Patent Application
20250108772
The present invention relates to a component for a vehicle interior.
It is known to provide a component for a vehicle interior configured to facilitate deployment of an airbag through an opening formed as an airbag door in the component.
It would be advantageous to provide an improved component comprising a panel comprising a weakened area such as a recess configured to direct formation of an opening for deployment of the airbag through the component.
The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door comprising a structural substrate comprising a fiber panel; the fiber panel may comprise a base area and weakened area; the weakened area may comprise a recess comprising a profile; the profile of the recess may comprise a bottom and a set of walls; the fiber panel has a reduced thickness in the recess at the bottom of the profile; the profile of the recess is configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag. The fiber panel may comprise an inner surface and an outer surface; the recess comprising the profile is formed into the inner surface of the fiber panel; the recess is configured to form a seam for an opening through the weakened area of the fiber panel for the airbag door. The profile may comprise a multi-side form. The multi-side form may comprise the bottom and the set of side walls. The multi-side form may comprise a generally trapezoidal form. The profile may comprise a variable depth. The profile may comprise a transition area. The transition area may comprise a thickness greater than a nominal thickness of the base area of the fiber panel. The fiber panel may have a nominal average thickness in the base area and the reduced thickness at the weakened area. The recess for the weakened area may comprise a center recess and a set of lateral recesses; the weakened area may comprise the set of lateral recesses connected by the center recess; the center recess may comprise a connector. The weakened area may comprise a set of segments. The recess may comprise a formed recess and/or an indentation. The recess may comprise a groove; the groove is formed in the fiber panel. The profile may comprise a multi-segmented form and/or the profile is formed to provide the weakened area in the fiber panel. A structure formed on the fiber panel may comprise an injection-molded resin; the structure may comprise a set of ribs at the weakened area of the fiber panel; the set of ribs is configured to direct the formation of the airbag door. The weakened area may comprise a generally H-shaped area and/or a generally U-shaped area. The component may comprise (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door comprising a fiber panel comprising a base area and weakened area; the weakened area may comprise a recess comprising a multi-sided profile; the multi-sided profile of the recess may comprise a bottom and a set of walls; the fiber panel has a reduced thickness in the recess at the bottom of the profile; the profile of the recess is configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. A component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may comprise a structural substrate comprising a fiber panel the fiber panel may comprise a base area and weakened area; the weakened area may comprise a recess comprising a profile; the profile of the recess may comprise a bottom and a set of walls; the fiber panel has a reduced thickness in the recess at the bottom of the profile; the profile of the recess is configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag. The fiber panel may comprise an inner surface and an outer surface; the recess comprising the profile is formed into the inner surface of the fiber panel; the recess is configured to form a seam for an opening through the weakened area of the fiber panel for the airbag door. The profile may comprise a multi-side form. The multi-side form may comprise the bottom and the set of side walls. The multi-side form may comprise a generally trapezoidal form. The profile may comprise a variable depth. The profile may comprise a transition area. The transition area may comprise a thickness greater than a nominal thickness of the base area of the fiber panel. The fiber panel may have a nominal average thickness in the base area and the reduced thickness at the weakened area. The recess for the weakened area may comprise a center recess and a set of lateral recesses; the weakened area may comprise the set of lateral recesses connected by the center recess; the center recess may comprise a connector. The weakened area may comprise a set of segments. The recess may comprise a formed recess and/or an indentation. The recess may comprise a groove; the groove may be formed in the fiber panel. The profile may comprise a multi-segmented form and/or the profile is formed to provide the weakened area in the fiber panel. A structure formed on the fiber panel may comprise an injection-molded resin; the structure may comprise a set of ribs at the weakened area of the fiber panel; the set of ribs is configured to direct the formation of the airbag door. The weakened area may comprise a generally H-shaped area and/or a generally U-shaped area. The component may comprise (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door comprising a fiber panel comprising a base area and weakened area; the weakened area may comprise a recess comprising a multi-sided profile; the multi-sided profile of the recess may comprise a bottom and a set of walls; the fiber panel has a reduced thickness in the recess at the bottom of the profile; the profile of the recess is configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The component may comprise a cover on the fiber panel. The component may comprise a structure formed onto the fiber panel; the structure may comprise an injection-molded resin; the structure may comprise a set of ribs at the weakened area of the fiber panel; the set of ribs is configured to direct the formation of the airbag door. The component may comprise a structure formed onto the fiber panel; the structure may comprise an injection-molded resin; the structure may comprise a set of ribs at the weakened area of the fiber panel; the set of ribs is configured to direct the formation of the airbag door. The groove may comprise a center groove and a set of lateral grooves; the weakened area may comprise the set of lateral grooves connected by the center groove; the center groove may comprise a connector. The rib may comprise a nominal height of between about 2.5 mm and about 3.5 mm. The rib may comprise a nominal width of between about 1.5 mm and about 2.0 mm. A distance between the set of ribs may comprise a nominal width of between about 5 mm and about 7 mm. The proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal width across the profile is in a range of between about 5 and about 12. the proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal thickness at the base area is in a range of between about 1.5 and 4; the proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal width across the profile of the recess is in a range of between about 1.5 and about 12; the proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess is in a range of between about 1 and 5; the proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess is greater than 2; the proportional relationship of a nominal reduced thickness at the bottom of the profile of the recess divided by a nominal thickness at the base area is in a range of between about 1.5 and 4. The proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal width across the profile of the recess is in a range of between about 1.5 and about 12; the proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess is in a range of between about 1 and 5; the proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess is greater than 2; the proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal thickness at the bottom of the recess is in a range of about 1 to 2. The proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal thickness at the bottom of the recess is in a range of about 0.5 to 3; the nominal width at the bottom of the profile of the recess is in a range of between about 0.5 and 3 times greater that a nominal thickness at the bottom of the recess; the nominal width across the profile of the recess is in a range of about 1 to 5 times greater than a nominal thickness of the base area of the fiber panel; the nominal thickness of the base area of the fiber panel is in a range of between about 1.5 and 3.5 times greater than a nominal thickness of the bottom of the recess; the nominal thickness of the base area of the fiber panel is in a range of between about 2 and 4 times greater than a nominal width of the bottom of the recess; the nominal width across the profile of the recess is in a range of about 1 to 12 times greater than a nominal thickness of the bottom of the recess; the nominal width of the bottom of the profile of the recess may comprise between about 0.2 mm and 2.0 mm. The reduced thickness at the bottom of the profile may be less than 0.85 mm; the reduced thickness may be greater than 0.4 mm; the fiber panel may comprise a thickness may be greater than about 1 mm; the nominal thickness at the base area may be less than 1.7 mm; the thickness may be greater than 1.5 mm. The component may comprise (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door comprising a structural substrate comprising a fiber panel. The fiber panel may comprise a base area and weakened area. The weakened area may comprise a recess comprising a profile. The profile of the recess may comprise a bottom and a set of walls. The fiber panel has a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag. The weakened area may comprise a generally H-shaped area. The weakened area may comprise a generally U-shaped area. The fiber panel may comprise an inner surface and an outer surface; the recess comprising the profile may be formed into the inner surface of the fiber panel. The recess may be configured to form a seam for an opening through the weakened area of the fiber panel for the airbag door. The profile may comprise a multi-side form. The multi-side form may comprise the bottom and the set of side walls. The multi-side form may comprise a generally trapezoidal form. The profile may comprise a variable depth. The profile may comprise a transition area. The transition area may comprise a transition into the profile. The transition area may comprise a transition into a generally trapezoidal section of the profile. The transition area may comprise a generally curved form. The transition area may comprise a feature formed adjacent to the recess; the feature may comprise a ridge segment. The transition area may comprise a thickness less than a nominal thickness of the base area of the fiber panel. The transition area may comprise a thickness greater than a nominal thickness of the base area of the fiber panel. The fiber panel may have a nominal average thickness in the base area and the reduced thickness at the weakened area. The recess for the weakened area may comprise a center recess and a set of lateral recesses; the weakened area may comprise the set of lateral recesses connected by the center recess; the center recess may comprise a connector. The weakened area may comprise a set of segments. The set of segments may comprise a set of lateral segments connected by a center line. The recess may comprise a formed recess. The recess may comprise an indentation. The recess may comprise a groove; the groove may be formed in the fiber panel. The groove may comprise a center groove and a set of lateral grooves; the weakened area may comprise the set of lateral grooves connected by the center groove; the center groove may comprise a connector. The profile may comprise a transition area into the groove. The groove may comprise a wavy line. The bottom may comprise a generally flat bottom. The set of walls may comprise a set of flat tapered walls adjacent to the bottom. The profile may comprise a generally curved form. The profile may comprise a rounded form comprising the bottom and a set of walls adjacent to the bottom. The profile may comprise a multi-segmented form. The profile may comprise a transition area from the base area into the weakened area. The profile may be formed to provide the weakened area in the fiber panel. The component may comprise a structure formed on the fiber panel; the structure may comprise an injection-molded resin; the structure may comprise a set of ribs at the weakened area of the fiber panel; the set of ribs may be configured to direct the formation of the airbag door. Fiber of the fiber panel may be at least partially intermingled with the resin of the structure. The fiber panel may comprise a compression-formed fiber panel. The component may comprise a panel comprising the fiber panel; the panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The recess may comprise at least one of (a) a tear line configured to establish an opening for deployment of the airbag; (b) a weakening line configured to establish an opening for deployment of the airbag. The component may comprise a cover on the fiber panel; the weakened area may not be generally visible at the cover. The reduced thickness at the bottom of the profile of the recess may comprise between above 0.4 mm and below 0.85 mm. A nominal width of the bottom of the profile of the recess may comprise between about 0.4 mm and 0.6 mm. A nominal width of the bottom of the profile of the recess may comprise between about 0.2 mm and 2.0 mm. The recess may comprise a width across the profile; the width across the profile may comprise between about 5 mm and about 6 mm. The recess may comprise a width across the profile; the width across the profile may comprise greater than 2 mm. The fiber panel may comprise a nominal thickness at the base area of between about 1.5 mm and 1.7 mm. The component may comprise a structure formed onto the fiber panel; the structure may comprise at least one rib; the at least one rib may comprise a set of ribs at the weakened area of the fiber panel. The at least one rib may comprise a nominal height of between about 2.5 mm and about 3.5 mm. The at least one rib may comprise a nominal width of between about 1.5 mm and about 2.0 mm. A distance between the set of ribs may comprise a nominal width of between about 5 mm and about 7 mm. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal width across the profile may be in a range of between about 5 and about 12. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal thickness at the base area may be in a range of between about 1.5 and 4. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal width across the profile of the recess may be in a range of between about 1.5 and about 12. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be in a range of between about 1 and 5. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be greater than 2. A proportional relationship of a nominal reduced thickness at the bottom of the profile of the recess divided by a nominal thickness at the base area may be in a range of between about 1.5 and 4. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal width across the profile of the recess may be in a range of between about 1.5 and about 12. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be in a range of between about 1 and 5. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be greater than 2. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal thickness at the bottom of the recess may be in a range of about 1 to 2. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal thickness at the bottom of the recess may be in a range of about 0.5 to 3. A nominal width at the bottom of the profile of the recess may be in a range of between about 0.5 and 3 times greater that a nominal thickness at the bottom of the recess. A nominal width across the profile of the recess may be in a range of about 1 to 5 times greater than a nominal thickness of the base area of the fiber panel. A nominal thickness of the base area of the fiber panel may be in a range of between about 1.5 and 3.5 times greater than a nominal thickness of the bottom of the recess. A nominal thickness of the base area of the fiber panel may be in a range of between about 2 and 4 times greater than a nominal width of the bottom of the recess. A nominal width across the profile of the recess may be in a range of about 1 to 12 times greater than a nominal thickness of the bottom of the recess. A nominal width of the bottom of the profile of the recess may comprise between about 0.2 mm and 2.0 mm. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door comprising a fiber panel comprising a base area and weakened area. The weakened area may comprise a recess comprising a multi-sided profile. The multi-sided profile of the recess may comprise a bottom and a set of walls. The fiber panel has a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The component may comprise a cover on the fiber panel. The component may comprise a structure formed onto the fiber panel; the structure may comprise an injection-molded resin. The structure may comprise a set of ribs at the weakened area of the fiber panel; the set of ribs may be configured to direct the formation of the airbag door.
The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a panel comprising fibers. The panel may comprise a front side providing a surface and a rear side configured for contact from the airbag to establish an opening for deployment of the airbag. The panel may comprise a recess in the rear side of the panel to establish the opening for deployment of the airbag and direct deployment of the airbag through the panel. The front side of the panel may comprise a substantially planar surface opposite the recess. The panel comprising fibers may comprise a compressed fiber panel; the recess may be formed as a depression in the rear side of the panel or an indentation in the rear side of the panel. The recess may be formed in a mold by (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) penetrating material of the fiber panel at the rear side with a protrusion of the mold to push material of the fiber panel aside to form the recess in the rear side and maintain a continuous surface at the front side. The recess may comprise a path comprising at least one of (a) a continuous wave portion comprising a periodic function; (b) a sinusoidal shape. The panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The panel may comprise a resin rib formed on the panel adjacent the recess at the rear side of the panel; the resin rib may be configured to direct deployment of the airbag through the panel. The resin rib may extend from the recess below the rear side of the panel. The recess may comprise a path comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape; the panel may comprise a rib adjacent the connector of the recess at the rear side of the panel; the rib may comprise a generally sinusoidal shape. The rib may comprise a first rib on a side of the connector and a second rib on an opposite side of the connector. The recess may comprise a cavity comprising a cross-sectional profile; the cross-sectional profile of the cavity may comprise a depth within the panel. The cross-sectional profile of the cavity may comprise a set of facets; the set of facets may comprise a first set of connected facets opposite a second set of connected facets. The set of facets may comprise a floor facet connecting the first set of connected facets and the second set of connected facets; the floor facet may comprise a surface generally parallel to the front side of the panel. The cross-sectional profile of cavity may comprise at least one of (a) a bevel; (b) a fillet; (c) a chamfer. The cross-sectional profile of the cavity may comprise a wall and a floor; the floor may be generally parallel to the surface of the front side of the panel. The cross-sectional profile of cavity may comprise at least one angled surface connecting the wall and the floor. The wall may comprise at least two generally planar surfaces. The wall may comprise a first surface and a second surface; the second surface may extend from the floor to the first surface; the first surface may extend from the second surface to the rear side of the panel. The wall may comprise a first generally planar wall connected to a second generally planar wall at a radius. The recess may comprise a width at the rear side of the panel; the floor may comprise a width less than the width of the recess at the rear side of the panel.
The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag and comprising a panel comprising fibers. The panel may comprise a front side providing a surface and a rear side configured for contact from the airbag to establish an opening for deployment of the airbag. The panel may comprise a recess formed as a depression in the rear side of the panel to establish the opening for deployment of the airbag and direct deployment of the airbag through the panel. The front side of the panel may comprise a substantially planar surface opposite the recess. The recess may be formed as an indentation in the rear side of the panel; the recess may comprise a depth within the panel. The recess may comprise a set of facets; the set of facets may comprise a floor facet connecting a first set of connected facets and a second set of connected facets; the floor facet may comprise a surface generally parallel to the front side of the panel. The recess may comprise a wall and a floor and at least one angled surface connecting the wall and the floor.
The present invention relates to a vehicle interior component formed in a mold and configured to facilitate deployment of an airbag from an airbag module comprising a panel comprising a fiber panel. The fiber panel may comprise a base area and weakened area. The weakened area may comprise a recess. The recess may comprise a multi-sided profile. The multi-sided profile of the recess may comprise a bottom and a set of walls. The fiber panel has a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The recess may be formed by (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) penetrating material of the fiber panel at the rear side with a protrusion of the mold to push material of the fiber panel aside to form the recess in the rear side and maintain a continuous surface at the front side; and (c) filling a depression of the mold with material of the fiber panel to form a protrusion at the rear side. The panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The recess may comprise a notch configured to direct deployment of the airbag through the panel. The feature may comprise a protrusion configured to provide a relief for the notch.
The present invention relates to a method of manufacturing a vehicle interior component comprising (a) providing a mold comprising a first surface and a second surface comprising a protrusion and a depression; (b) disposing a fiber panel comprising a first side and a second side onto the first surface of a mold; (c) compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; (d) penetrating material of the fiber panel at the first side of the panel with the protrusion of the second surface of the mold to push material of the fiber panel aside to form a notch in the first side of the fiber panel and maintain a continuous surface at the second side of the fiber panel; and (e) filling the depression of the second surface of the mold with material of the fiber panel to form a protrusion at the first side of the fiber panel. The fiber panel may comprise a base area and weakened area. The weakened area may comprise the notch. The notch may comprise a recess. The recess may comprise a multi-sided profile. The multi-sided profile of the recess may comprise a bottom and a set of walls. The fiber panel has a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The method may comprise a step of injecting resin into the mold at the depression of the second surface of the mold to form a rib.
The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag and comprising a panel comprising fibers. The panel may comprise a front side providing a surface and a rear side configured for contact from the airbag to establish an opening for deployment of the airbag. The panel may comprise a recess formed as a depression in the rear side of the panel to establish the opening for deployment of the airbag and direct deployment of the airbag through the panel. The front side of the panel may comprise a substantially planar surface opposite the recess. The recess may be formed as an indentation in the rear side of the panel. The recess may be formed in a mold by compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold, and penetrating material of the fiber panel at the rear side with a protrusion of the mold to push material of the fiber panel aside to form the recess in the rear side and maintain a continuous surface at the front side. The recess may comprise a generally H-shaped arrangement comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape. The recess may comprise a generally U-shaped arrangement comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape. The recess may comprise a path comprising a continuous wave portion comprising a periodic function. The recess may comprise a path comprising a sinusoidal shape. The panel may comprise at least one of a resin; a thermoplastic resin; polypropylene; acrylonitrile butadiene styrene; polycarbonate. The panel may comprise a rib adjacent the recess at the rear side of the panel. The rib may be configured to direct deployment of the airbag through the panel. The rib may be formed on the panel. The rib may comprise a resin material. The rib may extend from the recess. The rib may comprise a height below the rear side of the panel; the recess may comprise a cavity in the panel comprising a depth. The recess may comprise a path comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape; the panel may comprise a rib adjacent the connector of the recess at the rear side of the panel; the rib may comprise a generally sinusoidal shape. The component may comprise a first rib on a side of the connector and a second rib on an opposite side of the connector. The rib may comprise a resin material and the rib may extend from the recess. The recess may comprise a cavity comprising a cross-sectional profile. The profile of the cavity may comprise a depth within the panel. The profile of the cavity may comprise a set of facets. The set of facets may comprise a first set of connected facets opposite a second set of connected facets. The set of facets may comprise a floor facet connecting the first set of connected facets and the second set of connected facets. The floor facet may comprise a surface generally parallel to the front side of the panel. The profile of the cavity may comprise an angled surface. The profile of the cavity may comprise a multi-faceted shape. The profile of cavity may comprise at least one of (a) a bevel; (b) a fillet; (c) a chamfer. The profile of the cavity may comprise a wall and a floor. The profile of cavity may comprise at least one angled surface connecting the wall and the floor. The floor may be generally parallel to the surface of the front side of the panel. The wall may comprise at least two generally planar surfaces. The wall may comprise a first surface and a second surface; the second surface may extend from the floor to the first surface. The first surface may extend from the second surface to the rear side of the panel. The wall may comprise a first generally planar wall connected to a second generally planar wall. The recess may comprise a width at the rear side of the panel; the floor may comprise a width less than the width of the recess at the rear side of the panel. The recess may comprise at least one of (a) a tear line configured to establish an opening for deployment of the airbag; (b) a weakening line configured to establish an opening for deployment of the airbag. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
The present invention also relates to a method of manufacturing the component may comprise providing a mold comprising a first surface and a second surface comprising a protrusion, disposing a fiber panel comprising a first side and a second side onto the first surface of a mold, compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold, and penetrating material of the fiber panel at the first side of the panel with the protrusion of the second surface of the mold to push material of the fiber panel aside to form the recess in the first side of the fiber panel and maintain a continuous surface at the second side of the fiber panel. The method may comprise a step of injecting resin into the mold at a depression of the second surface of the mold to form a rib. The recess may be configured to establish an opening in the vehicle interior component for deployment of an airbag through the vehicle interior component.
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The fiber panel FP/PL may comprise a compression-formed fiber panel. The component may comprise a panel comprising the fiber panel; the panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate.
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According to an exemplary embodiment as shown schematically in 5A-5D, 6A-6C, 9A-9B, 10C-10G, 11A-11B, 12A-12B, 13A-13C, 14A-14C, 15A-15C, 16A-16C, 17, 18A-18B, 10, 20A-20B, 21 and 34A-34B, a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may comprise a structural substrate comprising a fiber panel. The fiber panel may comprise a base area and weakened area. The weakened area may comprise a recess comprising a profile. The profile of the recess may comprise a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag. The weakened area may comprise a generally H-shaped area. The weakened area may comprise a generally U-shaped area. The fiber panel may comprise an inner surface and an outer surface. The recess may be formed into the inner surface of the fiber panel. The recess comprising the profile may be formed into the inner surface of the fiber panel. The recess may be configured to form a seam for an opening for the airbag door. The seam may be configured to form a tear line for an opening for the airbag door. The recess may be configured to form a seam for an opening through the weakened area of the fiber panel for the airbag door. The profile may comprise a generally trapezoidal form. The profile may comprise a multi-feature form. The profile may comprise a multi-faceted form. The profile may comprise a multi-side form. The multi-side form may comprise the bottom and the set of side walls. The multi-side form may comprise a generally trapezoidal form. The multi-side form may comprise a generally symmetrical form. The profile may comprise a variable profile. The profile may comprise a variable depth. The weakened area may comprise a transition area. The weakened area may comprise a transition section. The profile may comprise a transition section. The profile may comprise a transition area. The transition area may comprise a transition into the profile. The transition area may comprise a transition into a generally trapezoidal section of the profile. The transition area may comprise a generally curved form. The transition area may comprise a feature formed adjacent to the recess. The transition area may comprise a thickness less than a nominal thickness of the base area of the fiber panel. The transition area may comprise a thickness greater than a nominal thickness of the base area of the fiber panel. The transition area may comprise a reduced thickness segment. The transition area may comprise a ridge segment. The transition area may comprise a ridge adjacent to the profile of the recess. The recess may comprise a width. The recess may comprise a width across the profile. The fiber panel may have a nominal average thickness in the base area and the reduced thickness at the weakened area. The recess for the weakened area may comprise a center recess and a set of lateral recesses. The weakened area may comprise the set of lateral recesses connected by the center recess. The center recess may comprise a connector. The weakened area may comprise a set of segments. The set of segments may comprise a set of lateral segments. The set of segments may comprise a center segment. The set of segments may comprise a set of lateral segments connected by the segment line. The set of segments may comprise a set of lines. The weakened area may comprise a set of lines. The set of lines may comprise a set of lateral lines. The set of lines may comprise a center line. The set of lines may comprise a set of lateral lines connected by the center line. The recess may comprise a formed recess. The recess may comprise an indentation. The indentation may comprise a groove. The recess may comprise a cavity. The recess may comprise a notch. The recess may comprise a groove. The groove may comprise a line. The groove may comprise a wavy line. The groove may comprise a set of grooves. The groove may comprise a set of lateral grooves. The groove may comprise a center groove. The groove may comprise a center groove and a set of lateral grooves. The weakened area may comprise the set of lateral grooves connected by the center groove. The center groove may comprise a connector. The bottom may comprise a generally flat bottom. The bottom may comprise a generally curved bottom. The set of walls may comprise a set of angled walls. The set of walls may comprise a set of flat walls. The set of walls may comprise a set of flat angled walls. The set of walls may comprise a set of flat tapered walls. The set of walls may comprise a set of flat tapered walls adjacent to the bottom. The profile may comprise a generally curved form. The profile may comprise a rounded form. The profile may comprise a rounded form comprising the bottom and the set of walls adjacent to the bottom. The profile may comprise a segmented form. The profile may comprise a multi-segmented form. The profile may comprise a generally continuous form. The profile may comprise a transition area into the groove. The profile may comprise a transition area from the base area into the weakened area. The groove may be formed in the fiber panel. The profile may be formed in the fiber panel. The profile may be formed to provide the weakened area in the fiber panel. The component may comprise a structure formed onto the fiber panel. The structure may comprise a resin. The resin may comprise an injection-molded resin. The structure may comprise a set of ribs at the weakened area of the fiber panel. The set of ribs may be configured to direct the formation of the airbag door. The set of ribs may comprise a resin material; the fiber panel may comprise fibers. The set of ribs may comprise a resin material; the fiber panel may comprise fibers; the set of ribs may be formed on the fiber panel. The set of ribs may comprise a resin material; the fiber panel may comprise fibers; the set of ribs may be formed on the fiber panel; the resin material of the set of ribs may be at least partially mixed with fiber of the fiber panel. The set of ribs may comprise a resin material; the fiber panel may comprise fibers; the set of ribs may be formed on the fiber panel; fiber of the fiber panel may be at least partially mixed into the resin material of the set of ribs. The set of ribs may comprise a resin material; the fiber panel may comprise fibers; the set of ribs may be formed on the fiber panel; fiber of the fiber panel may be at least partially intermingled with the resin material of the set of ribs. The component may comprise an airbag chute for deployment of the airbag. The airbag chute may be disconnected from the structure. The fiber panel may comprise a compression-formed fiber panel. The component may comprise a panel comprising the fiber panel; the panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The recess may comprise at least one of (a) a tear line configured to establish an opening for deployment of the airbag; (b) a weakened/weakening line configured to establish an opening for deployment of the airbag. The airbag door may be formed as an opening in the fiber panel. The component may comprise a cover on the fiber panel. The weakened area may not be generally visible at the cover. The airbag may be configured to deploy through an airbag door formed at the front of a trim panel. The airbag may be configured to deploy through an airbag door formed at the bottom of a trim panel. The nominal reduced thickness at the bottom of the profile of the recess may comprise between 0.4 mm and 0.8 mm. The reduced thickness at the bottom of the profile of the recess may comprise between above 0.4 mm and below 0.85 mm. The reduced thickness at the bottom of the profile of the recess may comprise between above 0.45 mm and below 0.65 mm. The reduced thickness at the bottom of the profile of the recess may comprise between about 0.45 mm and 0.65 mm. The reduced thickness at the bottom of the profile of the recess may comprise between above about 0.45 mm and below about 0.75 mm. The nominal reduced thickness at the bottom of the profile of the recess may comprise about 0.5 mm. The nominal reduced thickness at the bottom of the profile of the recess may comprise about 0.55 mm. A nominal width of the bottom of the profile of the recess may comprise between about 0.4 mm and 0.6 mm. A nominal width of the bottom of the profile of the recess may comprise between about 0.2 mm and 2.0 mm. The recess may comprise a width. The recess may comprise a width across the profile; the width across the profile may comprise between about 5 mm and about 6 mm. The recess may comprise a width across the profile; the width across the profile may comprise greater than 2 mm. The recess may comprise a width across the profile; the width across the profile may comprise greater than 3 mm. The fiber panel may comprise a nominal thickness at the base area of at least about 1.5 mm. The fiber panel may comprise an effective nominal thickness at the base area of at least about 1.5 mm. The fiber panel may comprise a nominal thickness at the base area of between about 1.5 mm and 1.7 mm. The fiber panel may comprise a nominal thickness at the base area of about 1.7 mm. The fiber panel may comprise a nominal thickness at the base area of about 1.5 mm. The fiber panel may comprise a nominal thickness at the base area of less than about 2.0 mm. The component may comprise a structure formed onto the fiber panel; the structure may comprise at least one rib. The at least one rib may comprise an injection-molded resin. The at least one rib may comprise a set of ribs at the weakened area of the fiber panel. The at least one rib may comprise a nominal height of between about 2.5 mm and about 3.5 mm. The at least one rib may comprise a nominal width of between about 1.5 mm and about 2.0 mm. A distance between the set of ribs may comprise a nominal width of between about 5 mm and about 7 mm. A distance across the set of ribs may comprise a nominal width of between about 8 mm and about 9 mm. A distance across the set of ribs may comprise a nominal width varying between about 8 mm and about 9 mm. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal width across the profile may be in a range of between about 5 and about 12. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal width across the profile may be in a range of between about 8 and about 12. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal width across the profile may be about 10. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal thickness at the base area may be in a range of between about 2 and 3. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal thickness at the base area may be in a range of between about 1.5 and 4. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal thickness at the base area may be about 2. A proportional relationship between a nominal reduced thickness at the bottom of the profile of the recess and a nominal thickness at the base area may be about 3. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal width across the profile of the recess may be in a range of between about 1.5 and about 12. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal width across the profile of the recess may be about 10. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be in a range of between about 1 and 5. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be in a range of between about 3 and 4. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be greater than 2. A proportional relationship of a nominal reduced thickness at the bottom of the profile of the recess divided by a nominal thickness at the base area may be in a range of between about 1.5 and 4. A proportional relationship of a nominal reduced thickness at the bottom of the profile of the recess divided a nominal thickness at the base area may be about 2. A proportional relationship of a nominal reduced thickness at the bottom of the profile of the recess divided a nominal thickness at the base area may be about 3. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal width across the profile of the recess may be in a range of between about 1.5 and about 12. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal width across the profile of the recess may be about 10. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be in a range of between about 1 and 5. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be in a range of between about 3 and 4. A proportional relationship between a nominal thickness of the base area of the fiber panel and a nominal width across the profile of the recess may be greater than 2. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal thickness at the bottom of the recess may be in a range of about 1 to 2. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal thickness at the bottom of the recess may be in a range of about 0.5 to 3. A proportional relationship between a nominal width at the bottom of the profile of the recess and a nominal thickness at the bottom of the recess may be about 1. A nominal width at the bottom of the profile of the recess may be in a range of between about 0.5 and 3 times greater that a nominal thickness at the bottom of the recess. A nominal width at the bottom of the profile of the recess may be substantially equal to a nominal thickness at the bottom of the recess. A nominal width at the bottom of the profile of the recess may be greater than a nominal thickness at the bottom of the recess. A nominal width at the bottom of the profile of the recess may be less than a nominal thickness at the bottom of the recess. A nominal width at the bottom of the profile of the recess may be no more than 0.5 mm less than a nominal thickness at the bottom of the recess. A nominal width across the profile of the recess may be in a range of about 1 to 5 times greater than a nominal thickness of the base area of the fiber panel. A nominal width across the profile of the recess may be in a range of about 1 to 5 times greater than a nominal thickness of the base area of the fiber panel. A nominal width across the profile of the recess may be less than a nominal thickness of the base area of the fiber panel. A nominal width across the profile of the recess may be greater than a nominal thickness of the base area of the fiber panel. A nominal thickness of the base area of the fiber panel may be in a range of between about 1.5 and 3.5 times greater than a nominal thickness of the bottom of the recess. A nominal thickness of the base area of the fiber panel may be in a range of between about 2 and 3 times greater than a nominal thickness of the bottom of the recess. A nominal thickness of the base area of the fiber panel may be greater than a nominal thickness of the bottom of the recess. A nominal thickness of the base area of the fiber panel may be at least 1 mm greater than a nominal thickness of the bottom of the recess. A nominal thickness of the base area of the fiber panel may be in a range of between about 1 and 3 times greater than a nominal width of the bottom of the recess. A nominal thickness of the base area of the fiber panel may be in a range of between about 2 and 4 times greater than a nominal width of the bottom of the recess. A nominal thickness of the base area of the fiber panel may be greater than a nominal width of the bottom of the recess. A nominal thickness of the base area of the fiber panel may be at least 1 mm greater than a nominal width of the bottom of the recess. A nominal width across the profile of the recess may be in a range of about 1 to 12 times greater than a nominal thickness of the bottom of the recess. A nominal width across the profile of the recess may be in a range of about 2 to 10 times greater than a nominal thickness of the bottom of the recess. A nominal width across the profile of the recess may be less than a nominal thickness of the bottom of the recess. A nominal width across the profile of the recess may be greater than a nominal thickness of the bottom of the recess. A nominal width across the profile of the recess may be in a range of about 1.5 to 12 times greater than a nominal width of the bottom of the recess. A nominal width across the profile of the recess may be in a range of about 2 to 10 times greater than a nominal width of the bottom of the recess. A nominal width across the profile of the recess may be at least 1 mm greater than a nominal width of the bottom of the recess. A nominal width of the bottom of the profile of the recess may comprise between about 0.2 mm and 2.0 mm. The component may comprise an airbag chute; the airbag chute may be disconnected from the structure. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may comprise a fiber panel comprising a base area and weakened area. The weakened area may comprise a recess comprising a multi-sided profile. The multi-sided profile of the recess may comprise a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The component may comprise a cover on the fiber panel. The component may comprise a structure formed onto the fiber panel. The structure may comprise an injection-molded resin. The structure may comprise a set of ribs at the weakened area of the fiber panel. The set of ribs may be configured to direct the formation of the airbag door.
According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior configured to facilitate deployment of an airbag may comprise a panel comprising fibers. The panel may comprise a front side providing a surface and a rear side configured for contact from the airbag to establish an opening for deployment of the airbag. The panel may comprise a recess in the rear side of the panel to establish the opening for deployment of the airbag and direct deployment of the airbag through the panel. The front side of the panel may comprise a substantially planar surface opposite the recess. The panel comprising fibers may comprise a compressed fiber panel. The recess may be formed as a depression in the rear side of the panel. The recess may be formed as an indentation in the rear side of the panel. The recess may be formed in a mold by (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) penetrating material of the fiber panel at the rear side with a protrusion of the mold to push material of the fiber panel aside to form the recess in the rear side and maintain a continuous surface at the front side. The recess may comprise a generally H-shaped arrangement comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape. The recess may comprise a generally U-shaped arrangement comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape. The recess may comprise a path comprising a continuous wave portion comprising a periodic function. The recess may comprise a path comprising a sinusoidal shape. The panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The panel may comprise a rib adjacent the recess at the rear side of the panel. The rib may be configured to direct deployment of the airbag through the panel. The rib may be formed on the panel. The rib may comprise a resin material. The rib may extend from the recess. The rib may comprise a height below the rear side of the panel; the recess may comprise a cavity in the panel comprising a depth. The recess may comprise a path comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape; the panel may comprise a rib adjacent the connector of the recess at the rear side of the panel; the rib may comprise a generally sinusoidal shape. The rib may comprise a first rib on a side of the connector and a second rib on an opposite side of the connector. The rib may comprise a resin material and the rib may extend from the recess. The recess may comprise a cavity comprising a cross-sectional profile. The profile of the cavity may comprise a depth within the panel. The profile of the cavity may comprise a set of facets. The set of facets may comprise a first set of connected facets opposite a second set of connected facets. The set of facets may comprise a floor facet connecting the first set of connected facets and the second set of connected facets. The floor facet may comprise a surface generally parallel to the front side of the panel. The profile of the cavity may comprise an angled surface. The profile of the cavity may comprise a multi-faceted shape. The profile of cavity may comprise at least one of (a) a bevel; (b) a fillet; (c) a chamfer. The profile of the cavity may comprise a wall and a floor. The profile of cavity may comprise at least one angled surface connecting the wall and the floor. The floor may be generally parallel to the surface of the front side of the panel. The wall may comprise at least two generally planar surfaces. The wall may comprise a first surface and a second surface; the second surface may extend from the floor to the first surface. The first surface may extend from the second surface to the rear side of the panel. The wall may comprise a first generally planar wall connected to a second generally planar wall. The recess may comprise a width at the rear side of the panel; the floor may comprise a width less than the width of the recess at the rear side of the panel. The recess may comprise at least one of (a) a tear line configured to establish an opening for deployment of the airbag; (b) a weakening line configured to establish an opening for deployment of the airbag. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior configured to facilitate deployment of an airbag may comprise a panel comprising fibers. The panel may comprise a front side providing a surface and a rear side configured for contact from the airbag to establish an opening for deployment of the airbag. The panel may comprise a recess formed as a depression in the rear side of the panel to establish the opening for deployment of the airbag and direct deployment of the airbag through the panel. The front side of the panel may comprise a substantially planar surface opposite the recess. The recess may be formed as an indentation in the rear side of the panel. The recess may be formed in a mold by (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) penetrating material of the fiber panel at the rear side with a protrusion of the mold to push material of the fiber panel aside to form the recess in the rear side and maintain a continuous surface at the front side. The recess may comprise a generally H-shaped arrangement comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape. The recess may comprise a generally U-shaped arrangement comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape. The recess may comprise a path comprising a continuous wave portion comprising a periodic function. The recess may comprise a path comprising a sinusoidal shape. The panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The panel may comprise a rib adjacent the recess at the rear side of the panel. The rib may be configured to direct deployment of the airbag through the panel. The rib may be formed on the panel. The rib may comprise a resin material. The rib may extend from the recess. The rib may comprise a height below the rear side of the panel; the recess may comprise a cavity in the panel comprising a depth. The recess may comprise a path comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape; the panel may comprise a rib adjacent the connector of the recess at the rear side of the panel; the rib may comprise a generally sinusoidal shape. The rib may comprise a first rib on a side of the connector and a second rib on an opposite side of the connector. The rib may comprise a resin material. The rib may extend from the recess. The recess may comprise a cavity comprising a cross-sectional profile. The profile of the cavity may comprise a depth within the panel. The profile of the cavity may comprise a set of facets. The set of facets may comprise a first set of connected facets opposite a second set of connected facets. The set of facets may comprise a floor facet connecting the first set of connected facets and the second set of connected facets. The floor facet may comprise a surface generally parallel to the front side of the panel. The profile of the cavity may comprise an angled surface. The profile of the cavity may comprise a multi-faceted shape. The profile of cavity may comprise at least one of (a) a bevel; (b) a fillet; (c) a chamfer. The profile of the cavity may comprise a wall and a floor. The profile of the cavity may comprise at least one angled surface connecting the wall and the floor. The floor may be generally parallel to the surface of the front side of the panel. The wall may comprise at least two generally planar surfaces. The wall may comprise a first surface and a second surface; the second surface may extend from the floor to the first surface. The first surface may extend from the second surface to the rear side of the panel. The wall may comprise a first generally planar wall connected to a second generally planar wall. The recess may comprise a width at the rear side of the panel; the floor may comprise a width less than the width of the recess at the rear side of the panel. The recess may comprise at least one of (a) a tear line configured to establish an opening for deployment of the airbag; (b) a weakening line configured to establish an opening for deployment of the airbag. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
According to an exemplary embodiment as shown schematically in the FIGURES, a method of manufacturing a component for a vehicle interior configured to facilitate deployment of an airbag through an airbag door may comprise (a) providing a mold comprising a first surface and a second surface comprising a protrusion; (b) disposing a fiber panel comprising a first side and a second side onto the first surface of a mold; (c) compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; (d) penetrating material of the fiber panel at the first side of the panel with the protrusion of the second surface of the mold to push material of the fiber panel aside to form a recess in the first side of the fiber panel and maintain a continuous surface at the second side of the fiber panel. The fiber panel may comprise a base area and weakened area. The weakened area may comprise the recess. The recess may comprise a multi-sided profile. The multi-sided profile of the recess may comprise a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The method may comprise a step of injecting resin into the mold at a depression of the second surface of the mold to form a rib. The recess may be configured to establish an opening in the vehicle interior component for deployment of an airbag through the vehicle interior component.
According to an exemplary embodiment as shown schematically in the FIGURES, a vehicle interior component formed in a mold and configured to facilitate deployment of an airbag from an airbag module may comprise a panel comprising a fiber panel. The fiber panel may comprise a base area and weakened area. The weakened area may comprise a recess. The recess may comprise a multi-sided profile. The multi-sided profile of the recess may comprise a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The recess may be formed by (a) compressing at least a first portion of the fiber panel between a first surface and a second surface of the mold; (b) penetrating material of the fiber panel at the rear side with a protrusion of the mold to push material of the fiber panel aside to form the recess in the rear side and maintain a continuous surface at the front side; and (c) filling a depression of the mold with material of the fiber panel to form a protrusion at the rear side. The fiber panel may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) acrylonitrile butadiene styrene; (e) polycarbonate. The recess may comprise a notch configured to direct deployment of the airbag through the panel. The feature may comprise a protrusion configured to provide a relief for the notch. The component may comprise a rib adjacent the notch. The rib may be configured to direct deployment of the airbag through the panel. The front side of the panel may comprise a substantially non-planar surface. The feature may comprise a rib configured to direct deployment of the airbag through the panel. The rib may be formed on the panel. The rib may comprise a resin portion comprising resin and a fiber portion comprising fibers of the panel.
According to an exemplary embodiment as shown schematically in the FIGURES, a vehicle interior component formed in a mold and configured to facilitate deployment of an airbag from an airbag module may comprise a panel comprising fibers. The panel may comprise a front side and a rear side. The panel may comprise a first portion comprising a first thickness, a second portion comprising a second thickness less than the first thickness and a third portion comprising a third thickness greater than the first thickness. The rear side of the panel may be configured to support the airbag module. The front side of the panel may be configured to provide a surface. The first portion of the panel may be separated from the second portion of the panel by the third portion of the panel. The second portion of the panel may comprise a notch formed as a depression in the rear side of the panel and configured to direct deployment of the airbag through the panel. The third portion of the panel may comprise at least one feature at the rear side of the panel adjacent the notch: The panel comprising fibers may comprise a fiber panel. The notch may be formed by (a) compressing the fiber panel in the mold; (b) penetrating material of the fiber panel at the rear side with a protrusion of the mold to push material of the fiber panel aside to form the notch in the rear side and maintain a continuous surface at the front side; and (c) filling a depression of the mold with material of the fiber panel to form a protrusion at the rear side. The fiber panel may comprise a base area and weakened area. The notch may comprise a recess. The weakened area may comprise the recess. The recess may comprise a multi-sided profile. The multi-sided profile of the recess may comprise a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The first portion, the second portion and the third portion comprise a substantially constant density. The first portion, the second portion and the third portion comprise a substantially continuous surface at the front side of the panel. The third portion may extend from the second portion and/or may be adjacent the second portion. The second portion and the third portion may be formed concurrently; the third portion may be formed in response to formation of the second portion. The component may comprise a rib formed on the panel adjacent the notch.
According to an exemplary embodiment as shown schematically in the FIGURES, a method of manufacturing a vehicle interior component may comprise (a) providing a mold comprising a first surface and a second surface comprising a protrusion and a depression; (b) disposing a fiber panel comprising a first side and a second side onto the first surface of a mold; (c) compressing at least a first portion of the fiber panel between the first surface and the second surface of the mold; (d) penetrating material of the fiber panel at the first side of the panel with the protrusion of the second surface of the mold to push material of the fiber panel aside to form a notch in the first side of the fiber panel and maintain a continuous surface at the second side of the fiber panel; and (e) filling the depression of the second surface of the mold with material of the fiber panel to form a protrusion at the first side of the fiber panel. The fiber panel may comprise a base area and weakened area. The weakened area may comprise the notch. The notch may comprise a recess. The recess may comprise a multi-sided profile. The multi-sided profile of the recess may comprise a bottom and a set of walls. The fiber panel may have a reduced thickness in the recess at the bottom of the profile. The profile of the recess may be configured to direct the formation of the airbag door at the weakened area of the fiber panel during deployment of the airbag through the fiber panel. The method may comprise a step of injecting resin into the mold at the depression of the second surface of the mold to form a rib. The step of injecting resin into the mold may comprise moving material of the fiber panel toward the second surface of the fiber panel. The notch may be configured to establish an opening in the vehicle interior component for deployment of an airbag through the vehicle interior component.
As indicated schematically according to an exemplary embodiment in
According to an exemplary embodiment as shown schematically in
According to an exemplary embodiment as shown schematically in the FIGURES, a component C for a vehicle interior configured to facilitate deployment of an airbag may comprise a panel PL comprising fibers. Panel PL may comprise a front side providing a surface SF and a rear side configured for contact from the airbag to establish an opening for deployment of the airbag. Panel PL may comprise a recess RS formed as a depression in the rear side of panel PL to establish the opening for deployment of the airbag and direct deployment of the airbag through panel PL. The front side of panel PL may comprise a substantially continuous surface opposite recess RS. Recess RS may be formed as an indentation in the rear side of panel PL. Recess RS may be formed in a mold by compressing at least a first portion of the panel PL between a first surface and a second surface of the mold, and penetrating material of panel PL at the rear side with a protrusion PN of the mold to push material of panel PL aside to form recess RS in the rear side and maintain a continuous surface at the front side. Recess RS may comprise a generally H-shaped arrangement comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape. Recess RS may comprise a generally U-shaped arrangement comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape. Recess RS may comprise a path comprising a continuous wave portion comprising a periodic function. Recess RS may comprise a path comprising a sinusoidal shape. Panel PL may comprise at least one of a resin; a thermoplastic resin; polypropylene; acrylonitrile butadiene styrene; polycarbonate. Panel PL may comprise a rib RB adjacent recess RS at the rear side of panel PL. Rib RB may be configured to direct deployment of the airbag through panel PL. Rib RB may be formed on panel PL. Rib RB may comprise a resin material. Rib RB may extend from recess RS. Rib RB may comprise a height below the rear side of panel PL; recess RS may comprise a cavity in panel PL comprising a depth. Recess RS may comprise a path comprising a connector between generally parallel segments; the connector may comprise a generally sinusoidal shape; panel PL may comprise a rib RB adjacent the connector at the rear side of panel PL; rib RB may comprise a generally sinusoidal shape. The component may comprise a first rib on a side of the connector and a second rib on an opposite side of the connector. Rib RB may comprise a resin material and rib RB may extend from recess RS. Recess RS may comprise a cavity comprising a cross-sectional profile. The profile of the cavity may comprise a depth within panel PL. The profile of the cavity may comprise a set of facets. The set of facets may comprise a first set of connected facets opposite a second set of connected facets. The set of facets may comprise a floor facet connecting the first set of connected facets and the second set of connected facets. The floor facet may comprise a surface generally parallel to the front side of panel PL. The profile of the cavity may comprise a wall and a floor. The profile of cavity may comprise at least one angled surface connecting the wall and the floor. The floor may be generally parallel to a surface of the front side of panel PL. The wall may comprise at least two generally planar surfaces. The wall may comprise a first surface and a second surface; the second surface may extend from the floor to the first surface. The first surface may extend from the second surface to the rear side of panel PL. The wall may comprise a first generally planar wall connected to a second generally planar wall. Recess RS may comprise a width at the rear side of panel PL; the floor may comprise a width less than the width of recess RS at the rear side of panel PL. Recess RS may comprise at least one of (a) a tear line configured to establish an opening for deployment of the airbag; (b) a weakening line configured to establish an opening for deployment of the airbag. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
According to an exemplary embodiment as shown schematically in the FIGURES, a vehicle interior component C configured to facilitate deployment of an airbag from an airbag module may comprise a panel PL comprising fibers. Panel PL may comprise a structural substrate for the component. Component C may comprise a panel PL comprising a recess RS; panel PL may comprise a recess RS and a rib RB. The panel may comprise a rear side and a front/facing side and a recess RS formed in the rear side as a depression, a notch, or an indentation; the front/facing side of the panel may comprise a substantially planar surface opposite the recess on the rear side of the panel. The panel may comprise at least one of a resin, a thermoplastic resin, polypropylene, acrylonitrile butadiene styrene, polycarbonate. As shown schematically in
According to an exemplary embodiment as shown schematically in
According to an exemplary embodiment, fiber mat FM may include a combination of structural fibers and thermoset resin (e.g. epoxy, polyester, etc.). According to an exemplary embodiment, fiber mat FM may be compressed within a heated mold to form a partially compressed fiber mat FM with a desired shape and to induce curing of the thermoset resin. According to an exemplary embodiment, a substantially rigid composite panel may be formed after the thermoset resin is cured.
According to an exemplary embodiment as shown schematically in
According to an exemplary embodiment, reinforcements SR may improve structural integrity of panel PL. According to an exemplary embodiment, panel PL may be able to maintain structural integrity during an airbag deployment; the position/placement of reinforcements SR may be intended to create a strength differential between different areas of panel PL; energy needed for an airbag to break through panel PL may be directed to recess RS of panel PL; reinforcements SR on the backside of panel PL may help prevent or minimize panel PL from ripping or tearing at any location other than recess RS (i.e. score line) during an airbag deployment. According to an exemplary embodiment as shown schematically in
According to an exemplary embodiment, panel PL may comprise a compressed fiber mat FM and a visible surface. According to an exemplary embodiment, the visible surface may include a cover, such as leather or other aesthetically-pleasing material.
According to an exemplary embodiment, panel PL may comprise a recess RS. According to an exemplary embodiment, recess RS may be configured to provide a weakened area within panel PL; the weakened area at recess RS may aid airbag deployment. As shown schematically in
According to an exemplary embodiment, recess RS may comprise a cross-sectional profile. The profile of recess RS may comprise a depth within panel PL. The profile of recess RS may comprise a set of facets. The set of facets may comprise a first set of connected facets opposite a second set of connected facets. The set of facets may comprise a floor facet connecting the first set of connected facets and the second set of connected facets. The floor facet may comprise a surface generally parallel to the visible surface of panel PL. The profile of recess RS may comprise an angled surface. The profile of recess RS may comprise a multi-faceted shape. The profile of recess RS may comprise at least one of (a) a bevel; (b) a fillet; (c) a chamfer. Recess RS may comprise a wall and a floor. The profile of recess RS may comprise at least one angled surface connecting the wall and the floor. The floor may be generally parallel to the visible surface of panel PL. The wall may comprise at least two generally planar surfaces. The wall may comprise a first surface and a second surface; the second surface may extend from the floor to the first surface. The first surface may extend from the second surface to a rear surface/rear side of panel PL.
According to an exemplary embodiment, recess RS may comprise at least one of (a) a notch, (b) a recess, (c) an indentation, (d) a depression, (e) a cavity.
According to an exemplary embodiment, panel PL may provide a smooth visible surface; additional material may not be required to cover the visible surface of panel PL.
According to an exemplary embodiment, panel PL may comprise a rib RB formed on panel PL behind a visible surface of panel PL and adjacent to a recess RS. According to an exemplary embodiment, resin may be injection molded onto the backside of panel PL to form rib RB. According to an exemplary embodiment, panel PL may have a smaller thickness at recess RS than a thickness at positions on panel PL other than at recess RS. Rib RB may comprise a height greater than the thickness of panel PL.
According to an exemplary embodiment as shown schematically in
According to an exemplary embodiment as shown schematically in
As shown schematically in
According to an exemplary embodiment as shown schematically in
According to a conventional embodiment, a conventional trim panel PLx is shown schematically as a conventional instrument panel Cx/IPx in
It is important to note that the present inventions (e.g. inventive concepts, etc.) have been described in the specification and/or illustrated in the FIGURES of the present patent document according to exemplary embodiments; the embodiments of the present inventions are presented by way of example only and are not intended as a limitation on the scope of the present inventions. The construction and/or arrangement of the elements of the inventive concepts embodied in the present inventions as described in the specification and/or illustrated in the FIGURES is illustrative only. Although exemplary embodiments of the present inventions have been described in detail in the present patent document, a person of ordinary skill in the art will readily appreciate that equivalents, modifications, variations, etc. of the subject matter of the exemplary embodiments and alternative embodiments are possible and contemplated as being within the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. It should also be noted that various/other modifications, variations, substitutions, equivalents, changes, omissions, etc. may be made in the configuration and/or arrangement of the exemplary embodiments (e.g. in concept, design, structure, apparatus, form, assembly, construction, means, function, system, process/method, steps, sequence of process/method steps, operation, operating conditions, performance, materials, composition, combination, etc.) without departing from the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. The scope of the present inventions is not intended to be limited to the subject matter (e.g. details, structure, functions, materials, acts, steps, sequence, system, result, etc.) described in the specification and/or illustrated in the FIGURES of the present patent document. It is contemplated that the claims of the present patent document will be construed properly to cover the complete scope of the subject matter of the present inventions (e.g. including any and all such modifications, variations, embodiments, combinations, equivalents, etc.); it is to be understood that the terminology used in the present patent document is for the purpose of providing a description of the subject matter of the exemplary embodiments rather than as a limitation on the scope of the present inventions.
It is also important to note that according to exemplary embodiments the present inventions may comprise conventional technology (e.g. as implemented and/or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or may comprise any other applicable technology (present and/or future) with suitability and/or capability to perform the functions and processes/operations described in the specification and/or illustrated in the FIGURES. All such technology (e.g. as implemented in embodiments, modifications, variations, combinations, equivalents, etc.) is considered to be within the scope of the present inventions of the present patent document.
The present application is a continuation of PCT/International Patent Application No. PCT/US2023/027262 titled “COMPONENT FOR VEHICLE INTERIOR” filed Jul. 10, 2023, which claims priority to U.S. Provisional Patent Application No. 63/368,115 titled “COMPONENT FOR VEHICLE INTERIOR” filed Jul. 11, 2022, and U.S. Provisional Patent Application No. 63/427,088 titled “COMPONENT FOR VEHICLE INTERIOR” filed Nov. 21, 2022. The present application claims priority to and incorporates by reference in full the following patent applications: (a) U.S. Provisional Patent Application No. 63/368,115 titled “COMPONENT FOR VEHICLE INTERIOR” filed Jul. 11, 2022; (b) U.S. Provisional Patent Application No. 63/427,088 titled “COMPONENT FOR VEHICLE INTERIOR” filed Nov. 21, 2022; (c) PCT/International Patent Application No. PCT/US2023/027262 titled “COMPONENT FOR VEHICLE INTERIOR” filed Jul. 10, 2023. The present application is related to and incorporates by reference in full the following patent applications: (a) PCT/International Patent Application No. PCT/US2012/052534 titled “SYSTEM AND METHOD FOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSION FORMING AND INJECTION MOLDING” filed Aug. 27, 2012; (b) PCT/International Patent Application No. PCT/US2013/056751 titled “SYSTEM AND METHOD FOR MOUNTING AN AIRBAG CHUTE ASSEMBLY WITHIN A VEHICLE TRIM COMPONENT” filed Aug. 27, 2013; (c) PCT/International Patent Application No. PCT/US2017/038572 titled “TRIM COMPONENT FOR VEHICLE INTERIOR” filed Jun. 21, 2017.
| Number | Date | Country | |
|---|---|---|---|
| 63368115 | Jul 2022 | US | |
| 63427088 | Nov 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US2023/027262 | Jul 2023 | WO |
| Child | 18981375 | US |
