Vehicle trim component

Abstract

A vehicle trim component is disclosed. A method for forming the trim component is also disclosed. The trim component is configured to support an airbag chute providing an airbag. The airbag is configured to be deployed through an opening. The trim component may comprise (a) a substrate a structure, (b) a cover comprising a skin made of a thermoplastic material (e.g. TPO having a substantially constant thickness of less than 0.7 mm) and a support layer coupled to the skin, and (c) a thermoplastic (e.g. foam) layer between the cover and the substrate. The thermoplastic foam) layer may be configured to attach the cover to the substrate. The airbag chute may be secured between the thermoplastic (e.g. foam) layer and the substrate. The support layer may be made of a foam material (e.g. polypropylene and/or polyethylene foam). The process for forming the trim component may comprise the steps of (a) providing a skin; (b) applying a support layer to the skin to create a cover; (c) providing the cover in a mold; (d) providing an airbag chute in the mold; (e) providing a substrate in the mold; and (I) injecting a thermoplastic (e.g. foam) material between the cover and the substrate.

1 . A trim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening comprising:
 (a) a substrate providing a structure;   (b) a cover comprising a skin layer and a support layer coupled to the skin layer; and   (c) a core layer configured to attach the cover to the substrate;   wherein the skin layer comprises a thermoplastic material provided in a generally uniform thickness less than 0.7 mm.   
     
     
         2 . The trim component of  claim 1  wherein the support layer is provided in a thickness in a range between 1 mm and 4 mm. 
     
     
         3 . The trim component of  claim 1  wherein the chute is secured between the core layer and the substrate. 
     
     
         4 . The trim component of  claim 1  wherein the core layer comprises a foam layer; wherein the foam layer is formed from a foam material applied as a liquid and configured to attach the cover to the substrate; wherein the foam layer comprises a foam material provided in a thickness in a range between 3 and 15 mm. 
     
     
         5 . The trim component of  claim 1  wherein the core layer comprises a foam material provided to solidify to attach the cover to the substrate. 
     
     
         6 . The trim component of  claim 1  wherein the support layer has a density between 3 and 7 pounds per cubic foot; wherein the support layer is configured to at least partially prevent deformation of the skin layer when force is applied to the cover; wherein deformation comprises at least one of (a) stretching or (b) elongating. 
     
     
         7 . The trim component of  claim 1  wherein the skin layer is provided without a localized area of reduced thickness. 
     
     
         8 . The trim component of  claim 1  wherein the substrate comprises a notch configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the core layer and support layer and skin layer. 
     
     
         9 . A rim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening prepared by a process using a mold comprising the steps of:
 (a) providing a skin layer;   (b) applying a support layer to the skin layer to form a cover;   (c) providing the cover in the mold;   (d) providing the chute in the mold;   (e) providing a substrate in the mold; and   (f) injecting a thermoplastic material between the cover and the substrate;   wherein the thermoplastic material attaches the cover and the substrate.   
     
     
         10 . The trim component of  claim 9  wherein the cover comprises a skin layer of a generally uniform thickness of less than 0.7 mm. 
     
     
         11 . The trim component of  claim 9  wherein the thermoplastic material comprises a foam material; wherein the process comprises the step of the foam material solidifying to attach the cover to the substrate. 
     
     
         12 . The trim component of  claim 9  wherein the process comprises the step of securing the chute between the thermoplastic material and the substrate. 
     
     
         13 . The trim component of  claim 9  wherein the skin layer comprises a thermoplastic olefin material. 
     
     
         14 . The trim component of  claim 9  wherein the support layer comprises a foam comprising polypropylene and polyethylene with a density between 3 and 7 pounds per cubic foot and a thickness in a range between 1 and 4 mm. 
     
     
         15 . A method using a mold for forming a trim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening comprising the steps of:
 (a) providing a skin layer as a sheet made of a thermoplastic material having a substantially uniform thickness less than 0.7 mm;   (b) applying a support layer to the skin layer to form a cover;   (c) providing the cover in the mold;   (d) providing the chute in the mold;   (e) providing a substrate in the mold;   (f) injecting a thermoplastic material between the cover and the substrate; and   (g) solidifying the thermoplastic material to form a core layer to attach the cover to the substrate.   
     
     
         16 . The method of  claim 15  wherein the thermoplastic material comprises a foam material; wherein the core layer comprises a foam layer; wherein solidifying the foam material comprises at least one of (a) hardening or (b) curing. 
     
     
         17 . The method of  claim 15  wherein the skin layer is provided as a substantially uniform layer without a localized area of reduced thickness. 
     
     
         18 . The method of  claim 15  further comprising the step of securing the chute between the thermoplastic material and the substrate. 
     
     
         19 . The method of  claim 15  wherein applying the support layer to the skin layer to form the cover comprises laminating the support layer to the skin layer. 
     
     
         20 . The method of  claim 15  further comprising providing a first gap between the cover and the chute and providing a second gap between the cover and the substrate; wherein the thermoplastic material is injected to fill the first gap and to fill the second gap to form the core layer.