阅读说明：本技术 车辆内部部件 (Vehicle interior component ) 是由 W·克鲁斯米尔 P·蒂尔霍恩 C·肯特尼克 B·麦劳尔 于 2020-02-20 设计创作，主要内容包括：公开了一种具有加热元件的车辆内部部件。该部件可以包括通过包括下述各者的过程在模具工具中生产的具有该加热元件的组件：将加热元件组装在覆盖层与纤维层之间以提供预成形组件；使预成形组件固结(例如,包括修整/压缩和/或加热)；将预成形组件放置到模具工具中；将预成形组件成形为具有一形状的压缩成形体；将覆盖物施加至压缩成形体以提供压缩成形面板。压缩成形面板可以设置成具有所述形状和由覆盖物提供的外表面。部件的压缩成形面板的外表面处的纹理/触感会掩盖部件内的加热元件的存在。该部件可以包括控制台；地板控制台；通道控制台；扶手；仪表面板；门；门面板；装饰部件；或面板。(A vehicle interior component having a heating element is disclosed. The component may comprise an assembly having the heating element produced in a mould tool by a process comprising: assembling a heating element between the cover layer and the fibrous layer to provide a preformed assembly; consolidating (e.g., including trimming/compressing and/or heating) the preform assembly; placing the preform assembly into a mold tool; forming the preform assembly into a compression molded body having a shape; applying a covering to the compression molded body to provide a compression molded panel. The compression-formed panel may be provided with said shape and an outer surface provided by the covering. The texture/feel at the outer surface of the compression-formed panel of the component may mask the presence of the heating element within the cover component. The component may include a console; a floor console; a channel console; a handrail; an instrument panel; a door; a door panel; a decorative member; or a panel.)

1. A component for a vehicle interior, the component comprising:

a panel assembly; and

a cover;

wherein the panel assembly includes a top layer, a heater, and a structural layer.

2. The component of claim 1, wherein the top layer comprises an outer surface having a smooth texture and the structural layer comprises an outer surface having a rough texture.

3. The component of claim 1, wherein the top layer is configured to provide improved contour tolerance for the component.

4. The component of claim 1, wherein the top layer comprises at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet.

5. The component of claim 1, wherein the structural layer comprises natural fibers and resin; wherein the top layer comprises polypropylene and polyester.

6. The component of claim 5, wherein the resin comprises polypropylene and the natural fibers comprise at least one of: (a) flax; (b) kenaf.

7. The component as recited in claim 1, wherein the structural layer comprises at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat.

8. The component of claim 1, wherein the covering comprises at least one of: (a) leather; (b) artificial leather; (c) a textile fabric; (d) a nonwoven fabric; (e) a decoration piece; (f) a vinyl material; (g) a foil.

9. The component of claim 1, wherein the heater comprises a substrate and a wire coupled to the substrate of the heater; wherein the substrate of the heater comprises polypropylene fibers.

10. The component of claim 9, wherein the polypropylene fibers are bonded to at least one of: (a) the top layer; (b) the structural layer.

11. The component of claim 1, comprising at least one of: (a) a console; (b) a floor console; (c) a channel console; (d) a handrail; (e) an instrument panel; (f) a door; (g) a door panel; (h) a decorative member; (i) a panel.

12. The component of claim 1, produced by a process comprising:

assembling the heater with a fibrous layer to provide a preform assembly;

consolidating the preform assembly;

placing the preform assembly into a mold tool;

forming the preform assembly into a compression molded body having a shape;

applying the covering to the compression molded body to provide a compression molded panel;

such that the compression-formed panel is arranged to have the shape and an outer surface.

13. The component of claim 1, produced by a process comprising:

assembling the heater between the top layer and the structural layer to provide a pre-formed assembly;

consolidating the preform assembly;

placing the preform assembly into a mold tool;

forming the preform assembly into a compression molded body having a shape;

applying the covering to the compression molded body to provide a compression molded panel;

such that the compression-formed panel is arranged to have the shape and an outer surface provided by the covering.

14. A vehicle interior component comprising a heating element, the vehicle interior component being produced in a mold tool by a process comprising the steps of:

assembling the heating element with a fibrous layer to provide a preform assembly;

consolidating the preform assembly;

placing the preform assembly into the mold tool;

forming the preform assembly into a compression molded body having a shape;

applying a covering to the compression molded body to provide a compression molded panel;

such that the compression-formed panel is arranged to have the shape and an outer surface.

15. The component of claim 14, wherein the fibrous layer comprises a structural layer for the preformed assembly.

16. The component of claim 14, wherein the fiber layer comprises at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat; (g) a natural fiber material; (h) a polypropylene material; (i) natural fibers and polypropylene mats; (j) a mat formed of natural fibers and polypropylene fibers.

17. The component of claim 14, wherein the step of forming the preform assembly into the compressed shaped body comprises compressing the preform assembly in the mold tool.

18. The component of claim 14, wherein the step of shaping the preform assembly into a compressed shaped body comprises compressing the fiber layer and the heating element in the mold tool.

19. The component of claim 14, wherein the outer surface of the compression-formed panel comprises a texture provided by the covering.

20. The component of claim 14, wherein the mold tool comprises a mold cavity having a surface; wherein the outer surface of the compression-formed panel comprises a texture formed at least in part by the surface of the mold tool.

21. The component of claim 20, wherein the outer surface of the compression-formed panel comprises a texture provided by the covering and at least partially by the surface of the mold tool.

22. The component of claim 14, wherein the mold tool comprises a mold cavity having a shape; wherein the shape of the compression-formed panel is provided at least in part by the shape of the mold tool.

23. The component of claim 14, wherein the mold tool comprises a textured surface; and wherein the step of forming the preform assembly into the compressed shaped body comprises compressing the fiber layer and the heating element and at least partially forming the textured surface on the compressed shaped body.

24. The component of claim 23, wherein the textured surface is at least partially formed on the outer surface of the compression-formed panel.

25. The component of claim 14, wherein the process further comprises the step of applying a cover layer for the preformed assembly.

26. The component of claim 25, wherein the cover layer for the preformed assembly comprises at least one of a fibrous layer or a fabric layer.

27. The component of claim 25, wherein the cover layer for the preform assembly comprises at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet.

28. The component of claim 25, wherein the fibrous layer of the preform assembly comprises a structural layer; wherein the structural layer comprises natural fibers and resin; wherein the cover layer comprises polypropylene and polyester.

29. The component of claim 14, wherein the step of assembling the heating element with the fibrous layer comprises assembling the heating element with the fibrous layer and a cover layer to provide the preform assembly; and wherein the step of consolidating the preform assembly comprises consolidating the fiber layer with the heating element and the cover layer.

30. The component of claim 29, wherein the step of forming the preform assembly into a compression molded body having a shape comprises compressing the fiber layer with the heating element and the cover layer to form the compression molded body.

31. The component of claim 30, wherein the mold tool comprises a textured surface; and wherein compressing the fibrous layer with the heating element and the cover layer in the mold tool comprises at least partially forming the textured surface on the cover layer of the compressed shaped body.

32. The component of claim 14, wherein the step of consolidating the preform assembly comprises at least one of: (a) shaping the preform assembly; (b) heating the preform assembly.

33. The component of claim 14, wherein the process further comprises the steps of shaping the preform assembly and trimming the preform assembly.

34. The component of claim 14, wherein the step of forming the preform assembly into the compression shape comprises compressing the preform assembly into the shape.

35. The component of claim 14, wherein the step of forming the preform assembly into the compression molded body comprises applying heat to shape the compression molded body into the shape.

36. The component of claim 14, wherein the shape comprises at least one of: (a) a wavy shape; (b) and (4) forming the shape.

37. The component of claim 14, wherein the covering comprises at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) coating; (f) and (4) surface texture.

38. A vehicle interior component assembly comprising a heating element, the vehicle interior component assembly produced in a mold tool by a process comprising the steps of:

assembling the heating element between a cover layer and a fibrous layer to provide a preformed assembly;

consolidating the preform assembly;

placing the preform assembly into the mold tool;

forming the preform assembly into a compression molded body having a shape;

applying a covering to the compression molded body to provide a compression molded panel;

such that the compression-formed panel is arranged to have the shape and an outer surface provided by the covering.

39. The component assembly of claim 38, wherein the mold tool comprises a surface; wherein the outer surface of the compression-formed panel is provided at least in part by the surface of the mold tool.

40. The component assembly of claim 38, wherein consolidating the preformed assembly comprises at least partially compressing the cover layer and the heating element and the fibrous layer.

41. The component assembly of claim 38, wherein the step of consolidating the preform assembly comprises at least one of: (a) securing the heating element between the cover layer and the fibrous layer with an adhesive; (b) fusing the cover layer, the heating element, and the fibrous layer; (c) welding the cover layer, the heating element and the fibrous layer; (d) shaping the cover layer, the heating element and the fibrous layer; (e) cutting the cover layer, the heating element, and the fibrous layer to a size; (f) heating the cover layer, the heating element and/or the fibrous layer.

42. The component assembly of claim 38, wherein the cover layer is configured for application of the cover such that the cover is secured to the cover layer to provide the outer surface for the compression-formed panel.

43. The component assembly of claim 38, wherein the outer surface of the covering of the compression-formed panel is configured to provide a texture provided by the covering and the overlay.

44. The component assembly of claim 38, wherein the fiber layer of the preform assembly comprises a structural layer; wherein the structural layer comprises natural fibers and resin; wherein the cover layer comprises polypropylene and polyester.

45. The component assembly of claim 38, wherein the fiber layer comprises at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat; (g) a natural fiber material; (h) a polypropylene material; (i) natural fibers and polypropylene mats; (j) a mat formed of natural fibers and polypropylene fibers;

wherein the cover layer for the pre-formed component comprises at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet;

wherein the covering comprises at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) and (4) coating.

Technical Field

The present invention relates to a vehicle interior component.

The invention also relates to a vehicle interior component having a heating element, manufactured by a process comprising the step of compression forming the assembly.

Background

It is known to provide vehicle interior component assemblies that include a heating element.

It would be advantageous to provide an improved vehicle interior component having a heating element. It would also be advantageous to provide the following vehicle interior components that include a heating element: the vehicle interior component includes a structural layer and a covering having an outer surface with reduced texture/contour variations at the outer surface despite the heating element being housed within the component.

Disclosure of Invention

The present invention relates to a component for a vehicle interior, the component comprising a panel assembly and a covering. The panel assembly may include a top layer, a heater, and a structural layer. The top layer may include an outer surface having a smooth texture and the structural layer may include an outer surface having a rough texture. The top layer can be configured to provide improved contour tolerances for the component. The top layer may comprise at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet. The structural layer may include natural fibers and resins; the top layer may comprise polypropylene and polyester. The resin may include polypropylene, and the natural fibers include at least one of: (a) flax; (b) kenaf. The structural layer may include at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat. The covering may include at least one of: (a) leather; (b) artificial leather; (c) a textile fabric; (d) a nonwoven fabric; (e) a decoration piece; (f) a vinyl material; (g) a foil. The heater may include a substrate and a wire coupled to the substrate of the heater; the substrate of the heater may comprise polypropylene fibres. The polypropylene fibers may be bonded to at least one of: (a) a top layer; (b) and (5) a structural layer. The component may include at least one of: (a) a console; (b) a floor console; (c) a channel console (tunnel console); (d) a handrail; (e) an instrument panel; (f) a door; (g) a door panel; (h) a decorative member; (i) a panel. The component may be produced by a process comprising the steps of: assembling a heater with the fibrous layer to provide a preform assembly; consolidating the preform assembly; placing the preform assembly into a mold tool; forming the preform assembly into a compression molded body having a shape; applying a covering to the compression molded body to provide a compression molded panel; such that the compression-formed panel is arranged to have said shape and an outer surface. The component may be produced by a process comprising the steps of: assembling a heater between the top layer and the structural layer to provide a preformed assembly; consolidating the preform assembly; placing the preform assembly into a mold tool; forming the preform assembly into a compression molded body having a shape; applying a covering to the compression molded body to provide a compression molded panel; such that the compression-formed panel is arranged to have said shape and an outer surface provided by the covering.

The invention relates to a vehicle interior component comprising a heating element, which vehicle interior component is produced in a mould tool by a process comprising the following steps: assembling a heating element with the fibrous layer to provide a preform assembly; consolidating the preform assembly; placing the preform assembly into a mold tool; forming the preform assembly into a compression molded body having a shape; applying a covering to the compression molded body to provide a compression molded panel; such that the compression-formed panel is arranged to have said shape and an outer surface. The fibrous layer may comprise a structural layer for preforming the assembly. The fibrous layer may comprise at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat; (g) a natural fiber material; (h) a polypropylene material; (i) natural fibers and polypropylene mats; (j) a mat formed of natural fibers and polypropylene fibers. The step of forming the pre-formed component into a compressed shaped body may comprise compressing the pre-formed component in a mould tool. The step of forming the preform assembly into a compressed shaped body may comprise compressing the fibre layer with the heating element in a mould tool. The outer surface of the compression-formed panel may include a texture provided by the covering. The mold tool may include a mold cavity having a surface; the outer surface of the compression-formed panel may include a texture formed at least in part by the surface of the mold tool. The outer surface of the compression-formed panel may include a texture provided by the covering and at least partially provided by the surface of the mold tool. The mold tool may include a mold cavity having a shape; the shape of the compression-formed panel may be provided at least in part by the shape of the mold tool. The mold tool may include a textured surface; the step of forming the preform assembly into a compressed shaped body may include compressing the fiber layer with the heating element and at least partially forming a textured surface on the compressed shaped body. The textured surface may be at least partially formed on an outer surface of the compression-formed panel. The process may include the step of applying a cover layer for the preformed component. The cover layer for the preformed component may comprise at least one of a fibrous layer or a fabric layer. The cover layer for the preformed component may comprise at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet. The fibrous layer of the preform assembly may comprise a structural layer; the structural layer may include natural fibers and resins; the cover layer may comprise polypropylene and polyester. The step of assembling the heating element with the fibrous layer may comprise assembling the heating element with the fibrous layer and the cover layer to provide a preformed assembly; the step of consolidating the preform assembly may include consolidating the fiber layer with the heating element and the cover layer. The step of forming the preform assembly into a compression-formed body having a shape may include compressing the fibrous layer with the heating element and the cover layer to form the compression-formed body. The mold tool may include a textured surface; compressing the fiber layer with the heating element and the cover layer in the mold tool may include at least partially forming a textured surface on the cover layer of the compressed shaped body. The step of consolidating the preform assembly may comprise at least one of: (a) shaping the preform assembly; (b) the preform assembly is heated. The process may include the steps of shaping the preformed component and trimming the preformed component. The step of forming the preform assembly into a compression-formed body may comprise compressing the preform assembly into said shape. The step of forming the preform assembly into a compression-formed body may comprise applying heat to form the compression-formed body into said shape. The shape may include at least one of: (a) a wavy shape; (b) and (4) forming the shape. The covering may include at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) coating; (f) and (4) surface texture.

The invention relates to a vehicle interior component assembly comprising a heating element, which is produced in a mould tool by a process comprising the following steps: assembling a heating element between the cover layer and the fibrous layer to provide a preformed assembly; consolidating the preform assembly; placing the preform assembly into a mold tool; forming the preform assembly into a compression molded body having a shape; applying a covering to the compression molded body to provide a compression molded panel; such that the compression-formed panel is arranged to have said shape and an outer surface provided by the covering. The mold tool may include a surface; the outer surface of the compression-formed panel may be provided at least in part by said surface of the mould tool. The step of consolidating the preform assembly may include at least partially compressing the cover layer and the heating element and the fibrous layer. The step of consolidating the preform assembly may comprise at least one of: (a) securing the heating element between the cover layer and the fibrous layer with an adhesive; (b) fusing (fusing) the cover layer, the heating element and the fibrous layer; (c) fusing the cover layer, heating element and fibrous layer; (d) shaping the cover layer, heating element and fibrous layer; (e) cutting the cover layer, the heating element and the fibrous layer to a size; (f) the cover layer, heating element and/or fibrous layer are heated. The cover layer may be configured for application of the cover such that the cover is secured to the cover layer to provide the outer surface for the compression-formed panel. The outer surface of the covering of the compression formed panel may be configured to provide the texture provided by the covering and the overlay. The fibrous layer of the preform assembly may comprise a structural layer; the structural layer may include natural fibers and resins; the cover layer may comprise polypropylene and polyester. The fibrous layer may comprise at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat; (g) a natural fiber material; (h) a polypropylene material; (i) natural fibers and polypropylene mats; (j) a mat formed of natural fibers and polypropylene fibers; the cover layer for the preformed component may comprise at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet; the covering may include at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) and (4) coating.

The present invention relates to a vehicle interior component assembly comprising a heating element in a compression molded body having a shape produced in a mold tool comprising a first surface and a second surface by a process comprising the steps of: placing a heating element on the fibrous layer; placing the fiber layer into a mold tool; and compressing the fiber layer and the heating element between the first surface of the mold tool and the second surface of the mold tool to form a compressed shaped body having the heating element and the shape. The process may include the step of providing a pre-formed assembly comprising a fibrous layer as a base for the heating element and a fabric layer on the heating element. The preform assembly may comprise a panel assembly. The process may include the steps of heating the preform assembly and trimming the panel assembly. The step of compressing the fibre layers may comprise compressing the preformed component into a compression-formed body having said shape. The fibrous layer may comprise at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat. The mold tool may include a textured surface and the compression molded body may be shaped to have a textured surface. The heating element may be encapsulated in the compression molded body; the heating element may comprise an electrical heating element. The process may include the step of placing the fabric sheet over the heating element such that the heating element is located between the fiber layer and the fabric sheet. The compression molded body may include a shaped panel assembly; the forming panel assembly may include a heating element and a structural layer; the inner surface of the heater may be coupled to the outer surface of the structural layer. The forming panel assembly may include a top layer coupled to an outer surface of the heating element; the top layer may include an outer surface having a smooth texture; the outer surface of the structural layer may include a rough texture. The top layer may be configured to provide improved contour tolerances for the vehicle interior component assembly. The structural layer may include natural fibers and resins, and the top layer may include polypropylene and polyester. The resin may include polypropylene, and the natural fibers include at least one of: (a) flax; (b) kenaf. The top layer may comprise at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet. The process may include the steps of activating the top layer of the panel assembly and adhering the overlay to the top layer of the panel assembly. The process may include the step of consolidating the top layer and heating elements and structural layer to form a formed panel assembly prior to forming the compressed formed body; the structural layer may comprise a fibrous layer and the top layer may comprise a fabric panel. The process may include the step of consolidating the heating element and structural layer to form a panel assembly. The process may include the step of heating the panel assembly; the panel assembly may be compressed as the panel assembly cools. The process may include the step of injecting resin into the mold tool after forming the compression-molded component to form an auxiliary component of the vehicle interior component assembly. The process may include the step of disposing a cover onto the compression molded body to form the vehicle interior component assembly. The component assembly may include at least one of: (a) a console; (b) a floor console; (c) a channel console; (d) a handrail; (e) an instrument panel; (f) a door; (g) a door panel; (h) a decorative member; (i) a panel.

The present invention relates to a vehicle interior component assembly comprising sub-system elements in a compression molded body having a shape produced in a mold tool comprising a first surface and a second surface by a process comprising the steps of: placing the subsystem components on the bottom layer; placing a top layer on the bottom layer with the subsystem components to provide a pre-formed assembly; placing the preform assembly into a mold tool; and compressing the preform assembly between the first surface of the mold tool and the second surface of the mold tool to form a compressed shaped body having the subsystem elements and the shape. The subsystem elements may include components configured for electrification; the subsystem elements may be at least partially concealed within the compression molded body. The compression molded body may include structural elements and subsystem elements. The compression molded body may include subsystem elements hidden between the top layer and the bottom layer. The top layer may comprise a panel and the bottom layer may comprise a structural element. The structural element may comprise a panel. The face sheet of the structural element may comprise a fibre mat. The bottom layer may comprise a fibrous mat and the top layer may comprise a fabric panel. The subsystem elements may include heating elements; the heating element may comprise a resistive heating element. The component assembly may include a cover for compressing the shaped body; the covering may include a surface texture. The covering may include at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) and (4) coating. The process may include the step of providing the base layer as a fibrous layer. The process may include the step of applying an adhesive to the subsystem components. The process may include the step of applying a fabric layer. The process may include the step of applying a covering to the compression molded body. The compression molded body may be formed into a panel.

The present invention relates to a vehicle interior component assembly comprising a heating element in a compression molded body having a shape produced in a mold tool comprising a first surface and a second surface by a process comprising the steps of: placing a heating element on the fibrous layer; the fiber layer is placed into a mold tool and compressed with the heating element between a first surface of the mold tool and a second surface of the mold tool to form a compressed shaped body having the heating element and the shape. The process may include the step of providing a pre-formed assembly comprising a fibrous layer as a base for the heating element and a fabric layer on the heating element. The preform assembly may comprise a panel assembly. The process may include the step of trimming the panel assembly. The process may include the step of heating the preform assembly. The step of compressing the fibre layers may comprise compressing the preformed component into a compression-formed body having said shape. The fibrous layer may comprise at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat. The mold tool may include a textured surface and the compression molded body may be shaped to have a textured surface. The heating element may be encapsulated in the compressed shaped body. The heating element may comprise an electrical heating element. The process may include the step of placing the fabric sheet over the heating element such that the heating element is located between the fiber layer and the fabric sheet. The compression molded body may comprise a shaped panel assembly. The panel assembly may include a heating element and a structural layer; the inner surface of the heater may be coupled to the outer surface of the structural layer. The panel assembly may include a top layer coupled to an outer surface of the heating element. The top layer may include an outer surface having a smooth texture; the outer surface of the structural layer may include a rough texture. The top layer may be configured to provide improved contour tolerances for the vehicle interior component assembly. The structural layer may include natural fibers and resins, and the top layer may include polypropylene and polyester. The resin may include polypropylene and the natural fibers may include at least one of: (a) flax; (b) kenaf. The top layer may comprise at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet. The top layer may comprise an areal weight of between 200 grams per square meter and 300 grams per square meter. The process may include the steps of activating the top layer of the panel assembly and adhering the overlay to the top layer of the panel assembly. The process may include the step of consolidating the top layer with the heating element and structural layer to form a panel assembly prior to forming the compressed shaped body. The structural layer may comprise a fibrous layer and the top layer may comprise a fabric panel. The process may include the step of consolidating the heating element and structural layer to form a panel assembly. The panel assembly may include an areal weight of between 1000 grams per square meter and 1800 grams per square meter. The panel assembly may include a thickness of between 1.5 millimeters and 4 millimeters. The process may include the step of heating the panel assembly; the panel assembly may be compressed as the panel assembly cools. The process may include the step of injecting resin into the mold tool after forming the compression-molded component to form an auxiliary component of the vehicle interior component assembly. The process may include the step of disposing a cover over the compression molded body to form the vehicle interior component assembly.

The present invention relates to a vehicle interior component assembly comprising sub-system elements in a compression molded body having a shape produced in a mold tool comprising a first surface and a second surface by a process comprising the steps of: placing the subsystem components on the bottom layer; placing a top layer on the bottom layer with the subsystem components to provide a pre-formed assembly; placing the preform assembly into a mold tool; and compressing the preform assembly between the first surface of the mold tool and the second surface of the mold tool to form a compressed shaped body having the subsystem elements and the shape. The subsystem elements may include components configured for electrification. The subsystem elements may be at least partially concealed within the compression molded body. The compression molded body may comprise a structural element. The compression molded body may include subsystem elements and structural elements. The compression molded body may include subsystem elements hidden between the top layer and the bottom layer. The top layer may comprise a panel and the bottom layer may comprise a structural element. The structural element may comprise a panel. The face sheet may comprise a fiber mat. The bottom layer may comprise a fibrous mat and the top layer may comprise a fabric panel. The bottom layer may comprise a fibrous mat. The subsystem components may include heating elements. The heating element may comprise an electrical heating element. The electrical heating element may comprise a resistive heating element. The component assembly may include a cover for the compression molded body. The covering may include a surface texture. The covering may include at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) and (4) coating. The process may include the step of providing the base layer as a fibrous layer. The process may include the step of applying an adhesive to the subsystem components. The process may include the step of applying a fabric layer. The process may include the step of applying a covering to the compression molded body. The compression molded body may be formed into a panel.

The present invention relates to a component for a vehicle interior, the component comprising a panel assembly and a covering; the panel assembly may include a top layer, a heater, and a structural layer. The top layer may include an outer surface having a smooth texture and the structural layer may include an outer surface having a rough texture. The top layer can be configured to provide improved contour tolerances for the component. The structural layer may include natural fibers and resins; the top layer may comprise polypropylene and polyester. The resin may include polypropylene, and the natural fibers include at least one of: (a) flax; (b) kenaf. The covering may include at least one of: (a) leather; (b) artificial leather. The covering may include at least one of: (a) a textile fabric; (b) a nonwoven fabric; (c) a decoration piece; (d) a vinyl material; (e) a foil. The heater may include a substrate and a wire coupled to the substrate of the heater. The substrate of the heater may comprise polypropylene fibres. The polypropylene fibers may be bonded to at least one of: (a) a top layer; (b) and (5) a structural layer.

The present invention relates to a vehicle interior component assembly comprising a heating element in a compression molded body having a shape produced in a mold tool comprising a first surface and a second surface by a process comprising the steps of: placing a heating element on the fibrous layer; placing the fiber layer into a mold tool; and compressing the fiber layer and the heating element between the first surface of the mold tool and the second surface of the mold tool to form a compressed shaped body having the heating element and the shape.

The present invention relates to a vehicle interior component assembly comprising sub-system elements in a compression molded body having a shape produced in a mold tool comprising a first surface and a second surface by a process comprising the steps of: placing the subsystem components on the bottom layer; placing a top layer on the bottom layer with the subsystem components to provide a pre-formed assembly; placing the preform assembly into a mold tool; and compressing the preform assembly between the first surface of the mold tool and the second surface of the mold tool to form a compressed shaped body having the subsystem elements and the shape. The subsystem elements may include components configured for electrification. The subsystem elements may be at least partially concealed within the compression molded body.

The invention relates to a component for a vehicle interior, comprising: a panel assembly; and a cover. The panel assembly may include a top layer, a heater, and a structural layer.

Drawings

Fig. 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.

Fig. 1B is a schematic perspective view of a vehicle showing a vehicle interior according to an exemplary embodiment.

Fig. 2A and 2B are schematic perspective views of a door panel according to an exemplary embodiment.

Fig. 2C is a schematic perspective view of a door panel according to an exemplary embodiment.

Fig. 3A is a schematic perspective view of a door panel according to an exemplary embodiment.

Fig. 3B is a schematic exploded perspective view of a door panel according to an exemplary embodiment.

Fig. 3C is a schematic exploded perspective view of a vehicle interior component according to an exemplary embodiment.

Fig. 4A to 4D are schematic perspective views of a process of forming a panel assembly for a vehicle interior according to an exemplary embodiment.

Fig. 5A to 5C are schematic perspective views of a process of forming a vehicle interior component from a panel assembly according to an exemplary embodiment.

FIG. 5D is a schematic perspective detail view of a backside portion of a vehicle interior component according to an exemplary embodiment.

Fig. 5E is a schematic perspective view of a covering and panel for a vehicle interior component according to an exemplary embodiment.

Fig. 5F is a schematic perspective view of a vehicle interior component according to an exemplary embodiment.

FIG. 6 is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 7A is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 7B is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 8A is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 8B is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 9A is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 9B is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 10A is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 10B is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 11A is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 11B is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

Fig. 12A to 12F are schematic sectional views of a process of forming a vehicle interior component according to an example embodiment.

Fig. 12G to 12H are schematic perspective views of a process of forming a vehicle interior component according to an example embodiment.

FIG. 13 is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 14A is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 14B is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 15A is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 15B is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

FIG. 15C is a schematic flow chart of a method for forming a vehicle interior component according to an exemplary embodiment.

Detailed Description

Referring to fig. 1A and 1B, a vehicle V providing an interior I according to an exemplary embodiment is shown. The interior I of the vehicle V may include interior components/systems, shown as component C, including panels (e.g., instrument panels, door panels, etc.) and consoles (e.g., floor consoles, overhead consoles, etc.) as well as other trim components. The interior I of the vehicle V may include a door/door panel D. See fig. 1B and 2A. Door/door panel D may provide heat H for interior I. See fig. 2B. Door/door panel D may include a heater/heating element/heating wire W configured to provide heat to interior I. See fig. 2C.

According to an exemplary embodiment as schematically illustrated in fig. 3A-3B, door panel 1000 may include at least one of: (a) a carrier 100; (b) a decorative member 200; (c) a vehicle interior component assembly C/300; (d) an armrest 400. According to an exemplary embodiment as schematically illustrated in fig. 3C, the vehicle interior component assembly 300 may include a structural layer/member/backing/natural fiber/polypropylene mat 10, a heater/electric heating element/resistive heating element 20, and a cover 310.

According to the exemplary embodiment schematically illustrated in fig. 4A to 4D and 5A to 5F, the vehicle interior component 300 may be manufactured by a process including: forming the natural fiber/polypropylene mat 10 (e.g., needle punching the natural fibers and polypropylene fibers to form the mat), trimming the natural fiber/polypropylene mat to a size, applying a binder to the natural fiber/polypropylene mat, applying a heater 20 to the natural fiber/polypropylene mat, applying a binder to the heater, and applying the fabric 30 to the binder on the heater. The process may include applying an adhesive to the fabric. The process may include: consolidating the layers together in a tool (see fig. 4B) to form a consolidated assembly 123a, placing the consolidated assembly in a forming press/injection molding apparatus and forming a compressed consolidated assembly 123B, and trimming the compressed consolidated assembly to form a preform assembly/panel assembly 123c (and excess material/scrap 123 x). See fig. 4D. The process may include heating the preform assembly (e.g. in an oven OV). See fig. 5A. The process may include placing the pre-formed component in a mold/mold tool M and shaping the pre-formed component into a compression molded body 123. See fig. 5B-5D. The process may include injection molding features/secondary elements 123r (e.g., ribs, retainers, etc.) on the compression molded body. See fig. 5D. The process may include joining the covering 310 to the compression molded body. See fig. 5E.

According to an exemplary embodiment schematically illustrated in fig. 2A to 2C, 3A to 3C, 4A to 4D and 5A to 5F, the vehicle interior part 300 may include the heating element 20 in the compression-molded body 123, the compression-molded body 123 having a shape produced in the mold tool M including the first surface M1 and the second surface M2 by a process including the steps of: placing the heating element on the fibrous layer/structural layer 10; placing the fiber layer into a mold tool; and compressing the fiber layer and the heating element between the first surface of the mold tool and the second surface of the mold tool to form a compressed shaped body having the heating element and the shape. The process may further include the step of providing a preform assembly 123c, the preform assembly 123c including a fiber layer as a base for the heating element and a fabric layer/fabric sheet/top layer 30 on the heating element. The preform assembly may comprise a panel assembly. The process may also include the step of trimming the panel assembly. See fig. 4D. The process may further include the step of heating the preform assembly. See fig. 5A. The step of compressing the fibre layers may comprise compressing the preformed component into a compression-formed body having said shape. The fibrous layer may comprise at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat. The mold tool may include a textured surface; the compressed shape can be formed with a textured surface. The heating element may be encapsulated in the compressed shaped body. The heating element may comprise an electrical heating element. The process may further include the step of placing the fabric sheet over the heating element such that the heating element is located between the fiber layer and the fabric sheet. See fig. 4A and 4B. The compression molded body may comprise a shaped panel assembly. The panel assembly may include a heating element and a structural layer; the inner surface of the heater may be coupled to the outer surface of the structural layer. The panel assembly may also include a top layer coupled to an outer surface of the heating element. The top layer may include an outer surface having a smooth texture; the outer surface of the structural layer may include a rough texture. The top layer may be configured to provide improved contour tolerances for the vehicle interior components. The structural layer may include natural fibers and resins; the top layer may comprise polypropylene and polyester. The resin may include polypropylene; the natural fibers may include at least one of: (a) flax; (b) kenaf. The top layer may comprise at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet. The top layer may comprise an areal weight of between 200 grams per square meter and 300 grams per square meter. The process may include the steps of activating the top layer of the panel assembly and adhering the cover 310 to the top layer of the panel assembly. The process may further include the step of consolidating the top layer and heating element and structural layer to form a panel assembly prior to forming the compressed shaped body. The structural layer may comprise a fibrous layer; the top layer may comprise a fabric panel. The process may include the step of consolidating the heating element and structural layer to form a panel assembly. The panel assembly may include an areal weight of between 1000 grams per square meter and 1800 grams per square meter. The panel assembly may include a thickness of between 1.5 millimeters and 4 millimeters. The process may include the step of heating the panel assembly; the panel assembly may be compressed as the panel assembly cools. The process may include the step of injecting resin into the mold tool after forming the compression-molded component to form an auxiliary component of the vehicle interior component assembly. The process may include the step of disposing a cover over the compression molded body to form the vehicle interior component assembly.

According to an exemplary embodiment as schematically illustrated in fig. 2A to 2C, 3A to 3C, 4A to 4D and 5A to 5F, the vehicle interior component assembly may comprise subsystem elements in a compression molded body, wherein the compression molded body has a shape produced in a mold tool comprising a first surface and a second surface by a process comprising the steps of: placing the subsystem components on the bottom layer; placing a top layer on the bottom layer with the subsystem components to provide a pre-formed assembly; placing the preform assembly into a mold tool; and compressing the preform assembly between the first surface of the mold tool and the second surface of the mold tool to form a compressed shaped body having the subsystem elements and the shape. The subsystem elements may include components configured for electrification. The subsystem elements may be at least partially concealed within the compression molded body. The compression molded body may comprise a structural element. The compression molded body may include subsystem elements and structural elements. The compression molded body may include subsystem elements hidden between the top layer and the bottom layer. The top layer may comprise a panel and the bottom layer may comprise a structural element. The structural element may comprise a panel; the face sheet may comprise a fiber mat. The bottom layer may comprise a fibrous mat and the top layer may comprise a fabric panel. The bottom layer may comprise a fibrous mat. The subsystem components may include heating elements. The heating element may comprise an electrical heating element. The electrical heating element may comprise a resistive heating element. The component assembly may further comprise a cover for the compression shape. The covering may include a surface texture. The covering may include at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) and (4) coating. The method may further comprise the step of providing the base layer as a fibrous layer. The process may further include the step of applying an adhesive to the subsystem components. The process may further comprise the step of applying a fabric layer. The process may further comprise the step of applying a covering to the compression molded body. The compression molded body may be formed into a panel.

According to the exemplary embodiments schematically illustrated in fig. 2A to 2C, 3A to 3C, 4A to 4D, and 5A to 5F, the component for the vehicle interior may include a panel assembly and a cover. The panel assembly may include a top layer, a heater, and a structural layer. The top layer may include an outer surface having a smooth texture and the structural layer may include an outer surface having a rough texture. The top layer can be configured to provide improved contour tolerances for the component. The structural layer may include natural fibers and resins; the top layer may comprise polypropylene and polyester. The resin may include polypropylene; the natural fibers may include at least one of: (a) flax; (b) kenaf. The covering may include at least one of: (a) leather; (b) artificial leather. The covering may include at least one of: (a) a textile fabric; (b) a nonwoven fabric; (c) a decoration piece; (d) a vinyl material; (e) a foil. The heater may include a substrate and a wire coupled to the substrate of the heater. The substrate of the heater may comprise polypropylene fibres. The polypropylene fibers may be bonded to at least one of: (a) a top layer; (b) and (5) a structural layer.

According to an exemplary embodiment schematically illustrated in fig. 6, the vehicle interior component may be manufactured by a process comprising: needle punching natural fibers and polypropylene fibers to form a natural fiber/polypropylene mat, trimming the natural fiber/polypropylene mat to a desired size, applying a subsystem element to a surface of the natural fiber/polypropylene mat, applying a fabric having a desired size to a surface of the subsystem element, consolidating the layers together in a tool, trimming the consolidated layers, and compression forming the layers.

According to an exemplary embodiment as schematically illustrated in fig. 7A, the vehicle interior component may be manufactured by a process comprising: forming a fiber/polypropylene mat, applying a heater to the mat, shaping the mat and heater, trimming the shaped part, and bonding the cover to the shaped part.

According to an exemplary embodiment schematically illustrated in fig. 7B, the vehicle interior component may be manufactured by a process comprising: the method includes needling fibers and polypropylene fibers to form a fiber/polypropylene mat, applying a film adhesive to a surface of the fiber/polypropylene mat, applying a heater to the film adhesive, consolidating the heater and the fiber/polypropylene mat to form a heater-containing fiber/polypropylene mat, compression forming the heater-containing fiber/polypropylene mat into a desired shape, trimming the compression formed part to a desired size, and bonding a cover to the formed heater-containing fiber/polypropylene mat.

According to an exemplary embodiment schematically illustrated in fig. 8A, a vehicle interior component may be manufactured by a process including: needle punching natural fibers and polypropylene fibers to form a natural fiber/polypropylene mat, trimming the natural fiber/polypropylene mat to a desired size, applying a heater to a surface of the natural fiber/polypropylene mat, applying a fabric having a desired size to a surface of the heater, consolidating the layers together in a tool, compression forming the layers, and trimming the compression-formed part to a desired size.

According to an exemplary embodiment schematically illustrated in fig. 8B, the vehicle interior component may be manufactured by a process comprising: needle punching natural fibers and polypropylene fibers to form a natural fiber/polypropylene mat, trimming the natural fiber/polypropylene mat to a desired size, applying a binder to a surface of the natural fiber/polypropylene mat, applying a heater to a surface of the natural fiber/polypropylene mat, applying a binder to a surface of a fabric, applying a fabric to a heater, applying a covering to a surface of the fabric, consolidating the layers together in a tool, compression forming the layers, back injection molding features (e.g., ribs, etc.) on the compression-formed part, and trimming the compression-formed part to a desired size.

According to an exemplary embodiment schematically illustrated in fig. 9A, a vehicle interior component may be manufactured by a process including: needle punching natural fibers and polypropylene fibers to form a natural fiber/polypropylene mat, trimming the natural fiber/polypropylene mat to a desired size, applying a heater to a surface of the natural fiber/polypropylene mat, applying a fabric to a surface of the heater, consolidating the layers together in a tool, placing the consolidated layers in a forming press/injection molding apparatus, forming and back-injection molding features (e.g., ribs, retainers, etc.) on the formed layers, trimming the formed and molded part to a desired size, and joining a cover material to the formed and molded part.

According to an exemplary embodiment schematically illustrated in fig. 9B, the vehicle interior component may be manufactured by a process comprising: needle punching natural fibers and polypropylene fibers to form a natural fiber/polypropylene mat, trimming the natural fiber/polypropylene mat to a desired size, applying a heater to a surface of the natural fiber/polypropylene mat, applying a fabric to a surface of the heater, applying an adhesive to a surface of the fabric, consolidating the layers together in a tool, placing the consolidated layers into a forming press/injection molding apparatus, forming and back injection molding features (e.g., ribs, retainers, etc.) on the layers, trimming the formed and molded part to a desired size, and joining a cover material to the formed and molded part.

According to an exemplary embodiment schematically illustrated in fig. 10A, a vehicle interior component may be manufactured by a process including: needle punching natural fibers and polypropylene fibers to form a natural fiber/polypropylene mat, trimming the natural fiber/polypropylene mat to a size, applying an adhesive to the natural fiber/polypropylene mat, applying a heater to the natural fiber/polypropylene mat, consolidating the layers together in a tool, placing the consolidated layers into a forming press/injection molding apparatus, forming and back-injection molding features (e.g., ribs, retainers, etc.) on the consolidated layers, trimming the formed and molded part to a desired size, and joining a cover to the formed and molded part.

According to an exemplary embodiment schematically illustrated in fig. 10B, the vehicle interior component may be manufactured by a process including: needle punching natural fibers and polypropylene fibers to form a natural fiber/polypropylene mat, trimming the natural fiber/polypropylene mat to a size, applying an adhesive to the natural fiber/polypropylene mat, applying a heater to the natural fiber/polypropylene mat, applying an adhesive to the heater, applying a fabric to the adhesive on the heater, applying an adhesive to the fabric, consolidating the layers together in a tool, placing the consolidated layers in a forming press/injection molding apparatus, forming and back-injection molding features (e.g., ribs, retainers, etc.) on the layers, trimming the formed and molded part to a desired size, and joining a cover to the formed and molded part.

According to an exemplary embodiment schematically illustrated in fig. 11A, a vehicle interior component may be manufactured by a process including: forming a fiber/polypropylene mat; applying a heater to the fiber/polypropylene mat; consolidating the heater and the fiber/polypropylene mat; applying the fabric to a heater; applying a covering to the fabric; consolidating the fiber/polypropylene mat, heater and fabric; compression forming the natural fiber/polypropylene mat, heater and fabric layer into a desired shape; and trimming the compression-formed part to a desired size.

According to an exemplary embodiment schematically illustrated in fig. 11B, the vehicle interior component may be manufactured by a process including: forming a fiber/polypropylene mat; applying an adhesive to the fiber/polypropylene mat; applying a heater to the adhesive on the fiber/polypropylene mat; applying an adhesive to the heater; consolidating the heater and the fiber/polypropylene mat; an adhesive for applying the fabric to the heater; applying a covering to the fabric; consolidating the fiber/polypropylene mat, heater and fabric; compression forming the natural fiber/polypropylene mat, heater and fabric layer into a desired shape; and trimming the compression-formed part to a desired size.

According to an exemplary embodiment schematically illustrated in fig. 2A-2C and 12A-12H, the vehicle interior component assembly 400 may include a subsystem element 420 in a forming body 423, the forming body 423 having a shape produced in a mold tool M1/M2 by a process including the steps of: placing subsystem element 420 into a mold tool; and molding (e.g., by injecting resin through port P) a shaped body having the subsystem components and the shape in a mold tool. The subsystem elements may include components configured for electrification. The subsystem elements may be at least partially concealed in the forming body. The shaped body may comprise a molded body. The subsystem components may be molded into the molded body. The component assembly may also include a cover 410. The covering may include a surface texture. The component assembly may also include a structural member. The process may further include the step of applying an adhesive to the subsystem components. The process may further comprise the step of applying a coating. The process may also include the step of applying a covering. The shaped body may be formed as a plastic material. The molded body may be formed of a resin. The mold tool may include a textured surface; the formed body may be formed of a resin to have a textured surface. The subsystem elements may include heating elements; the molded body may be formed of a resin to encapsulate the heating element. The heating element may comprise an electrical heating element, providing at least one wire configured to emerge from the forming body for connection with the electrical heating element. The subsystem components may include heaters.

According to the exemplary embodiment schematically illustrated in fig. 2A to 2C and 12A to 12H, the vehicle interior component may be manufactured by a process including: disposing a heater onto a first surface of a mold; and injecting resin into the mold between the heater and the second surface of the mold to form a panel assembly having a shape, wherein the shape corresponds to the first contour of the first surface and the second contour of the second surface. The first surface of the mold may include a texture configured to form a textured surface of the heater. The process may include the step of disposing a covering onto the panel assembly to form the vehicle interior component. The heater may include at least one wire; the textured surface of the heater can be configured to provide a generally planar surface to the covering.

According to an exemplary embodiment schematically illustrated in fig. 2A to 2C and 12A to 12H, the component for the vehicle interior may include: a panel assembly; and a cover coupled to the panel assembly. The panel assembly may include a heater coupled to the substantially rigid structural layer. The heater may include at least one connector. The cover may include a textured surface configured to provide a substantially flat outer surface for the component. The panel assembly may be formed by molding resin over the heater in a tool. The tool may include a surface configured to form a textured surface on the heater. The cover may be coupled to the heater. The covering may include at least one of: (a) coating; (b) leather; (c) artificial leather; (d) a vinyl material; (e) a woven fabric, (f) a nonwoven fabric; (g) a decoration piece; (h) a foil. The connector may comprise a wire. See, e.g., fig. 3C.

According to an exemplary embodiment schematically illustrated in fig. 13, the vehicle interior component may be manufactured by a process comprising: providing a heater having a desired size; applying a heater to the textured mold surface; injection molding resin behind the heater; and spraying or applying the covering to the heater.

According to an exemplary embodiment schematically illustrated in fig. 14A, a vehicle interior component may be manufactured by a process including: providing a heater; applying a heater to the textured mold surface; injection molding resin behind the heater; providing a cover and bonding the cover to the heater.

According to an exemplary embodiment schematically illustrated in fig. 14B, the vehicle interior component may be manufactured by a process including: providing a heater; applying a film adhesive to a surface of a heater; applying a heater with a film adhesive to the textured mold surface; injection molding resin behind a heater with adhesive; providing a cover material having a desired size and/or shape; and gluing and/or laminating the cover material to the injection molded part with the heater.

According to an exemplary embodiment schematically illustrated in fig. 15A, a vehicle interior component may be manufactured by a process including: providing a heater having a desired size; applying an adhesive to a surface of the heater; applying a heater with adhesive to the textured mold surface; injection molding resin behind a heater with adhesive; and an adhesive joining the cover to the heater.

According to an exemplary embodiment as schematically illustrated in fig. 15B, the vehicle interior component may be manufactured by a process comprising: providing a heater having a desired size; applying a heater to the textured mold surface; injection molding resin behind the heater; and spraying or applying the covering to the heater.

According to an exemplary embodiment schematically illustrated in fig. 15C, the vehicle interior component may be manufactured by a process including: providing a heater having a desired size; applying an adhesive to a surface of the heater; applying a heater with adhesive to the textured mold surface; injection molding resin behind a heater with adhesive; and spraying or applying the covering to the heater.

According to an exemplary embodiment, a process for forming/producing a component may include a combination (e.g., set/sub-set) of steps as schematically/representatively indicated in fig. 6, 7A, 7B, 8A, 8B, 9A, 9B, 10A, 10B, 11A, 1IB, 13, 14A, 14B, and 15A-15C.

Exemplary embodiment A

According to the exemplary embodiment schematically illustrated in fig. 6, 7A to 7B, 8A to 8B, 9A to 9B, 10A to 10B and 11A to 11B, a vehicle interior component assembly C comprising a heating element 20 may be manufactured in a mould tool M by a process comprising the following steps: assembling the heating element 20 with the fibrous layer 10 to provide a preform assembly 123 a; consolidating the preform assembly into a consolidated/formed preform assembly 123 b; placing the preform assembly into a mold tool; forming the preform assembly into a compression molded body 123 having a shape; applying a covering 310 to the compression molded body to provide a compression molded panel C/300; such that the compression-formed panel C/300 is provided with the shape and the outer surface. See also fig. 3A-3B, 4A-4D, and 5A-5F. According to an exemplary embodiment schematically illustrated in fig. 3C and 4A, the heating element may comprise a heating panel.

As schematically shown, the fibrous layer may comprise structural layers for pre-forming the assembly; the fibrous layer may comprise at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat; (g) a natural fiber material; (h) a polypropylene material; (i) natural fibers and polypropylene mats; (j) a mat formed of natural fibers and polypropylene fibers.

According to an exemplary embodiment schematically indicated in fig. 5A to 5F, the step of shaping the preform assembly into a compressed shaped body may comprise compressing the preform assembly in a mould tool. The step of forming the preform assembly into a compressed shaped body may comprise compressing the fibre layers and the heating element in a mould tool to form a compressed shaped panel having said shape. The outer surface of the compression-formed panel may include a texture provided by the covering. The mold tool may include a mold cavity having a surface. The outer surface of the compression-formed panel may include a texture formed at least in part by a surface of the mold tool. The outer surface of the compression-formed panel may include a texture provided by the covering and at least partially provided by the surface of the mold tool. The mold tool may include a mold cavity having a shape. The shape of the compression-formed panel may be provided at least in part by the shape of the mold tool.

According to an exemplary embodiment schematically illustrated in fig. 5E to 5F, the process may further comprise the step of providing the compression form 123 with a covering 310, such that the outer surface of the compression formed panel C/300 may be provided by the covering. According to the exemplary embodiment schematically illustrated in fig. 5A to 5F, the mold tool M may comprise a textured surface; the step of forming the preform assembly into a compressed shaped body may include compressing the fiber layers and heating elements and at least partially forming a textured surface on the compressed shaped body. A textured surface may be formed at least partially on the outer surface of the compression-formed panel.

According to the exemplary embodiment schematically illustrated in fig. 4A to 4D, the process may further comprise the step of applying a cover layer 30 for preforming the component 123a (with the heating element 20 and the fibre layer 10). The cover layer for the preformed component may comprise at least one of a fibrous layer or a fabric layer. The cover layer for the preformed component may comprise at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet. The fibrous layers 10 of the preform assembly 123a may comprise structural layers; the structural layer may include natural fibers and resins; the cover layer 30 may comprise polypropylene and polyester.

According to the exemplary embodiment schematically illustrated in fig. 4A-4D, the step of assembling the heating element with the fiber panel may comprise assembling the heating element with the fiber panel and the cover layer to provide a preformed assembly; and the step of consolidating the preform assembly may comprise consolidating the fiber panel with the heater and the cover layer. The step of compressing the fibre layers and the heating element in the mould tool to form the compressed shaped body may comprise compressing the fibre layers and the heating element and the cover layer to form the compressed shaped body. The mold tool may include a textured surface; and compressing the fiber layers and heating elements and covering in the mold tool can include forming a textured surface at least partially on the covering of the compressed shaped body.

According to the exemplary embodiment schematically illustrated in fig. 4A-4D, the step of consolidating the preform assembly 123a may comprise shaping the consolidated preform assembly 123b/123 c. The step of consolidating the preform assembly may comprise heating the preform assembly. The process may also include the step of trimming the preform assembly 123 c. See fig. 4D. The process may also include the step of shaping the preform assembly 123b/123 c. See fig. 4C-4D. The step of shaping the preform assembly may include trimming the preform assembly 123c (removing excess material 123 x). The preform assembly 123c may be heated, see fig. 5A.

According to the exemplary embodiment schematically illustrated in fig. 5A to 5F, the step of forming the preform assembly into a compression-formed body may comprise compressing the preform assembly 123c into a shape. The step of forming the preform assembly into the compression-formed body 123 may comprise applying heat to form the compression-formed body into said shape. As schematically indicated, the shape may comprise a wave-like shape; the shape may comprise a formed shape. According to the exemplary embodiments schematically indicated in fig. 2A, 3A and 5E to 5F, the covering may comprise a surface texture (e.g. suitable for use in a vehicle interior component). The covering may include at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) and (4) coating.

According to an exemplary embodiment, a vehicle interior component provided by a compression-formed panel with a covering will provide an exterior surface with the following texture/feel: this texture/feel masks the feel of the heated panel within the compression formed panel. See, e.g., fig. 2A and 3A.

According to the exemplary embodiment schematically illustrated in fig. 6, 7A to 7B, 8A to 8B, 9A to 9B, 10A to 10B and 11A to 11B, a vehicle interior component assembly C/300 comprising a heating element 20 may be produced in a mould tool M by a process comprising the following steps: assembling the heating element 20 between the cover layer 30 and the fibrous layer 10 to provide a preformed component 123 a; consolidating the preform assembly 123b/123 c; placing the preform assembly into a mold tool; forming the preform assembly 123c into a compression molded body 123 having a shape; applying a covering 310 to the compression molded body 123 to provide a compression molded panel C/300; the compression formed panel C/300 may be provided with the shape and the outer surface provided by the cover. See also fig. 4A to 4D and fig. 5A to 5F.

As schematically indicated in fig. 5A-5B, the mold tool M may comprise a surface; the outer surface of the compression-formed panel may be provided at least in part by a surface of a mold tool.

According to the exemplary embodiment schematically illustrated in fig. 4A to 4D, the step of consolidating the preform assembly may comprise at least partially compressing the cover layer 30 and the heating element 20 and the fiber layer 10. The step of consolidating the preform assembly may include shaping/trimming the preform assembly. See fig. 4C and 4D. The step of assembling the preform assembly may comprise applying an adhesive; the step of consolidating the preform assembly may include securing the heating element between the cover layer and the fibrous layer with an adhesive. According to the exemplary embodiment schematically illustrated in fig. 4A to 4D and 5A, the fibre layer 10 may comprise a structural layer for a preform. The cover layer may be configured for application of the cover such that the cover may be secured to the cover layer to provide an outer surface for the compression-formed panel. See fig. 5E and 5F. The outer surface of the covering of the compression formed panel may be configured to provide the texture provided by the covering and the overlay. The fibrous layer of the preform assembly may comprise a structural layer; the structural layer may include natural fibers and resins; the cover layer may comprise polypropylene and polyester. The fibrous layer may comprise at least one of: (a) a panel; (b) a pad; (c) felt; (d) a fiber panel; (e) a fibrous mat; (f) a fiber mat; (g) a natural fiber material; (h) a polypropylene material; (i) natural fibers and polypropylene mats; (j) a mat formed of natural fibers and polypropylene fibers. The cover layer for the preformed component may comprise at least one of: (a) a fabric; (b) a nonwoven fabric; (c) a synthetic fabric; (d) a thermoplastic fabric; (e) a nonwoven fibrous web; (f) flax; (g) a fibrous mat; (h) a fibrous mat comprising a fabric material; (i) a fabric sheet. The covering may include at least one of: (a) a film; (b) a fabric; (c) a sheet material; (d) coating; (e) and (4) coating.

The heating element may comprise a heating panel (e.g. with a connector), see fig. 3C and 4A.

As schematically indicated in fig. 4A-4D, the vehicle interior component assembly C/300 may be produced by assembling the heating element 20 between the cover layer 30 and the fiber layer 10 to provide a preform assembly 123a, wherein the preform assembly 123a is consolidated into a consolidated preform assembly 123b/123C (e.g., compressed and/or shaped and/or formed and/or trimmed, etc.); the consolidated preform assembly 123c can be heated and placed into a die tool M to form/compress into a compression molded body 123 having a shape; the compression formed panel C/300 may be produced by applying a cover 310 to the compression formed body 123. See fig. 5A to 5F. As schematically indicated according to the exemplary embodiments in fig. 2A-2B, 3A and 5F, the compression formed panel C/300 with the heating element 20 (with the connector) may comprise said shape and the outer surface provided by the cover. See also fig. 3C, 4A and 5A to 5E.

According to an exemplary embodiment, a vehicle interior component having a heating element (shown as heating panel 20) may include a fibrous layer providing a structural layer (shown schematically/representatively as carrier/material 10) and a fibrous layer providing a cover layer (shown schematically/representatively as top layer/material 30). As schematically shown, the fiber layers for the structural and cover layers may comprise any of a variety of fibers/materials that are made into any of a variety of forms/pads/panels by any of a variety of techniques and processes. According to an exemplary embodiment, the fibrous layer may be selected to provide the component with an outer surface that: although the heating element is contained within the component, the outer surface has reduced texture/contour variations at the outer surface (e.g., such that the heating element is substantially invisible and/or substantially imperceptible). The fibrous layer may comprise a nonwoven material comprising fibers in various forms (e.g., lengths, types, etc.); the fibrous layer may be formed by a variety of processes (e.g., dry processes, such as by laying, blowing, carding, etc., or wet processes, such as water-based processes, etc.) and treated (e.g., mechanically strengthened, needled, heat treated, calendered, chemically treated, treated with a binder, impregnated with a material, sprayed, etc.) to provide a shaped piece (e.g., a panel, a mat, a felt, etc.) of the fibrous layer. See, for example, fig. 4A and 6.

As schematically indicated according to the exemplary embodiment shown in fig. 4A and 6, the construction/material type of the fibrous layer for the structural layer (e.g., with natural fibers, with longer fibers, with resin, with greater thickness, with wider variation, etc.) may be different from the construction/material type of the fibrous layer for the cover layer (e.g., with natural fibers, with shorter fibers, with resin, with polypropylene, with polyester, etc.); the structural layer may include fibers (e.g., long fibers) having a length of about 10cm to 15 cm; the cover layer may include shorter length fibers (e.g., for decorative effects, textures, finer surface qualities, etc.). As schematically illustrated in fig. 2A-2B, 3A, 4A-4D, 5A-5F, and 6, the cover layer may include a fibrous layer/panel exhibiting an outer surface with a relatively smooth texture (e.g., with shorter fibers, by a wet process to provide finer surface quality, etc.); the structural layer may comprise a fibrous layer/panel having a relatively coarse texture (e.g., having longer fibers, being mechanically reinforced such as by needling, being spun, etc.). According to an exemplary embodiment, the cover layer may be configured to provide a relatively smooth texture on the heating element and to provide improved contour tolerances for the outer surface of a compression-formed panel comprising the vehicle interior component. See fig. 2A, 3A, and 5F.

According to the exemplary embodiments schematically indicated in fig. 4A to 4D, 5A to 5F and 6, the fibrous layer may be produced by any suitable process: these processes are configured to provide a suitable form of fibrous layers for the structural and overlay layers of a compression-formed panel for a vehicle interior component. See also U.S. patent publication No.2005/0215698a1 (incorporated by reference) and U.S. patent publication No.2007/0269645a1 (incorporated by reference).

Exemplary embodiment B

As schematically illustrated according to an exemplary embodiment in fig. 12A-12H, a vehicle interior component assembly may include subsystem elements in a shaped body having a shape produced in a mold tool by a process including the steps of: placing the subsystem component into a mold tool; and molding the shaped body in a mold tool to have the subsystem elements and the shape.

As schematically shown according to an exemplary embodiment in fig. 12A-12H, the vehicle interior component may be manufactured by a process comprising: disposing a heater onto a first surface of a mold; and injecting resin into the mold between the heater and the second surface of the mold to form a panel assembly having a shape, wherein the shape corresponds to the first contour of the first surface and the second contour of the second surface.

As schematically shown according to an exemplary embodiment in fig. 12A to 12H, the components for the vehicle interior may include: a panel assembly; and a cover coupled to the panel assembly. The panel assembly may include a heater coupled to the substantially rigid structural layer. The heater may include at least one connector. The cover may include a textured surface configured to provide a substantially flat outer surface for the component.

As schematically illustrated according to an exemplary embodiment in fig. 12A-12H, a vehicle interior component assembly may include subsystem elements in a shaped body having a shape produced in a mold tool by a process including the steps of: placing the subsystem elements into a mold tool and molding a shaped body having the subsystem elements and the shape in the mold tool. The subsystem elements may include components configured for electrification. The subsystem elements may be at least partially concealed in the forming body. The shaped body may comprise a molded body. The subsystem components may be molded into the molded body. The component assembly may include a cover. The covering may include a surface texture. The component assembly may comprise a structural member. The process may include the step of applying an adhesive to the subsystem components. The process may include the step of applying a coating. The process may include the step of applying a covering. The shaped body may be shaped as a plastic material. The molded body may be formed of a resin. The mold tool may include a textured surface and the shaped body may be formed of a resin to have a textured surface. The subsystem elements may include heating elements and the form may be formed of a resin to encapsulate the heating elements. The heating element may comprise an electrical heating element, providing at least one wire configured to emerge from the forming body for connection with the electrical heating element. The subsystem components may include heaters.

As schematically shown according to an exemplary embodiment in fig. 12A-12H, the vehicle interior component may be manufactured by a process comprising: the method includes providing a heater on a first surface of a mold, and injecting resin into the mold between the heater and a second surface of the mold to form a panel assembly having a shape. The shape may correspond to a first contour of the first surface and a second contour of the second surface. The first surface of the mold may include a texture configured to form a textured surface of the heater. The process may include the step of disposing a covering onto the panel assembly to form the vehicle interior component. The heater may include at least one wire; the textured surface of the heater may be configured to provide a generally planar surface for the covering.

As schematically shown according to an exemplary embodiment in fig. 12A-12H, a component for a vehicle interior may include a panel assembly and a covering coupled to the panel assembly. The panel assembly may include a heater coupled to the substantially rigid structural layer. The heater may include at least one connector. The cover may include a textured surface configured to provide a substantially flat outer surface for the component. The panel assembly may be formed by molding resin over the heater in a tool. The tool may include a surface configured to form a textured surface on the heater. The cover may be coupled to the heater. The covering may include at least one of: (a) coating; (b) leather; (c) artificial leather; (d) a vinyl material; (e) a woven fabric, (f) a nonwoven fabric, (g) a trim, and (h) a foil. The connector may comprise a wire.

It is important to note that the present invention (e.g., inventive concepts, etc.) has been described in the specification and/or illustrated in the drawings of the present patent document, in accordance with exemplary embodiments; the embodiments of the present invention are presented by way of example only and are not intended to limit the scope of the invention. The construction and/or arrangement of the elements of the inventive concept as embodied in the present invention, as described in the specification and/or illustrated in the drawings, is illustrative only. Although exemplary embodiments of the present invention have been described in detail in this patent document, those of ordinary skill in the art will readily appreciate that equivalents, modifications, variations, and the like of the subject matter of the exemplary embodiments and alternative embodiments are possible and are considered to be within the scope of the present invention; all such subject matter (e.g., modifications, variations, embodiments, combinations, equivalents, etc.) are intended to be included within the scope of this invention. It should also be noted that various/other modifications, adaptations, alternatives, equivalents, changes, omissions, and substitutions may be made in the configuration and/or arrangement of the exemplary embodiments (e.g., in the aspects of concept, design, structure, device, form, assembly, construction, means, function, system, process/method, step, sequence of process/method steps, operation, operating conditions, performance, materials, composition, combination, and so forth) without departing from the scope of the present inventions; all such subject matter (e.g., modifications, variations, embodiments, combinations, equivalents, etc.) are intended to be included within the scope of this invention. The scope of the present invention is not intended to be limited to the subject matter (e.g., details, structures, functions, materials, acts, steps, sequences, systems, results, etc.) described in the specification and/or illustrated in the drawings of this patent document. It is intended that the claims of this patent document be appropriately interpreted to cover the full scope of the subject matter of the present invention (e.g., including any and all such modifications, alterations, embodiments, combinations, equivalents, and the like); it is to be understood that the terminology used in the patent document is for the purpose of providing a description of the subject matter of the exemplary embodiments, and is not intended to limit the scope of the invention.

It is also important to note that, according to exemplary embodiments, the present invention may include conventional techniques (e.g., implemented or integrated in exemplary embodiments, adaptations, modifications, combinations, equivalents, etc.) or may include any other practical technique (current and/or future) having the applicability and/or capability to perform the function and process/operation described in the specification and/or illustrated in the drawings. All such techniques (e.g., as implemented in embodiments, adaptations, variations, combinations, equivalents, etc.) are deemed to be within the scope of the present invention as set forth in the claims.