or a channel with reduced thickness during a forming process (e.g. compression form, injection molding, etc.). According to an exemplary embodiment, material may be removed from a base layer to form a feature or a portion such as a groove or a channel with reduced thickness after a forming process.

[0025] As shown schematically in FIGURE 6D and 7D, base layer 30 comprises a feature or a portion 38 such as a groove or a channel with reduced thickness; base layer 30 also comprises two opposing features or portions 36 such as edges or ridges adjacent to portion 38; stitch 50 is applied (e.g. sewn) through feature 38 of base layer 30. According to an exemplary

embodiment, features 36 may be used for reinforcement for base layer 30; features 36 may be used for alignment and/or guidance for stitch 50.

[0026] As shown schematically in FIGURE 6E and 7E, base layer 30 comprises a feature or a portion 38 such as a groove or a channel with reduced thickness; base layer 30 also comprises a feature or portion 36 such as an edge or a ridge adjacent to feature 38; stitch 50 is applied (e.g. sewn) through feature 38 of base layer 30. According to an exemplary embodiment, feature 36 may be used for reinforcement for base layer 30; feature 36 may be used for alignment and/or guidance for stitch 50. [0027] As shown schematically in FIGURE 6F and 7F, base layer 30 comprises a feature or a portion 38 such as a groove or a channel with reduced thickness; base layer 30 also comprises two opposing features or portions 36 such as edges or ridges adjacent to portion 38; stitch 50 is applied (e.g. sewn) through portion 38 of base layer 30. As shown schematically in FIGURE 6F, feature 38 and features 36 have a lower density than the remainder of base layer 30. According to an exemplary embodiment, features 36 may be used for reinforcement for base layer 30;

features 36 may be used for alignment and/or guidance for stitch 50.

[0028] As shown schematically in FIGURE 6G and 7G, base layer 30 comprises a feature or a portion 37 with increased thickness and lower density; stitch 50 is applied (e.g. sewn) through feature 37 of base layer 30. As shown schematically in FIGURE 6G and 7G, base layer 30 comprises two opposing features 39 shown as recess adjacent to feature 37.

[0029] As shown schematically in FIGURE 6H and 7H, base layer 30 comprises a feature or a portion 37 with increased thickness and lower density; stitch 50 is applied (e.g. sewn) through feature 37 of base layer 30.

[0030] Referring to FIGURES 8A to 8F, a method for manufacturing a vehicle interior component in a mold apparatus M is shown according to an exemplary embodiment. As shown schematically in FIGURES 8A to 8F, mold M comprises a top part shown as a mold top MT and a bottom part shown as mold bottom MB.

[0031] As shown schematically in FIGURES 8A to 8F according to an exemplary embodiment, base layer 30 provides base or support for a bi-laminate sheet 20b. According to an exemplary embodiment, the base layer may be made of any suitable material, including any natural fiber and/or any polymer (e.g. polypropylene, polyethylene, copolymers, compressed fibers, thermoplastic olefin (TPO), filled plastics, polycarbonate, ABS blends, ABS, or any of a variety of other materials); the base layer may be formed in any shape, size and configuration and may include other features (e.g. apertures for door locks and handles, molded-in designs, etc.).

[0032] As shown schematically in FIGURES 8A and 8B according to an exemplary

embodiment, base layer 30 is shown as a fiber panel 30 prepared (e.g. pre-formed) prior to the molding process; base layer 30 is placed (e.g. attached or fixed) to mold top MT. Bi-laminate cover layer 20b is provided in mold bottom MB of mold M. As shown schematically in

FIGURES 8A and 8B, pre-formed bi-laminate cover layer 20b comprises a skin layer 22 with a foam layer 42.

[0033] As shown schematically in FIGURE 8C, mold M is at a closed position; a gap/cavity G is defined between bi-laminate cover layer 20b and base layer 30. As shown schematically in FIGURE 8D, a foam material 40 is injected or filled into gap/cavity G between the surfaces of bi-laminate cover layer 20b and fiber panel 30 in mold M.

[0034] As shown schematically in FIGURES 8D and 8E according to an exemplary

embodiment, foam material 40 fills gap G (e.g. void) and establishes an adhesion between bi- laminate cover layer 20b and fiber panel 30 as foam material 40 solidifies and/or cools to form a foam layer 40. According to an exemplary embodiment, foam material 40 may be injected in mold cavity G through a nozzle from the side of mold M.

[0035] As shown schematically in FIGURE 8F, after the forming process has completed, mold top MT and mold bottom MB of mold M are separated; a trim component 200 for a vehicle interior is removed from mold M. [0036] As shown schematically in FIGURE 9, trim component 200 comprises a bi-laminate cover layer 20b, a foam layer 40 and a base layer 30.

[0037] As shown schematically in FIGURES 10A to 10E, a stitch 50 can be sewn into the trim component.

[0038] As shown schematically in FIGURE 10A, a stitch 50 is applied (e.g. sewn) into the trim component according to an exemplary embodiment.

[0039] As shown schematically in FIGURE 10B, base layer 30 comprises a portion 32 and a portion 34. According to an exemplary embodiment, portion 32 has a lower density than portion 34; stitch 50 is applied (e.g. sewn) through portion 32 of base layer 30.

[0040] As shown schematically in FIGURE IOC, base layer 30 comprises a feature or portion 31 such as a groove or a channel with reduced thickness; stitch 50 is applied (e.g. sewn) through portion 31 of base layer 30. According to an exemplary embodiment, the base layer may provide a feature or a portion such as a groove or a channel with reduced thickness during a forming process (e.g. compression form, injection molding, etc.). According to an exemplary

embodiment, material may be removed from a base layer to form a feature or a portion such as a groove or a channel with reduced thickness after a forming process.

[0041] As shown schematically in FIGURE 10D, base layer 30 comprises a feature or a portion 38 with reduced thickness; base layer 30 also comprises two opposing features or portions 36 such as edges or ridges adjacent to feature 38; stitch 50 is applied (e.g. sewn) through feature 38 of base layer 30. According to an exemplary embodiment, features 36 may be used for reinforcement for base layer 30; features 36 may be used for alignment and/or guidance for stitch 50. [0042] As shown schematically in FIGURE 10E, base layer 30 comprises a feature or a portion 38 such as a groove or a channel with reduced thickness; base layer 30 also comprises a feature or a portion 36 such as an edge or a ridge adjacent to feature 38; stitch 50 is applied (e.g. sewn) through feature 38 of base layer 30. According to an exemplary embodiment, feature 36 may be used for reinforcement for base layer 30; feature 36 may be used for alignment and/or guidance for stitch 50.

[0043] According to an exemplary embodiment, the trim component may be formed with various materials with various density and/or thickness; the stitch is applied (e.g. sewn or stitched) into (or through) a trim component with various configurations.

[0044] As shown schematically in FIGURE 11 according to an exemplary embodiment, a method for forming a component comprises the steps of: (la) provide fiber panel into first mold; (2a) compress fiber panel within first mold to form compression-formed component having shape with feature for stitch; (3a) inject resin into first mold to form base; (4a) place base in second mold; (lb) provide cover; (2b) place cover in second mold; (5) inject material between cover and base to form component; (6) apply stitch to component.

[0045] As shown schematically in FIGURE 12 according to an exemplary embodiment, a method for forming a component comprises the steps of: (la) provide fiber panel onto first surface of first mold; (2a) compress fiber panel between first surface and second surface of first mold to form third layer with feature for stitch; (3a) inject resin into first mold to fill at least on void; (4a) place third layer in second mold; (lb) provide first layer; (2b) provide material on first layer to form cover; (3b) place cover in second mold; (5) inject foam between cover and third layer to form component; (6) apply stitch to component. [0046] Referring to FIGURES 1 A and IB, a vehicle V may include a trim component for a vehicle interior I. As shown schematically in FIGURE IB, vehicle V may include doors D, an instrument panel IP, a floor console FC, and seats ST. According to an exemplary embodiment, the component may be used for surfaces of structures within the vehicle interior (e.g. doors, instrument panel, floor console, seats, etc.). As shown schematically in FIGURES 1C, 2A and 2B, stitching S may be provided on trim components (e.g. doors D, instrument panel IP, floor console FC, seats ST, etc.). According to an exemplary embodiment, the trim component may be applied to a variety of components in interior I of vehicle V (e.g. portions of a steering wheel, bezels, buttons, overhead consoles, glove compartments, etc.).

[0047] As shown schematically in FIGURES 3 A to 3F according to an exemplary embodiment, a method for forming a trim component comprises process steps.

[0048] As shown schematically in FIGURES 3A and 3B, a pre-formed base layer 30 and a preformed skin layer 20 may be inserted into a mold M. According to an exemplary embodiment, mold M may be a foam-in-place apparatus. As shown schematically in FIGURE 3B, pre-formed base layer 30 is placed (e.g. fixed) on the top part (i.e. mold top MT) of mold M; pre-formed skin layer 20 is placed in the bottom part (i.e. mold bottom MB) of mold M. According to an exemplary embodiment, base layer 30 may comprise substantially natural fiber; skin layer 20 may comprise a thermoplastic olefin. According to an exemplary embodiment, the base layer and/or the skin layer may be formed with any suitable material.

[0049] As shown schematically in FIGURE 3C, mold M is in a closed position; a gap G is between pre-formed base layer 30 and pre-formed skin layer 20. As shown schematically in FIGURE 3D, a foam material 40f is injected into mold M within gap G between pre-formed base layer 30 and pre-formed skin layer 20. As shown schematically in FIGURE 3E, foam material 40f fills gap G between pre-formed base layer 30 and pre-formed skin layer 20 and forms a foam layer 40. As shown schematically in FIGURE 3F, mold M is in an open position; a trim component 100 for a vehicle interior is removed from mold M. According to an exemplary embodiment, seams/stitches 50 may be applied to trim component 100 after the component is removed from the mold. See FIGURES 6A to 6H.

[0050] As shown schematically in FIGURES 4A and 4B, trim component 100 comprises skin layer 20, foam layer 40 and base layer 30.

[0051] According to an exemplary embodiment, skin layer 20 is intended to provide an exterior (e.g. outer) surface visible to vehicle occupants. According to an exemplary embodiment, the skin layer may be formed with various shapes, patterns and/or textures causing the outer surface to be visually pleasing to vehicle occupants. See FIGURES 4A and 4B.

[0052] According to an exemplary embodiment, the skin layer may comprise a thermoplastic olefin (TPO). According to an exemplary embodiment, a variety of materials could be used to form the skin layer (e.g. polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), cloth, leather, etc.).

[0053] According to an exemplary embodiment, the skin layer may be configured to have a substantially constant thickness that is sufficient to provide necessary structural integrity.

According to an exemplary embodiment, the thickness of the skin layer may be less than about 0.7 mm; a thickness can provide necessary structural integrity. See FIGURES 4A and 4B.

[0054] As shown schematically in FIGURES 4A and 4B, foam layer 40 is provided between skin layer 20 and base layer 30. According to an exemplary embodiment, the foam layer may be provided to improve the tactile sensation by adding softness to the trim component. According to an exemplary embodiment, the foam layer could be configured and structured for other purposes.

[0055] According to an exemplary embodiment, foam layer 40 can be formed of conventional foam materials (e.g. a conventional resin). According to an exemplary embodiment, foam layer 40 is formed from a polyurethane material; other suitable foams and/or other materials may be used to create foam layer 40. See FIGURES 4A and 4B.

[0056] According to an exemplary embodiment, foam layer 40 has a density in a range of about 6 pounds per cubic foot to about 12 pounds per cubic foot. According to an exemplary embodiment, foams or other materials having different densities may be used to form foam layer 40. See FIGURES 4 A and 4B.

[0057] According to an exemplary embodiment, foam layer 40 may have a thickness of about 3 millimeters to about 15 millimeters, and more preferably about 8 mm. According to an exemplary embodiment, other thicknesses for foam layer 40 could be utilized.

[0058] According to an exemplary embodiment, base layer 30 may provide a structural support and a foundation for the form of the trim component. According to an exemplary embodiment, base layer 30 can be made of any of a variety of conventional materials.

[0059] According to an exemplary embodiment, base layer 30 may be formed from fibers.

According to an exemplary embodiment, base layer 30 may be formed from substantially natural fibers. According to an exemplary embodiment, a base layer 30 formed from natural fibers can provide lighter weight; base layer 30 formed from natural fiber can be configured to meet the same requirements as a conventional injection molded plastic base layer; base layer 30 formed from natural fiber can be less massive due to the material used (including natural fibers). See FIGURES 4 A and 4B. According to an exemplary embodiment, a conventional thermoplastic olefin (TPO) base layer may be 2400 grams per square meter (gsm); a natural fiber base layer may be 1400 gsm.

[0060] According to an exemplary embodiment, base layer 30 is formed by Compression Hybrid Molding (CHyM). A CHyM base layer can provide weight advantages and structural advantages.

[0061] As shown schematically in FIGURES 5A to 5C according to an exemplary embodiment, a CHyM base layer can be prepared by disposing a fiber component or panel onto a first surface of a mold cavity and compressing the fiber component between a first surface and a second surface of the mold cavity to form the fiber component into a desired shape. The desired shape may correspond to a first contour of the first surface and a second contour of the second surface. Resin is then injected into the mold cavity to fill a void. The void can (a) be between the first surface and the second surface adjacent to the compression formed fiber component; (b) be at a portion of a periphery of the compression formed fiber component (e.g. injecting resin into the second mold forms a border disposed about the at least the portion of the periphery of the compression formed fiber component); (c) be between the compression formed component and the second surface to form an ancillary component of the component; or (d) correspond to a gap within the fiber component enclosed by material of the fiber component. According to an exemplary embodiment, other voids could be filled to form the base layer. According to an exemplary embodiment, other process steps and materials can make providing stitching easier.

[0062] As shown schematically in FIGURE 6A according to an exemplary embodiment, a stitching 50 can be sewn into the trim component after skin layer 20, foam layer 40 and base layer 30 are combined to form the trim component. According to an exemplary embodiment, the density and/or configuration of the base layer 30 may allow for stitch 50 to extend through all three layers.

[0063] As shown schematically in FIGURE 6B according to an exemplary embodiment, base layer 30 comprises a first portion 32 with a first density and a second portion 34 with a second density; the first density is lower than the second density. According to an exemplary embodiment, the lower density of the first portion 32 makes the stitch 50 to pierce the base layer 30 easier; the lower density also makes stitch 50 to insert through all three layers (i.e. skin layer 20, foam layer 40, base layer 30) easier.

[0064] As shown schematically in FIGURE 6C according to an exemplary embodiment, the base layer 30 can be formed by an area with reduced thickness known as a portion 31. Portion 31 makes stitch 50 to pierce base layer 30 easier; portion 31 makes stitch 50 to insert through all three layers (i.e. skin layer 20, foam layer 40 and base layer 30) easier. Portion 31 with reduced thickness can be formed in base layer 30 during the initial formation; according to an exemplary embodiment, portion 31 can be formed by deforming or machining base layer 30 after the initial formation. According to an exemplary embodiment, portion 31 with reduced thickness may have a density that is higher than a surrounding area of base layer 30 (e.g. in the case of deformation). According to an exemplary embodiment, portion 31 has a density that is the same or lower than the surrounding area of the base layer 30. According to an exemplary

embodiment, portion 31 is a fourth portion with a second thickness and the surrounding area is a third portion with a first thickness; the first thickness is greater than the second thickness.

[0065] According to an exemplary embodiment, additional features can be provided to aid stitching. As shown schematically in FIGURES 6D and 6E according to an exemplary embodiment, a feature or portion 36 shown as an edge or a ridge or multiple features 36 can be provided on base layer 30; feature 36 or multiple features 36 may be used for alignment and/or for reinforcement for the base layer 30 in the area of the stitching. According to an exemplary embodiment, feature(s) 36 can allow the stitching apparatus to locate the region in which the stitch 50 should be applied. As shown schematically in FIGURES 6D and 6E, the region may be the location of the area of reduced thickness 38. According to an exemplary embodiment, the region could also be the location of first portion 32 with a lower density (see FIGURE 6B). According to an exemplary embodiment, feature(s) 36 may be formed from a resin.

[0066] According to an exemplary embodiment, a trim component involves the use of base layer 30 and foam layer 40; the trim component uses a laminated skin layer. As shown schematically in FIGURE 9, the trim component 200 comprises base layer 30 and foam layer 40; the laminated skin layer 20b includes both a skin layer 22 and a foam layer 42. According to an exemplary embodiment, foam layer 42 is laminated to skin layer 22 to form a bi-laminate construction; additional layers could be utilized.

[0067] According to an exemplary embodiment, skin layer 22 can be formed from thermoplastic olefin (TPO). According to an exemplary embodiment, skin layer 22 can be formed from other materials; skin layer 22 may be configured to have a substantially uniform thickness of less than about 0.7 mm. See FIGURES 8A through 8F and 9.

[0068] According to an exemplary embodiment, foam layer 42 reinforces the skin layer 22; foam layer 42 may be laminated onto the skin layer 22 by conventional techniques; foam layer 42 may be made of polypropylene and polyethylene foam. According to an exemplary embodiment, foam layer 42 may be made of or include other various suitable materials. See FIGURES 8A through 8F and 9. [0069] According to an exemplary embodiment, the second foam layer may have a thickness of about 1 mm to about 4 mm; the preferred thickness is about 1.5 mm. See FIGURES 8 A through 5F and 6A.

[0070] According to an exemplary embodiment, the foam used to create the second foam layer 42 may have a density in a range of about 3 pounds per cubic foot to about 7 pounds per cubic foot; the preferred density is about 5 pounds per cubic foot. According to an exemplary embodiment, foams or other materials having different densities may be used.

[0071] According to an exemplary embodiment, the bi-laminate of skin layer 22 and second foam layer 42 is configured to meet the same requirements as a thicker skin; the bi-laminate has a lower density than the thicker skin layer. According to an exemplary embodiment, a conventional thermoplastic olefin (TPO) skin layer might be 1102 grams per square meter (gsm) while a laminated skin layer may be 581 gsm.

[0072] According to an exemplary embodiment, the bi-laminate construction of the laminated skin layer may make stitch 50 to insert through the trim component easier. According to an exemplary embodiment, a thick thermoplastic olefin (TPO) layer can be difficult to stitch. By using a thinner thermoplastic olefin (TPO) layer to form skin layer 22, the overall force required to insert a stitch 50 can be reduced. According to an exemplary embodiment, the bi-laminate skin layer may have an overall lower density that is easier to push through.

[0073] As shown schematically in FIGURES 8A to 8F, a method for forming a trim component comprises process steps according to an exemplary embodiment.

[0074] As shown schematically in FIGURES 8 A and 8B, a pre-formed base layer 30

(comprising substantially natural fiber) and a pre-formed laminated skin layer 20b (comprising skin layer 22 formed from a thermoplastic olefin laminated with foam layer 42) can be inserted into mold M. The mold can be a foam-in-place apparatus. The pre-formed base layer 30 is provided in molt top MT of mold M. Pre-formed laminated skin layer 20b is provided in the mold bottom of mold M. As shown schematically in FIGURE 8C, mold M is in a closed position. When the mold is closed, a gap G is between pre-formed base layer 30 and pre-formed laminated skin layer 20b.

[0075] As shown schematically in FIGURE 8D, foam material 40f is injected into mold M in gap G between pre-formed base layer 30 and pre-formed laminated skin layer 20. As shown schematically in FIGURE 8E, foam material 40f fills gap G between pre-formed base layer 30 and pre- formed laminated skin layer 20b and forms foam layer 40.

[0076] As shown schematically in FIGURE 8F, the two parts of the mold (mold top MT and mold bottom MB) are separated and a light weight component for a vehicle interior is removed from mold M.

[0077] After the component is removed from the mold, stitching 50 can be applied to the component. As shown schematically in FIGURES 10A through 10E according to an exemplary embodiment, base layer may be configured in any of the variations to aid in stitching. See FIGURES 6A to 6E.

[0078] According to an exemplary embodiment the component for a vehicle interior is configured to include a base layer, a foam layer and a skin layer. According to an exemplary embodiment, use of additional layers and other configurations of the individual layers may be possible * * *

[0079] It is important to note that the construction and arrangement of the elements of the inventive concepts and inventions as described in this application and as shown in the figures above is illustrative only. Although some embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible without materially departing from the novel teachings and advantages of the subject matter recited. Accordingly, all such

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

[0080] It is important to note that the apparatus of the present inventions can comprise conventional technology (e.g. as implemented in present configuration) or any other applicable technology (present or future) that has the capability to perform the functions and

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

Claims

1. A component for a vehicle interior comprising:

(a) a base formed from fibers;

(b) a foam layer adjacent the base; and

(c) a cover adjacent the first foam layer;

wherein the cover is stitched to the base through the foam layer.

2. The component of Claim 1 wherein the base comprises a first portion with a first density and a second portion with a second density; wherein the first density is greater than the second density.

3. The component of Claim 2 wherein the cover is stitched to the second portion of the base.

4. The component of Claim 1 wherein the base comprises a first portion with a first thickness and a second portion with a second thickness; wherein the first thickness is greater than the second thickness.

5. The component of Claim 4 wherein the cover is stitched to the second portion of the base.

6. The component of Claim 4 wherein the cover is stitched to the first portion of the base.

7. The component of Claim 1 wherein the base is formed from substantially natural fibers.

8. The component of Claim 1 wherein the foam layer is coupled to the cover.

9. The component of Claim 1 wherein the foam layer comprises a first foam layer and a second foam layer.

10. The component of Claim 9 wherein the second foam layer is laminated to the cover.

11. The component of Claim 1 wherein the cover comprises a thermoplastic material.

12. The component of Claim 1 wherein the cover is configured to have a substantially constant thickness of less than 0.7 mm.

13. The component of Claim 1 wherein the base comprises a feature; and wherein the feature for the stitch comprises at least one of (1) a stitch location; (2) a groove; (3) a channel; (4) a ridge; (5) a seam; (6) a track; (7) a rim; (8) a line; (9) a bead; (10) a pair of ridges; (11) an indentation; (12) a section of the base.

14. A vehicle interior component comprising:

(a) a base comprising a material formed from fibers;

(b) a cover comprising a cover material;

(c) a layer comprising a material applied between the base and the cover; and

(d) a stitch applied to the cover and the base;

wherein the base comprises a feature and the stitch is applied in or adjacent to the feature.

15. The component of Claim 14 wherein the base comprises a first section and a second section wherein the stitch is applied to the second section.

16. The component of Claim 14 wherein the feature for the stitch comprises at least one of (1) a stitch location; (2) a groove; (3) a channel; (4) a ridge; (5) a seam; (6) a track; (7) a rim; (8) a line; (9) a bead; (10) a pair of ridges; (11) an indentation; (12) a section of the base.

17. The component of Claim 14 wherein the base comprises a high-density section.

18. The component of Claim 14 wherein the base comprises a compressed section; wherein the compressed section comprises fibers in a localized greater density in the base.

19. The component of Claim 14 wherein the feature comprises a low-density section of the base.

20. A method of manufacturing a component for a vehicle interior comprising the steps of:

(a) providing a base;

(b) providing a cover; and

(c) injecting a material between the cover and the base;

wherein the base is prepared by:

(a) providing a fiber panel;

(b) compressing at least a portion of the fiber panel to form a compression-formed component having a shape; and

(c) forming a feature for a stitch in the fiber panel.

21. The method of Claim 20 wherein the feature for the stitch comprises at least one of (1) a stitch location; (2) a groove; (3) a channel; (4) a ridge; (5) a seam; (6) a track; (7) a rim; (8) a line; (9) a bead; (10) a pair of ridges; (11) an indentation; (12) a section of the base.

22. The method of Claim 20 wherein the material comprises foam.

23. The method of Claim 20 wherein the base comprises a first portion with a first density and a second portion with a second density; wherein the cover is stitched to the second portion of the base.

24. The method of Claim 23 wherein the first portion is compressed and the second portion is relatively uncompressed relative to the first portion.

25. The method of Claim 20 wherein the base comprises a first portion with a first thickness and a second portion with a second thickness; wherein the cover is stitched to the second portion of the base.