Patent Description:
The present invention also relates to vehicle interior component prepared by a process to produce a panel assembly from a compression-formed structure formed from a pre-form substrate comprising a surface layer and a substrate layer.

It is known to provide a vehicle interior component comprising a panel assembly with a substrate and a cover providing a surface effect.

It would be advantageous to provide an improved vehicle interior component such as a panel assembly comprising a substrate formed from a surface layer and a substrate layer and with a cover with the surface effect for the panel assembly generally provided by the substrate and cover.

The present invention is defined by the method of claim <NUM>. Claim <NUM> addresses a related product and further embodiments are set out in the dependent claims. The present invention relates to a vehicle interior component produced in a mold comprising a first surface and a second surface by a process comprising placing a pre-form substrate onto the first surface of the mold; forming a compression-formed structure from the pre-form substrate by compressing the pre-form substrate between the first surface of the mold and the second surface of the mold; applying a cover to the compression-formed structure to form a panel assembly providing a surface effect. The cover may comprise the exterior surface of the panel assembly providing at least partially the surface effect of the panel assembly. The pre-form substrate may comprise a substrate layer and a surface layer. The compression-formed structure may comprise the substrate layer and the surface layer. The surface effect of the panel assembly may be at least partially provided by a surface effect of the surface layer of the compression-formed structure. The surface effect of the panel assembly may be at least partially provided by a surface effect of the surface layer of the pre-form substrate. The surface layer of the pre-form substrate may comprise a surface effect comprising a generally smooth texture. The surface layer of the compression-formed structure may comprise a surface effect comprising a generally smooth texture. The substrate layer for the pre-form substrate may comprise a surface effect comprising a generally rough texture. The pre-form substrate may comprise a surface effect comprising the surface effect of the surface layer. The compression-formed structure may comprise a surface effect comprising the surface effect of the surface layer. The step of forming the compression-formed structure may comprise forming the compression-formed structure with a surface effect generally comprising the surface effect of the pre-form substrate. The surface effect of the panel assembly may generally comprise the surface effect of the surface layer of the compression-formed structure. The surface effect of the panel assembly may generally comprise a surface effect of the surface layer of the compression-formed structure and a surface effect of the cover of the panel assembly. The substrate layer for the pre-form substrate may comprise a fiber mat. The substrate layer in the compression-formed structure may comprise a generally rigid fiber mat. The step of forming the compression-formed structure may comprise forming the substrate layer into a generally rigid form. The surface effect of the panel assembly may comprise the generally rigid form of the compression-formed structure. The surface effect of the panel assembly may comprise the generally rigid form of the substrate layer of the compression-formed structure. The surface effect of the panel assembly may comprise a generally smooth texture and a generally rigid form. The generally smooth texture of the panel assembly may be provided by (a) a surface effect of the cover and (b) a surface effect of the surface layer of the compression-formed structure formed from the pre-form substrate. The generally rigid form of the panel assembly may be provided by the substrate layer of the compression-formed structure formed from the pre-form substrate. The surface effect of the panel assembly may comprise a generally smooth surface effect of the surface layer of the compression-formed structure rather than a generally rough surface effect of the substrate layer for the pre-form substrate. The cover of the panel assembly may comprise at least one of (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric; (g) a woven fabric; (h) a non-woven fabric; (i) an applique; (j) vinyl; (k) a foil. The compression-formed structure may comprise a shape. The panel assembly may comprise at least partially the shape of the compression-formed structure. The shape may comprise a first contour provided by the first surface of the mold and a second contour provided by the second surface of the mold. The substrate layer for the pre-form substrate may comprise a fiber mat. The surface layer for the pre-form substrate may comprise at least one of a fabric material or a fleece material. The surface layer of the pre-form substrate may comprise at least one of (a) a fabric; (b) a textile; (c) a fleece material; (d) a woven material; (e) a non-woven material; (f) a fiber-based material; (g) a textile material; (h) a woven sheet material; (i) a non-woven sheet material; (j) a fleece sheet material; (k) a resin-based material; (l) a polymer material; (m) polypropylene; (n) polyester. The process may further comprise the step of forming the pre-form substrate from a fiber mat. The process may further comprise the step of forming the pre-form substrate from a fiber mat and a fabric layer. The pre-form substrate may comprise a top layer and a structural layer; the top layer may comprise the surface layer and the structural layer may comprise the substrate layer. The vehicle interior component may further comprise the step of forming the pre-form substrate. The step of forming the pre-form substrate may comprise forming an interface between the surface layer and the substrate layer so that the surface effect of the pre-form substrate may comprise the surface effect of the surface layer. The step of forming the pre-form substrate may comprise forming an interface between the surface layer and the substrate layer so that the surface effect of the pre-form substrate may comprise a generally smooth surface effect of the surface layer rather than a generally rough surface effect of the substrate layer. Forming the interface between the surface layer and the substrate layer may comprise at least partial melting of the substrate layer into the surface layer. The process may further comprise the step of forming the pre-form substrate from a substrate layer and a surface layer. The step of forming the pre-form substrate may comprise applying the surface layer to the substrate layer. The substrate layer for the pre-form substrate may comprise a generally compressible fiber mat. The substrate layer in the compression-formed structure may comprise a generally rigid fiber mat. The step of forming the pre-form substrate may comprise consolidating the surface layer and the substrate layer. The step of forming the pre-form substrate may comprise consolidating the surface layer and the substrate layer into a generally rigid form. The step of forming the compression-formed structure may comprise forming the substrate layer into a generally rigid form. The process may further comprise the step of removing the compression-formed structure from the mold before applying the cover. The surface layer may be configured to provide improved profile tolerance for the panel assembly. The substrate layer may comprise natural fibers and a resin and the surface layer may comprise polypropylene and polyester. The resin may comprise polypropylene and the natural fibers comprise at least one of (a) flax; (b) kenaf. The surface layer may comprise at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric. The pre-form substrate may comprise an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The surface comprises an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The pre-form substrate may comprise a thickness of between <NUM> and <NUM> and the compression-formed structure may comprise a thickness of between <NUM> and <NUM>. The pre-form substrate may comprise a pre-formed component; the process may further comprise the step of consolidating the surface layer and the substrate layer to form the pre-formed component. The process may comprise the step of heating the pre-formed component; the pre-formed component may be compressed as the pre-formed component cools. The process may comprise the step of injecting resin into the mold after the compression-formed component is formed to form an ancillary component of the panel assembly. The process may comprise the steps of activating the surface layer of the pre-formed component and adhering the cover to the surface layer of the pre-formed component.

The present invention relates to a vehicle interior component comprising a compression-formed structure formed from a pre-form substrate comprising a surface layer and a substrate layer; and a cover applied to the compression-formed structure to form a panel assembly providing a surface effect. The cover may comprise the exterior surface of the panel assembly. The surface effect of the panel assembly may generally comprise a surface effect of the surface layer of the compression-formed structure and a surface effect of the cover of the panel assembly. The surface layer of the pre-form substrate may comprise a surface effect comprising a generally smooth texture. The surface layer of the compression-formed structure may comprise a surface effect comprising a generally smooth texture. The substrate layer for the pre-form substrate may comprise a surface effect comprising a generally rough texture. The surface effect of the panel assembly may generally comprise the surface effect of the surface layer of the compression-formed structure. The substrate layer for the pre-form substrate may comprise a fiber mat. The substrate layer in the compression-formed structure may comprise a generally rigid fiber mat. The compression-formed structure may comprise a generally rigid form. The surface effect of the panel assembly may comprise the generally rigid form of the compression-formed structure. The surface effect of the panel assembly may comprise a generally rigid form of the substrate layer of the compression-formed structure. The surface effect of the panel assembly may comprise a generally smooth texture and a generally rigid form. The generally smooth texture of the panel assembly may be provided by (a) the surface effect of the cover and (b) the surface effect of the surface layer of the compression-formed structure formed from the pre-form substrate. The generally rigid form of the panel assembly may be provided by the substrate layer of the compression-formed structure formed from the pre-form substrate. The surface effect of the panel assembly may comprise a generally smooth surface effect of the surface layer of the compression-formed structure rather than a generally rough surface effect of the substrate layer for the pre-form substrate. The cover of the panel assembly may comprise at least one of (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric; (g) a woven fabric; (h) a non-woven fabric; (i) an applique; (j) vinyl; (k) a foil. The compression-formed structure may comprise a shape. The panel assembly may at least partially comprise the shape of the compression-formed structure. The substrate layer for the pre-form substrate may comprise a fiber mat. The substrate layer for the pre-form substrate may comprise a generally flexible fiber mat. The substrate layer of the compression-formed structure may comprise a generally rigid fiber mat. The surface layer for the pre-form substrate may comprise at least one of a fabric material or a fleece material. The surface layer of the pre-form substrate may comprise at least one of (a) a fabric; (b) a textile; (c) a fleece material; (d) a woven material; (e) a non-woven material; (f) a fiber-based material; (g) a textile material; (h) a woven sheet material; (i) a non-woven sheet material; (j) a fleece sheet material; (k) a resin-based material; (l) a polymer material; (m) polypropylene; (n) polyester; (o) polypropylene and polyester; (p) polyethylene terephthalate.

The present invention relates to a vehicle interior component produced in a mold comprising a first surface and a second surface by a process comprising placing a pre-formed component onto the first surface of the mold; compressing the pre-formed component between the first surface of the mold and the second surface of the mold to form the pre-formed component into a compression-formed component; removing the compression-formed component from the mold; and applying a cover to the compression-formed component to form a panel assembly. The cover may comprise an exterior surface providing a surface effect of the panel assembly. The cover of the panel assembly may comprise at least one of (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric; (g) a woven fabric; (h) a non-woven fabric; (i) an applique; (j) vinyl; (k) a foil. The pre-formed component may comprise a substrate layer and a top layer. The process may further comprise the step of forming the pre-formed component from a substrate and a top layer. The substrate layer for the pre-formed component may comprise a fiber mat. The top layer for the pre-formed component may comprise at least one of a fabric material or a fleece material. The top layer may comprise at least one of (a) a fabric; (b) a textile; (c) a fleece material; (d) a woven material; (e) a non-woven material; (f) a fiber-based material; (g) a textile material; (h) a woven sheet material; (i) a non-woven sheet material; (j) a fleece sheet material. The process may further comprise the step of forming the pre-formed component from a fiber mat. The process may further comprise the step of forming the pre-formed component from a fiber mat and a fabric layer. The pre-formed component may comprise a top layer and a structural layer. The structural layer may comprise a fiber mat. The top layer may comprise an outer surface with a smooth texture and a surface of the structural layer may comprise a rough texture. The top layer may be configured to provide improved profile tolerance for the panel assembly. The structural layer may comprise natural fibers and a resin and the top layer may comprise polypropylene and polyester. The resin may comprise polypropylene and the natural fibers comprise at least one of (a) flax; (b) kenaf. The top layer may comprise at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric. The pre-formed component may comprise an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The top layer comprises an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The pre-formed component may comprise a thickness of between <NUM> and <NUM> and the compression-formed component may comprise a thickness of between <NUM> and <NUM>. The process may comprise the step of consolidating the top layer and the structural layer to form the pre-formed component. The process may comprise the step of heating the pre-formed component and the pre-formed component may be compressed as the pre-formed component cools. The process may comprise the step of injecting resin into the mold after the compression-formed component is formed to form an ancillary component of the panel assembly. The process may comprise the steps of activating the top layer of the pre-formed component and adhering the cover to the top layer of the pre-formed component.

The present invention relates to a component for a vehicle interior comprising a pre-formed component and a cover. The pre-formed component may comprise a top layer coupled to a structural layer at a surface of the structural layer. The top layer may comprise an outer surface with a smooth texture and the surface of the structural layer may comprise a rough texture. The top layer may be configured to provide improved profile tolerance for the panel assembly. The structural layer may comprise natural fibers and a resin and the top layer may comprise at least one of (a) polypropylene; (b) polyester; (c) polypropylene and polyester; (d) polyethylene terephthalate. The resin may comprise polypropylene and the natural fibers may comprise at least one of flax and kenaf. The cover may comprise at least one of (a) leather; (b) artificial leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric. The cover may comprise at least one of (a) woven fabric; (b) non-woven fabric; (c) an applique; (d) vinyl; (e) foil.

The present invention relates to a vehicle interior component produced by a process. The process may comprise placing a pre-formed component onto a first surface of a mold. The process may comprise compressing the pre-formed component between the first surface of the mold and a second surface of the mold to form the pre-formed component into a compression-formed component having a shape wherein the shape corresponds to a first contour of the first surface and a second contour of the second surface. The process may comprise removing the compression-formed component from the mold. The process may comprise placing a cover onto the compression-formed component to form a panel assembly. The pre-formed component may comprise a top layer coupled to a structural layer at a surface of the structural layer. The top layer may comprise an outer surface with a smooth texture and the surface of the structural layer may comprise a rough texture. The top layer may be configured to provide improved profile tolerance for the panel assembly. The structural layer may comprise natural fibers and a resin. The top layer may comprise polypropylene and/or polyester. The top layer may comprise at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric; (e) a fabric made of polypropylene fibers and polyester fibers. The resin may comprise polypropylene and the natural fibers may comprise at least one of flax and kenaf. The pre-formed component may comprise an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The top layer comprises an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The pre-formed component may comprise a thickness of between <NUM> millimeters and <NUM> millimeters. The compression-formed component may comprise a thickness of between <NUM> millimeters and <NUM> millimeters. The process may comprise the step of consolidating the top layer and the structural layer to form the pre-formed component. The process may comprise the step of heating the pre-formed component. The pre-formed component may compressed as the pre-formed component cools. The process may comprise the step of injecting resin into the mold after the compression-formed component is formed to form an ancillary component of the panel assembly. The process may comprise the steps of activating the top layer of the pre-formed component and adhering the cover to the top layer of the pre-formed component.

The present invention also relates to a vehicle interior component comprising a pre-formed component and a cover. The pre-formed component may comprise a top layer coupled to a structural layer at a surface of the structural layer. The top layer may comprise an outer surface with a smooth texture and the surface of the structural layer may comprise a rough texture. The top layer may be configured to provide improved profile tolerance for the panel assembly. The structural layer may comprise natural fibers and a resin. The top layer may comprise polypropylene and polyester. The top layer may comprise at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric; (e) a fabric made of polypropylene fibers and polyester fibers. The resin may comprise polypropylene. The natural fibers comprise at least one of flax and kenaf. The cover may comprise at least one of (a) leather and artificial leather. The cover may comprise at least one of woven fabric, non-woven fabric, an applique, vinyl and foil.

Referring to <FIG>, a vehicle V providing and interior I is shown schematically according to an exemplary embodiment. As shown schematically according to an exemplary embodiment in <FIG>, the interior I of the vehicle may comprise any of a variety of types and forms of interior components C such as an instrument panel IP and door panels DP (with armrest AR) and other trim components (e.g. console, floor console, panels, trim panels, etc.).

As shown schematically in <FIG> and <FIG>, a component C (e.g. panel assembly, panel, trim panel, etc.) for the vehicle interior may comprise a substrate/structure S and a cover layer T; a surface effect for the component/panel C may comprise a combination of perceptible features including the smoothness/roughness and hardness/softness (e.g. surface effect as generally understood and perceptible/discernable qualitatively and/or determinable quantitatively with instrumentation, measurement, test, etc. according to generally accepted standards and criteria and/or tactile). Compare <FIG> (schematically indicating profile/surface effect of smooth/hard) with <FIG> (schematically indicating profile/surface effect of rough/soft).

As shown schematically in <FIG>, a cover T on a structure/substrate S comprising a resin R (e.g. plastic material) may provide a surface effect comprising a generally "hard" feel (e.g. discernable and/or perceptible as rigid, solid, firm, generally incompressible, little or no cushion effect, etc.) and a smooth surface SM (e.g. discernable and/or perceptible as generally consistent, providing little friction or resistance to sliding movement, slick/slippery, with few tactile irregularities, facilitating gliding/sliding movement, etc.) provided by the substrate and the cover. As shown schematically in <FIG>, a cover T on a structure/substrate S comprising a base layer BL such as a fiber mat may provide a surface effect comprising a generally "soft" feel (e.g. discernable and perceptible non-rigid/semi-rigid, flexible, compressible, providing a cushioning effect, etc.) and a rough surface SR (e.g. discernable and/or perceptible as with variations, tactile features such as bumps/obstructions, providing friction/resistance to sliding movement, etc.) provided by the substrate and the cover. See also <FIG> (showing base layer/fiber mat BL/MT for a substrate with a rough surface SR). As shown schematically in <FIG>, a cover T on a structure/substrate S comprising a base layer BL such as a fiber mat with a surface layer SL may provide a surface effect comprising a generally "hard" feel (e.g. discernable and/or perceptible as rigid, solid, firm, generally incompressible, little or no cushion effect, etc.) and a smooth surface SM (e.g. discernable and/or perceptible as generally consistent, providing little friction or resistance to sliding movement, slick/slippery, with few tactile irregularities, facilitating gliding/sliding movement, etc.) provided by the substrate and the cover. See also <FIG> (showing panel assembly C/P with a smooth surface SC/SM provided by the cover T and surface layer SL of the substrate shown as a compression-formed structure CF). (As shown schematically in <FIG> and <FIG>, the component C may comprise features RF formed from a resin R (e.g. plastic material) for various purposes such as structure/rigidity, attachment, reinforcement, other function/enhancement, etc.).

As shown schematically in <FIG> the component C may comprise a panel assembly P comprising a composite structure of a substrate provided by a compression-formed structure CF comprising a substrate layer BL and a surface layer SL and with a cover/cover layer T (attached such as by an adhesive A) with features such as resin features RF (e.g. molded plastic/resin features, borders, ribs, etc.). According to an exemplary embodiment shown schematically in <FIG>, the substrate of the panel assembly P is provided by the surface layer SL shown as a fabric/fleece layer F providing a generally smooth surface SM on the substrate layer BL shown a mat/fiber mat MT providing a generally rough surface SR; as shown schematically in <FIG>, the panel assembly is formed with the substrate consolidated/formed into a compression-formed structure CF with surface layer SL and substrate layer BL (consolidated by compression and partial melting, merging, etc.) and with cover T (with adhesive A); the surface effect SE of the panel assembly P is provided by the smooth surface SC of the cover T and the smooth surface SM of the surface layer SL of the substrate/compression-formed structure CF and by the generally rigid form of the compression-formed structure (e.g. by the compressed/consolidated mat/substrate layer BL and fabric/surface layer SL). See also <FIG>.

As indicated schematically in <FIG> and <FIG>, the component/panel assembly C/P may be formed from a substrate/structure S such as compression-formed structure CF comprising a substrate layer SL such as a fiber mat MT (e.g. of a lightweight material); the substrate layer/fiber mat may provide a rough surface SR and a semi-rigid/soft form (e.g. a surface effect that may be generally undesirable for a panel assembly of a vehicle interior component). As indicated schematically in <FIG> and <FIG>, the surface effect of the panel assembly P formed from with a substrate comprising the fiber mat MT does not indicate the rough surface and/or semi-rigid/soft construction of the substrate layer/fiber mat MT but rather presents a surface effect that comprises a smooth surface and a generally rigid form (e.g. a surface effect that may be generally desirable for a panel assembly of a vehicle interior component).

Referring to <FIG>, construction and formation of the panel assembly P for the component C is shown schematically according to an exemplary embodiment. A surface layer shown as fabric/fleece F providing a smooth surface SM is applied to a substrate layer shown as MT (e.g. a fiber mat) providing a rough surface SR and in a generally non-rigid/flexible form. A pre-form substrate PF is formed by consolidation with the merging/melting/fusion (at least partially) at the interface of the surface layer/fabric SLIP and the substrate layer/mat BL/MT; as indicated schematically, the pre-form substrate PF provides a smooth surface SM and a generally rigid form. Compare <FIG> (schematically indicating surface effect of smooth/soft for surface layer on substrate layer for pre-form substrate) with <FIG> (schematically indicating surface effect of smooth/hard of pre-form substrate with consolidation of surface layer and substrate layer). As shown schematically in <FIG>, to form the panel assembly P/C, the pre-form substrate PF is formed into a compression-formed structure CF with a cover T; as shown schematically in <FIG>, the panel assembly P/C provides a surface effect SE comprising a smooth surface SM (e.g. from the surface layer SL and cover T) and a generally rigid form (e.g. from the compression-formed structure CF). See also <FIG> (schematically indicating surface effect for panel assembly of smooth/hard).

As shown schematically according to an exemplary embodiment in <FIG> and <FIG>, the pre-form substrate (e.g. pre-formed component) of the panel assembly may comprise the fabric/fleece/sheet F providing a surface layer SL on the fiber/polymeric material mat MT providing a substrate layer BL. As indicated schematically, the pre-form substrate PF is formed by consolidation/compression (with heating/merging at the interface) of the mat/substrate layer BL/MT and the fabric/surface layer SLIP to provide a generally rigid form. See <FIG> and <FIG>. As indicated schematically in <FIG>, the pre-form substrate PF can be formed/shaped such as by cutting/trimming into a formed/shaped pre-form substrate PFs for formation of the panel assembly and with residual material PFx (e.g. available for disposal, reuse, recycling, etc.).

As shown schematically according to an exemplary embodiment in <FIG>, <FIG> and <FIG>, the pre-form substrate PF can be formed into a panel assembly P (e.g. for vehicle interior component C) providing a surface effect SE. As shown schematically in <FIG> and <FIG>, the pre-form substrate PF is pre-treated/heated (e.g. softened, made flexible, etc. as shown in oven OV) and then placed into a mold MO (shown as having mold sections MS) for forming into a compression-formed structure CF (e.g. having the form and shape for the panel assembly/component). See <FIG> and 9C. As shown schematically in <FIG> and <FIG>, the compression-formed structure CF may comprise features formed from a resin material R such as ribs/structure RF (see <FIG> and <FIG>) and/or a border RB (see <FIG>); the compression-formed structure CF may be provide with resin structure such as a compartment AS for an airbag system (see <FIG>). See also <FIG> (showing schematically the injection-molding process in mold MO with sections MS and voids V to use a resin material R to form features RF and/or border RB for and/or on the compression-formed structure CF). As shown schematically in <FIG> and <FIG>, a cover T may be provided on the compression-formed structure to form the panel assembly P (e.g. trim panel, interior component, etc.). Compare <FIG> (component as door panel) and <FIG> (component as instrument panel with airbag compartment AS).

Referring to <FIG>, a process for producing a pre-form substrate for a panel assembly is shown schematically as comprising a series of steps according to an exemplary embodiment. A surface layer/sheet and a substrate layer/mat may be arranged/consolidated and shaped/formed into a pre-formed substrate. See also <FIG> and <FIG>. Referring to <FIG>, <FIG>, <FIG> and <FIG>, a process for producing a panel assembly is shown schematically as comprising a series of steps according to an exemplary embodiment. A pre-form substrate may be formed/shaped into a compression-formed structure and provided with a cover to form the panel assembly (which may comprise resin features). See also <FIG>, <FIG> and <FIG>.

According to an exemplary embodiment as shown schematically in <FIG>, <FIG>, a vehicle interior component produced in a mold may comprise a first surface and a second surface by a process comprising placing a pre-form substrate onto the first surface of the mold; forming a compression-formed structure from the pre-form substrate by compressing the pre-form substrate between the first surface of the mold and the second surface of the mold; applying a cover to the compression-formed structure to form a panel assembly providing a surface effect. See <FIG> (exemplary embodiment of process for producing pre-form substrate for panel assembly) and <FIG>, <FIG>, <FIG> and <FIG> (exemplary embodiment of process for producing a panel assembly from the pre-form substrate). The cover may comprise the exterior surface of the panel assembly providing at least partially the surface effect of the panel assembly. The pre-form substrate may comprise a substrate layer and a surface layer. The compression-formed structure may comprise the substrate layer and the surface layer. The surface effect of the panel assembly may be at least partially provided by a surface effect of the surface layer of the compression-formed structure. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly); compare <FIG> (schematically indicating surface effect of rough/soft). The surface effect of the panel assembly may be at least partially provided by a surface effect of the surface layer of the pre-form substrate. The surface layer of the pre-form substrate may comprise a surface effect comprising a generally smooth texture. The surface layer of the compression-formed structure may comprise a surface effect comprising a generally smooth texture. The substrate layer for the pre-form substrate may comprise a surface effect comprising a generally rough texture. The pre-form substrate may comprise a surface effect comprising the surface effect of the surface layer. The compression-formed structure may comprise a surface effect comprising the surface effect of the surface layer. The step of forming the compression-formed structure may comprise forming the compression-formed structure with a surface effect generally comprising the surface effect of the pre-form substrate. The surface effect of the panel assembly may generally comprise the surface effect of the surface layer of the compression-formed structure. The surface effect of the panel assembly may generally comprise a surface effect of the surface layer of the compression-formed structure and a surface effect of the cover of the panel assembly. The substrate layer for the pre-form substrate may comprise a fiber mat. The substrate layer in the compression-formed structure may comprise a generally rigid fiber mat. The step of forming the compression-formed structure may comprise forming the substrate layer into a generally rigid form. The surface effect of the panel assembly may comprise the generally rigid form of the compression-formed structure. The surface effect of the panel assembly may comprise the generally rigid form of the substrate layer of the compression-formed structure. The surface effect of the panel assembly may comprise a generally smooth texture and a generally rigid form. The generally smooth texture of the panel assembly may be provided by (a) a surface effect of the cover and (b) a surface effect of the surface layer of the compression-formed structure formed from the pre-form substrate. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly); compare <FIG> (schematically indicating surface effect of rough/soft). The generally rigid form of the panel assembly may be provided by the substrate layer of the compression-formed structure formed from the pre-form substrate. The surface effect of the panel assembly may comprise a generally smooth surface effect of the surface layer of the compression-formed structure rather than a generally rough surface effect of the substrate layer for the pre-form substrate. The cover of the panel assembly may comprise at least one of (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric; (g) a woven fabric; (h) a non-woven fabric; (i) an applique; (j) vinyl; (k) a foil. The compression-formed structure may comprise a shape (for the panel assembly/component). See <FIG>, <FIG> and <FIG>. The panel assembly may comprise at least partially the shape of the compression-formed structure. The shape may comprise a first contour provided by the first surface of the mold and a second contour provided by the second surface of the mold. The substrate layer for the pre-form substrate may comprise a fiber mat. The surface layer for the pre-form substrate may comprise at least one of a fabric material or a fleece material. The surface layer of the pre-form substrate may comprise at least one of (a) a fabric; (b) a textile; (c) a fleece material; (d) a woven material; (e) a non-woven material; (f) a fiber-based material; (g) a textile material; (h) a woven sheet material; (i) a non-woven sheet material; (j) a fleece sheet material; (k) a resin-based material; (l) a polymer material; (m) polypropylene; (n) polyester. The process may further comprise the step of forming the pre-form substrate from a fiber mat. The process may further comprise the step of forming the pre-form substrate from a fiber mat and a fabric layer. The pre-form substrate may comprise a top layer and a structural layer; the top layer may comprise the surface layer and the structural layer may comprise the substrate layer. The vehicle interior component may further comprise the step of forming the pre-form substrate. The step of forming the pre-form substrate may comprise forming an interface between the surface layer and the substrate layer so that the surface effect of the pre-form substrate may comprise the surface effect of the surface layer. The step of forming the pre-form substrate may comprise forming an interface between the surface layer and the substrate layer so that the surface effect of the pre-form substrate may comprise a generally smooth surface effect of the surface layer rather than a generally rough surface effect of the substrate layer. Forming the interface between the surface layer and the substrate layer may comprise at least partial melting of the substrate layer into the surface layer. The process may further comprise the step of forming the pre-form substrate from a substrate layer and a surface layer. The step of forming the pre-form substrate may comprise applying the surface layer to the substrate layer. The substrate layer for the pre-form substrate may comprise a generally compressible fiber mat. The substrate layer in the compression-formed structure may comprise a generally rigid fiber mat. The step of forming the pre-form substrate may comprise consolidating the surface layer and the substrate layer. The step of forming the pre-form substrate may comprise consolidating the surface layer and the substrate layer into a generally rigid form. The step of forming the compression-formed structure may comprise forming the substrate layer into a generally rigid form. The process may further comprise the step of removing the compression-formed structure from the mold before applying the cover. The surface layer may be configured to provide improved profile tolerance for the panel assembly. The substrate layer may comprise natural fibers and a resin and the surface layer may comprise polypropylene and polyester. The resin may comprise polypropylene and the natural fibers comprise at least one of (a) flax; (b) kenaf. The surface layer may comprise at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric. The pre-form substrate may comprise an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The surface layer comprises an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The pre-form substrate may comprise a thickness of between <NUM> and <NUM> and the compression-formed structure may comprise a thickness of between <NUM> and <NUM>. The pre-form substrate may comprise a pre-formed component; the process may further comprise the step of consolidating the surface layer and the substrate layer to form the pre-formed component. The process may comprise the step of heating the pre-formed component; the pre-formed component may be compressed as the pre-formed component cools. The process may comprise the step of injecting resin into the mold after the compression-formed component is formed to form an ancillary component of the panel assembly. The process may comprise the steps of activating the surface layer of the pre-formed component and adhering the cover to the surface layer of the pre-formed component. See <FIG>, <FIG>, <FIG>, <FIG> and <FIG> (showing panel assembly component with pre-form substrate/compression-formed structure to provide surface effect).

According to an exemplary embodiment as shown schematically in <FIG>, <FIG>, a vehicle interior component may comprise a compression-formed structure formed from a pre-form substrate comprising a surface layer and a substrate layer; and a cover applied to the compression-formed structure to form a panel assembly providing a surface effect. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly) and <FIG>, <FIG> and <FIG>. The cover may comprise the exterior surface of the panel assembly. The surface effect of the panel assembly may generally comprise a surface effect of the surface layer of the compression-formed structure and a surface effect of the cover of the panel assembly. The surface layer of the pre-form substrate may comprise a surface effect comprising a generally smooth texture. The surface layer of the compression-formed structure may comprise a surface effect comprising a generally smooth texture. The substrate layer for the pre-form substrate may comprise a surface effect comprising a generally rough texture. The surface effect of the panel assembly may generally comprise the surface effect of the surface layer of the compression-formed structure. The substrate layer for the pre-form substrate may comprise a fiber mat. The substrate layer in the compression-formed structure may comprise a generally rigid fiber mat. The compression-formed structure may comprise a generally rigid form. The surface effect of the panel assembly may comprise the generally rigid form of the compression-formed structure. The surface effect of the panel assembly may comprise a generally rigid form of the substrate layer of the compression-formed structure. See <FIG>, <FIG>, <FIG>, <FIG> and <FIG> (showing panel assembly component with pre-form substrate/compression-formed structure to provide surface effect). The surface effect of the panel assembly may comprise a generally smooth texture and a generally rigid form. The generally smooth texture of the panel assembly may be provided by (a) the surface effect of the cover and (b) the surface effect of the surface layer of the compression-formed structure formed from the pre-form substrate. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly); compare <FIG> (schematically indicating surface effect of rough/soft). The generally rigid form of the panel assembly may be provided by the substrate layer of the compression-formed structure formed from the pre-form substrate. The surface effect of the panel assembly may comprise a generally smooth surface effect of the surface layer of the compression-formed structure rather than a generally rough surface effect of the substrate layer for the pre-form substrate. The cover of the panel assembly may comprise at least one of (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric; (g) a woven fabric; (h) a non-woven fabric; (i) an applique; (j) vinyl; (k) a foil. The compression-formed structure may comprise a shape. The panel assembly may at least partially comprise the shape of the compression-formed structure. The substrate layer for the pre-form substrate may comprise a fiber mat. The substrate layer for the pre-form substrate may comprise a generally flexible fiber mat. The substrate layer of the compression-formed structure may comprise a generally rigid fiber mat. The surface layer for the pre-form substrate may comprise at least one of a fabric material or a fleece material. The surface layer of the pre-form substrate may comprise at least one of (a) a fabric; (b) a textile; (c) a fleece material; (d) a woven material; (e) a non-woven material; (f) a fiber-based material; (g) a textile material; (h) a woven sheet material; (i) a non-woven sheet material; (j) a fleece sheet material; (k) a resin-based material; (l) a polymer material; (m) polypropylene; (n) polyester; (o) polypropylene and polyester; (p) polyethylene terephthalate.

According to an exemplary embodiment as shown schematically in <FIG>, <FIG>, a vehicle interior component produced in a mold may comprise a first surface and a second surface by a process comprising placing a pre-formed component onto the first surface of the mold; compressing the pre-formed component between the first surface of the mold and the second surface of the mold to form the pre-formed component into a compression-formed component; removing the compression-formed component from the mold; and applying a cover to the compression-formed component to form a panel assembly. See <FIG> (exemplary embodiment of process for producing pre-form substrate for panel assembly) and <FIG>, <FIG>, <FIG> and <FIG> (exemplary embodiment of process for producing a panel assembly from the pre-form substrate). The cover may comprise an exterior surface providing a surface effect of the panel assembly. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly); compare <FIG> (schematically indicating surface effect of rough/soft). The cover of the panel assembly may comprise at least one of (a) leather; (b) synthetic leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric; (g) a woven fabric; (h) a non-woven fabric; (i) an applique; (j) vinyl; (k) a foil. The pre-formed component may comprise a substrate layer and a top layer. The process may further comprise the step of forming the pre-formed component from a substrate and a top layer. The substrate layer for the pre-formed component may comprise a fiber mat. The top layer for the pre-formed component may comprise at least one of a fabric material or a fleece material. The top layer may comprise at least one of (a) a fabric; (b) a textile; (c) a fleece material; (d) a woven material; (e) a non-woven material; (f) a fiber-based material; (g) a textile material; (h) a woven sheet material; (i) a non-woven sheet material; (j) a fleece sheet material. The process may further comprise the step of forming the pre-formed component from a fiber mat. The process may further comprise the step of forming the pre-formed component from a fiber mat and a fabric layer. The pre-formed component may comprise a top layer and a structural layer. The structural layer may comprise a fiber mat. The top layer may comprise an outer surface with a smooth texture and a surface of the structural layer may comprise a rough texture. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly); compare <FIG> (schematically indicating surface effect of rough/soft). The top layer may be configured to provide improved profile tolerance for the panel assembly. The structural layer may comprise natural fibers and a resin and the top layer may comprise polypropylene and polyester. The resin may comprise polypropylene and the natural fibers comprise at least one of (a) flax; (b) kenaf. The top layer may comprise at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric. The pre-formed component may comprise an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The top layer comprises an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The pre-formed component may comprise a thickness of between <NUM> and <NUM> and the compression-formed component may comprise a thickness of between <NUM> and <NUM>. The process may comprise the step of consolidating the top layer and the structural layer to form the pre-formed component. The process may comprise the step of heating the pre-formed component and the pre-formed component may be compressed as the pre-formed component cools. The process may comprise the step of injecting resin into the mold after the compression-formed component is formed to form an ancillary component of the panel assembly. The process may comprise the steps of activating the top layer of the pre-formed component and adhering the cover to the top layer of the pre-formed component. See <FIG>, <FIG>, <FIG>, <FIG> and <FIG> (showing panel assembly component with pre-form substrate/compression-formed structure to provide surface effect).

According to an exemplary embodiment as shown schematically in <FIG>, <FIG>, component for a vehicle interior may comprise a pre-formed component and a cover. See also <FIG>, <FIG> and <FIG>. The pre-formed component may comprise a top layer coupled to a structural layer at a surface of the structural layer. The top layer may comprise an outer surface with a smooth texture and the surface of the structural layer may comprise a rough texture. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly); compare <FIG> (schematically indicating surface effect of rough/soft). The top layer may be configured to provide improved profile tolerance for the panel assembly. The structural layer may comprise natural fibers and a resin and the top layer may comprise at least one of (a) polypropylene; (b) polyester; (c) polypropylene and polyester; (d) polyethylene terephthalate. The resin may comprise polypropylene and the natural fibers may comprise at least one of flax and kenaf. The cover may comprise at least one of (a) leather; (b) artificial leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric. The cover may comprise at least one of (a) woven fabric; (b) non-woven fabric; (c) an applique; (d) vinyl; (e) foil.

According to an exemplary embodiment as shown schematically in <FIG>, <FIG>, a vehicle interior component may be produced by a process. See also <FIG>, <FIG> and <FIG>. The process may comprise placing a pre-formed component onto a first surface of a mold. The process may comprise compressing the pre-formed component between the first surface of the mold and a second surface of the mold to form the pre-formed component into a compression-formed component having a shape wherein the shape corresponds to a first contour of the first surface and a second contour of the second surface. See <FIG> (exemplary embodiment of process for producing pre-form substrate for panel assembly) and <FIG>, <FIG>, <FIG> and <FIG> (exemplary embodiment of process for producing a panel assembly from the pre-form substrate). The process may comprise removing the compression-formed component from the mold. The process may comprise placing a cover onto the compression-formed component to form a panel assembly. The pre-formed component may comprise a top layer coupled to a structural layer at a surface of the structural layer. The top layer may comprise an outer surface with a smooth texture and the surface of the structural layer may comprise a rough texture. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly); compare <FIG> (schematically indicating surface effect of rough/soft). The top layer may be configured to provide improved profile tolerance for the panel assembly. See <FIG>, <FIG>, <FIG>, <FIG> and <FIG> (showing panel assembly component with pre-form substrate/compression-formed structure to provide surface effect/profile tolerance). The structural layer may comprise natural fibers and a resin. The top layer may comprise polypropylene and/or polyester. The top layer may comprise at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric; (e) a fabric made of polypropylene fibers and polyester fibers. The resin may comprise polypropylene and the natural fibers may comprise at least one of flax and kenaf. The pre-formed component may comprise an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The top layer comprises an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. The pre-formed component may comprise a thickness of between <NUM> millimeters and <NUM> millimeters. The compression-formed component may comprise a thickness of between <NUM> millimeters and <NUM> millimeters. The process may comprise the step of consolidating the top layer and the structural layer to form the pre-formed component. The process may comprise the step of heating the pre-formed component. The pre-formed component may compressed as the pre-formed component cools. The process may comprise the step of injecting resin into the mold after the compression-formed component is formed to form an ancillary component of the panel assembly. The process may comprise the steps of activating the top layer of the pre-formed component and adhering the cover to the top layer of the pre-formed component.

According to an exemplary embodiment as shown schematically in <FIG>, <FIG>, a vehicle interior component may comprise a pre-formed component and a cover. See also <FIG>, <FIG> and <FIG>. The pre-formed component may comprise a top layer coupled to a structural layer at a surface of the structural layer. The top layer may comprise an outer surface with a smooth texture and the surface of the structural layer may comprise a rough texture. See <FIG> (schematically indicating surface effect of smooth/hard for panel assembly); compare <FIG> (schematically indicating surface effect of rough/soft). The top layer may be configured to provide improved profile tolerance for the panel assembly. The structural layer may comprise natural fibers and a resin. The top layer may comprise polypropylene and polyester. The top layer may comprise at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric; (e) a fabric made of polypropylene fibers and polyester fibers. The resin may comprise polypropylene. The natural fibers comprise at least one of flax and kenaf. The cover may comprise at least one of (a) leather and artificial leather. The cover may comprise at least one of woven fabric, non-woven fabric, an applique, vinyl and foil.

According to an exemplary embodiment as shown schematically in <FIG>, a vehicle V may comprise an interior including a door panel DP, an armrest AR and an instrument panel IP.

According to an exemplary embodiment, a vehicle interior component C is shown schematically in <FIG> as instrument panel IP.

According to an exemplary embodiment, vehicle interior component C is shown schematically in <FIG> as door panel DP with an arm rest AR.

According to an exemplary embodiment as shown schematically in <FIG>, vehicle interior component C may comprise a compression formed component FC coupled to a cover T with an adhesive A. Compression formed component FC may comprise a structural layer SL comprising a surface SR with a rough texture and a top layer TL comprising an outer surface SM with a smooth texture. The top layer may be configured to provide improved profile tolerance for vehicle trim component C at a surface SC. The top layer may be configured to provide a smooth textured surface SM for vehicle trim component C.

According to an exemplary embodiment as shown schematically in <FIG>, a fiber mat MT and a fabric F may be provided to form a panel assembly from which to make various vehicle interior components (e.g. door panels, instrument panels, floor consoles, etc.). Mat MT may comprise natural fibers and a resin. The resin may comprise polypropylene and the natural fibers may comprise at least one of flax and kenaf. Mat MT may include a combination of structural fibers (e.g. natural and/or synthetic fibers) and thermoplastic resin (e.g. polypropylene (PP), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), etc.). Fabric F may include a combination of polypropylene and polyester. A surface SR of mat MT may comprise a rough texture. Fabric F may comprise an outer surface SM with a smooth texture. Fabric F may be configured to provide improved profile tolerance for a vehicle trim component formed from mat MT. Fabric F may comprise an area weight of between <NUM> grams per square meter and <NUM> grams per square meter.

According to an exemplary embodiment as shown schematically in <FIG>, fabric F may be applied to mat MT.

According to an exemplary embodiment as shown schematically in <FIG>, fabric F and mat MT may be consolidated (e.g. heated and compressed, densified, fused, bonded, stiffened) to form a pre-from PF.

According to an exemplary embodiment as shown schematically in <FIG>, pre-from PF may be cut to form a pre-form PFs with a desired shape. Offal PFx may be formed as pre-form PF is cut to form pre-form PFs with a desired shape. Pre-form PF may comprise an area weight of between <NUM> grams per square meter and <NUM> grams per square meter. Pre-form PF may comprise a thickness of between <NUM> millimeters and <NUM> millimeters.

According to an exemplary embodiment as shown schematically in <FIG>, pre-form PF may be heated in an oven OV. As shown schematically in <FIG>, heated pre-form PF may be transferred into a mold MO. As shown schematically in <FIG>, a compression-formed component CF shown as a door panel substrate or carrier may be produced by a process of compression forming and injection molding. According to an exemplary embodiment, pre-form PF may be compressed and/or formed to form compression-formed component CF; plastic resin may be injected on compression-formed component CF to form panel assembly P comprising at least one of (a) a resin border RB; (b) a resin feature RF. As shown schematically in <FIG>, compression-formed component CF shown as a door panel substrate or carrier may be formed into a desired form and dimension with features RF at edges of compression-formed component CF; compression-formed component CF may provide features shown as plastic ribs on a back side of compression-formed component CF to improve structural integrity and rigidity. According to an exemplary embodiment, a plastic rib may be placed at various locations on a back side of compression-formed component CF (e.g. along an edge, in the middle of compression-formed component CF, etc.). According to an exemplary embodiment, multiple plastic ribs may be placed at various different locations on a side of compression-formed component CF.

According to an exemplary embodiment as shown schematically in <FIG>, pre-form PF may be heated in an oven OV. As shown schematically in <FIG>, heated pre-form PF may be transferred into a mold MO. As shown schematically in <FIG>, a compression-formed component CF shown as an instrument panel substrate or carrier may be produced by a process of compression forming and injection molding. According to an exemplary embodiment, pre-form PF may be compressed and/or formed to form compression-formed component CF; plastic resin may be injected on compression-formed component CF to form compression-formed component CF comprising features R/RF. As shown schematically in <FIG>, panel assembly P may be formed into a desired form and dimension with features R on compression-formed component CF; panel assembly P may provide features shown as plastic ribs on a back side of compression-formed component CF to improve structural integrity and rigidity and features shown as an airbag chute to guide deployment of an airbag. According to an exemplary embodiment, a plastic rib may be placed at various locations on a back side of compression-formed component CF (e.g. along an edge, in the middle of compression-formed component CF, etc.). According to an exemplary embodiment, multiple plastic ribs may be placed at various different locations on a side of compression-formed component CF.

According to an exemplary embodiment as shown schematically in <FIG>, a mold may comprise a first molding element MS with a port or set of ports and a second molding element MS. Pre-form PF may be placed between a surface of first molding element MS and a surface of second molding element MS.

According to an exemplary embodiment as shown schematically in <FIG>, second molding element MS may move toward first molding element MS; pre-form PF may be formed to the shape of a mold cavity between a surface of first molding element MS and a surface of second molding element MS.

According to an exemplary embodiment as shown schematically in <FIG>, a mold is at a closed position; pre-form PF may be compressed and/or formed to form compression-formed component CF. Compression-formed component CF may comprise a thickness of between <NUM> millimeters and <NUM> millimeters. As shown schematically in <FIG>, compression-formed component CF may not fill the entire mold cavity leaving at least one empty space or void (shown schematically as void V).

According to an exemplary embodiment as shown schematically in <FIG>, an empty space or void V may be filled with resin R. One or more voids may be on at least one of a surface or an edge of compression-formed component CF. According to an exemplary embodiment, feature or ancillary component RF may increase the structural integrity of a component C made from compression-formed component CF. According to an exemplary embodiment, feature R may comprise a resin border RB for compression-formed component CF. According to an exemplary embodiment, resin features R may be applied in different arrangements.

According to an exemplary embodiment as shown schematically in <FIG>, second molding element MS may move away from first molding element MS and panel assembly P may be removed from the mold.

According to an exemplary embodiment, a surface of panel assembly P may be activated to provide for improved adhesion and a cover may be adhered to the surface of panel assembly P. The cover may be glued or press laminated to panel assembly P. The cover may comprise at least one of (a) leather; (b) artificial leather; (c) imitation leather; (d) a composite of a plastic layer and textile backing; (e) a coated fabric; (f) polyvinylchloride coated fabric. The cover may comprise at least one of (a) a woven fabric; (b) a non-woven fabric; (c) an applique; (d) vinyl; (e) a foil.

Referring to <FIG>, a process for producing a panel assembly is shown schematically as comprising a series of steps according to an exemplary embodiment. A pre-form substrate comprising a surface layer/sheet and a substrate layer/mat may be consolidated into and formed/shaped into a compression-formed structure and provided with a cover to form a panel assembly. As shown schematically, natural fibers and polypropylene fibers may be needled or joined to form a natural fiber mat or structural layer; a fabric or top layer may be applied to a surface of the natural fiber mat or structural layer; fabric may comprise at least one of (a) a top layer, (b) a non-woven fabric, (c) a synthetic fabric, (d) a thermoplastic fabric, (e) a fabric made of polypropylene fibers and polyester fibers. The top layer and the structural layer may be consolidated and cut to a desired size to form a panel assembly; the panel assembly may be compression formed to a desired shape to form a compression formed component; a cover material may be cut to a desired size to form a cover; the cover may be glued or press laminated to the compression formed component to form the vehicle interior component. As shown schematically, natural fibers and Polypropylene fibers may be needled or joined and partially compressed to form a natural fiber mat or structural layer; the natural fiber mat or structural layer may be cut to a desired size; a fabric or top layer may be cut to a desired size and applied to a surface of the natural fiber mat or structural layer; the fabric may comprise at least one of (a) a top layer, (b) a non-woven fabric, (c) a synthetic fabric, (d) a thermoplastic fabric, (e) a fabric made of polypropylene fibers and polyester fibers. The top layer and the structural layer may be consolidated to form a panel assembly; the panel assembly may be compression formed to a desired shape to form a compression formed component; a cover material may be cut to a desired size to form a cover; the cover may be glued or press laminated to the compression formed component to form the vehicle interior component.

Claim 1:
A method of manufacturing a vehicle interior component (C) in a mold comprising a first surface and a second surface comprising:
- placing a pre-form substrate (PF) onto the first surface of the mold;
- forming a compression-formed structure (CF) from the pre-form substrate (PF) by compressing the pre-form substrate (PF) between the first surface of the mold and the second surface of the mold;
- applying a cover (T) to the compression-formed structure to form a panel assembly (P/C) providing a surface effect;
wherein the cover (T) comprises an exterior surface of the panel assembly (P/C) providing at least partially the surface effect of the panel assembly (PIC);
wherein the pre-form substrate (PF) comprises a substrate layer (BL) and a surface layer (SL/F), said surface layer (SL/F) comprising an area weight of between <NUM> grams per square meter and <NUM> grams per square meter; wherein the substrate layer (BL) comprises natural fibers and a resin; and wherein the surface layer (SL/F) comprises at least one of (a) a non-woven fabric; (b) a synthetic fabric; (c) a thermoplastic fabric; (d) a non-woven fiber fabric.