Abstract: A component for a vehicle interior configured to provide a moveable panel/door is disclosed. The component may comprise a structural substrate and a reinforcement for the panel at a hinge area. The reinforcement may comprise a stitch pattern to reinforce the hinge area during movement of the panel. The stitch pattern may comprise thread sewn into the structural substrate. The stitch pattern may be pressed into a surface of the structural substrate. The structural substrate may comprise a compression-formed component, a generally rigid fiber mat, or a fiber panel. The stitch pattern may be concealed at an exterior surface of the component by a cover. The component may comprise at least one of an instrument panel, a door panel, a trim panel, a trim component, etc. A vehicle interior/trim component comprising a structural substrate with a reinforcement to provide a door/opening for airbag deployment is also disclosed.

Abstract: A component for a vehicle interior configured to provide a moveable panel/door is disclosed. The component may comprise a structural substrate and a reinforcement for the panel at a hinge area. The reinforcement may comprise a stitch pattern to reinforce the hinge area during movement of the panel. The stitch pattern may comprise thread sewn into the structural substrate. The stitch pattern may be pressed into a surface of the structural substrate. The structural substrate may comprise a compression-formed component, a generally rigid fiber mat, or a fiber panel. The stitch pattern may be concealed at an exterior surface of the component by a cover. The component may comprise at least one of an instrument panel, a door panel, a trim panel, a trim component, etc. A vehicle interior/trim component comprising a structural substrate with a reinforcement to provide a door/opening for airbag deployment is also disclosed.

Abstract: A vehicle interior/trim component configured to support an airbag module is disclosed. The component may comprise a structural substrate with a reinforcement to provide a door/opening for airbag deployment. The reinforcement may comprise a pattern of threads (e.g. top stitch to secure the door and bottom stitch). The reinforcement may comprise threads sewn within and/or pressed into a surface of a substrate/panel. The top stitch thread weight may be greater than that of the bottom stitch. The top stitch may comprise a retaining thread/hinge; the bottom stitch may separate upon deployment. The reinforcement may comprise KEVLAR, aramid, nylon, polyester, thread, ceramic fibers, polymeric fibers, synthetic fibers, etc. The structural substrate may comprise a fiber panel, compression-formed component, generally rigid fiber mat, etc. The component may be formed by injecting resin into a mold to form an ancillary component of a composite structure.

Abstract: A component for a vehicle interior is disclosed. The component may comprise a structural substrate, an airbag chute and a structure coupling the chute and structural substrate. The structure may comprise a rib injection molded onto the structural substrate; the structure may be bonded to the structural substrate. The chute may be welded to the structure and/or the structural substrate. The structural substrate may comprise a panel comprised of fibers; the structure may be comprised of resin. The structure may comprise an interface bonding the chute and structural substrate; the interface may comprise a molded feature/resin feature/mounting area on the structural substrate; a structure/material/rib injection molded on the structural substrate; a bond; an attachment; a composite or resin material; a material comprising fibers; polypropylene with fibers. The component may comprise a trim component; an instrument panel; a trim panel.

Abstract: A vehicle interior/trim component configured to support an airbag module is disclosed. The component may comprise a structural substrate with a reinforcement to provide a door/opening for airbag deployment. The reinforcement may comprise a pattern of threads (e.g. top stitch to secure the door and bottom stitch). The reinforcement may comprise threads sewn within and/or pressed into a surface of a substrate/panel. The top stitch thread weight may be greater than that of the bottom stitch. The top stitch may comprise a retaining thread/hinge; the bottom stitch may separate upon deployment. The reinforcement may comprise KEVLAR, aramid, nylon, polyester, thread, ceramic fibers, polymeric fibers, synthetic fibers, etc. The structural substrate may comprise a fiber panel, compression-formed component, generally rigid fiber mat, etc. The component may be formed by injecting resin into a mold to form an ancillary component of a composite structure.

Abstract: A component for a vehicle interior is disclosed. The component may comprise a structural substrate, an airbag chute and a structure coupling the chute and structural substrate. The structure may comprise a rib injection molded onto the structural substrate; the structure may be bonded to the structural substrate. The chute may be welded to the structure and/or the structural substrate. The structural substrate may comprise a panel comprised of fibers; the structure may be comprised of resin. The structure may comprise an interface bonding the chute and structural substrate; the interface may comprise a molded feature/resin feature/mounting area on the structural substrate; a structure/material/rib injection molded on the structural substrate; a bond; an attachment; a composite or resin material; a material comprising fibers; polypropylene with fibers. The component may comprise a trim component; an instrument panel; a trim panel.

Abstract: A method of manufacturing a vehicle interior panel includes providing a composite panel having a first thickness, inserting the composite panel into a mold, heating the composite panel, and compressing a first portion of the composite panel in a first region of the mold to a second thickness that is less than the first thickness.

Abstract: A headliner made from a laminate comprising a core layer sandwiched between two stiffening layers to form an I-beam construction that provides the necessary strength for the headliner. The core layer is preferably a blend of nonwoven fibers including some fine denier fibers to provide improved sound absorption properties. The stiffening layers also comprise a blend of nonwoven fibers. Both the core layer and the stiffening layers include some binder fibers to bond together the various fibers within each layer and the layers to each other.

Abstract: A headliner made from a laminate comprising a core layer sandwiched between two stiffening layers to form an I-beam construction that provides the necessary strength for the headliner. The core layer is preferably a blend of nonwoven fibers including some fine denier fibers to provide improved sound absorption properties. The stiffening layers also comprise a blend of nonwoven fibers. Both the core layer and the stiffening layers include some binder fibers to bond together the various fibers within each layer and the layers to each other.