WO2026010618A1 - Vehicle trim panel assembly - Google Patents

Abstract

A panel is provided with a first region of knit fabric with a first thread concentration. The first region is sized to be displaced at least partially on a vehicle trim member. A second region of knit fabric is interrelated with the first region. The second region is sized to be displaced at least partially on the vehicle trim panel and at least partially over a media device. The second region provides a second thread concentration that is less than the first thread concentration. A vehicle trim assembly is provided with a vehicle door panel with a substrate with an external surface. A method is provided by digitally knitting the panel.

Description

VEHICLE TRIM PANEL ASSEMBLY

TECHNICAL FIELD

[0001 J Various embodiments relate to panels for vehicle trim panels.

BACKGROUND

[0002] The prior art has provided various fabrics for vehicle trim panels.

[0003] Digital knitting, also known as computerized knitting or computer-controlled knitting, refers to a process of using computer technology to control knitting machines. These machines use digital instructions, often in the form of computer-aided design (CAD) files or programming languages, to create knitted fabrics or garments automatically. Digital knitting offers several advantages over traditional hand knitting or even manual knitting machines. Digital knitting allows for precise control over stitch formation, resulting in consistent and accurate patterns. With computer control, knitting machines can produce fabrics or garments at a much faster and efficient rate than conventional methods. Digital knitting machines can create intricate patterns, textures, and even three-dimensional shapes that may be challenging to achieve with traditional knitting techniques. Digital knitting enables easy and flexible customization of designs, sizes, and colors, making it suitable for personalized or made-to-measure products. Once programmed, digital knitting machines operate autonomously, requiring minimal intervention during the production process. Digital knitting technology has applications in various industries, including fashion, textiles, automotive, and medical textiles. Digital knitting is used to produce a wide range of products, from fashion apparel and accessories to technical textiles and composite materials.

SUMMARY

[0004] According to an embodiment, a panel is provided with a first region of knit fabric with a first thread concentration. The first region is sized to be displaced at least partially on a vehicle door panel. A second region of knit fabric is interrelated with the first region. The second region is sized to be displaced at least partially on the vehicle door panel. The second region provides a second thread concentration that is less than the first thread concentration.

[0005] According to a further embodiment, a join is formed by the knit fabric about a periphery of the first region for attachment to the vehicle door panel.

[0006] According to another further embodiment, indicia is woven or knitted into the second region.

[0007] According to another embodiment, a vehicle trim assembly is provided with a vehicle door panel with a substrate with an external surface. A panel is provided with a first region of knit fabric with a first thread concentration. The first region is sized to be displaced at least partially on a vehicle door panel. A second region of knit fabric is interrelated with the first region. The second region is sized to be displaced at least partially on the vehicle door panel. The second region provides a second thread concentration that is less than the first thread concentration. The first region is displaced over the external surface of the substrate.

[0008] According to a further embodiment, the vehicle door panel is provided with a receptacle formed in the substrate, sized to support and receive a media device. The second region of the panel is displaced over the receptacle.

[0009] According to another further embodiment, a cushioning panel is displaced at least partially over the substrate and oriented between the substrate and the first region of the panel.

[0010] According to an even further embodiment, the cushioning panel is further provided with a knit fabric.

[0011] According to another embodiment, a panel is provided with a first region of knit fabric with a first thread concentration. The first region is sized to be displaced at least partially on a vehicle trim member. A second region of knit fabric is interrelated with the first region. The second region is sized to be displaced at least partially over a media device. The second region comprises a second thread concentration that is less than the first thread concentration. [0012] According to a further embodiment, the second region is at least partially acoustically transparent.

[0013] According to another further embodiment, the second region is at least partially optically transparent.

[0014] According to another embodiment, a panel assembly is provided with a panel with a first region of knit fabric with a first thread concentration. The first region is sized to be displaced at least partially on a vehicle trim member. A second region of knit fabric is interrelated with the first region. The second region is sized to be displaced at least partially over a media device. The second region comprises a second thread concentration that is less than the first thread concentration. A light source is provided in the second region.

[0015] According to a further embodiment, the light source is woven or knitted into the second region.

[0016] According to another further embodiment, the light source is further provided with a light pipe.

[0017] According to another embodiment, a panel assembly is provided with a panel with a first region of knit fabric with a first thread concentration. The first region is sized to be displaced at least partially on a vehicle trim member. A second region of knit fabric is interrelated with the first region. The second region is sized to be displaced at least partially over a media device. The second region comprises a second thread concentration that is less than the first thread concentration. A speaker assembly is provided in the second region.

[0018] According to a further embodiment, the speaker assembly is provided with an enclosure with an opening. A speaker is oriented in the enclosure facing out of the opening.

[0019] According to an even further embodiment, the opening of the enclosure is covered by the second region of the panel.

[0020] According to a further embodiment, a vehicle trim assembly is provided with a vehicle trim member provided with a substrate with an external surface. A panel assembly is provided with a panel with a first region of knit fabric with a first thread concentration. The first region is sized to be displaced at least partially on a vehicle trim member. A second region of knit fabric is interrelated with the first region. The second region is sized to be displaced at least partially over a media device. The second region comprises a second thread concentration that is less than the first thread concentration. The first region is displaced over the external surface of the substrate. The vehicle trim member is provided with a receptacle formed in the substrate, sized to support and receive the media device. The second region of the panel is displaced over the receptacle.

[0021] According to an embodiment, a method is provided by digitally knitting a first region of a panel with a first thread concentration, and is sized to be displaced at least partially on a vehicle trim member. A second region of the panel is digitally knit with a second thread concentration that is less than the first thread concentration, and is sized to be displaced at least partially over the vehicle trim member.

[0022] According to a further embodiment, the panel is knit to a periphery of the panel without cutting waste from the panel.

[0023] According to another further embodiment, the panel is knit from expandable thread. The expandable thread is heated to expand the thread.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIGURE 1 is an exploded view of a vehicle door panel assembly according to an embodiment;

[0025] FIGURE 2 is an exploded view of a vehicle door panel assembly according to another embodiment;

[0026] FIGURE 3 is a side elevation view of a vehicle interior according to another embodiment;

[0027] FIGURE 4 is a side perspective view of a portion of the vehicle interior of Figure 3; [0028] FIGURE 5 is a side elevation view of a vehicle interior according to another embodiment;

[0029] FIGURE 6 is a side perspective view of a portion of a vehicle interior according to another embodiment; and

[0030] FIGURE 7 is a side perspective view of a vehicle interior according to another embodiment.

DETAILED DESCRIPTION

[0031] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0032] Figure 1 illustrates an exploded view of a vehicle door panel assembly 100 according to an embodiment. The vehicle door panel assembly 100 may be provided for a land vehicle such as an automobile, an aircraft, a watercraft, or the like. The vehicle door panel assembly 100 is provided as an interior for a door for enclosing a door opening of a vehicle body.

[0033] The vehicle door panel assembly 100 includes a vehicle door panel 102. The vehicle door panel 102 is a vehicle trim member, and serves multiple functions, including structural support, sound insulation, and aesthetic enhancement. The door panel 102 is manufactured from molded plastic or a composite material according to some embodiments. For example, the door panel 102 may be molded from a polymeric material, such as acrylonitrile butadiene styrene. The door panel 102 includes a substrate 104 with a surface 106 that faces an interior of the vehicle and therefore, is an external surface 106 relative to the vehicle door. The external surface 106 is often referred to as an ‘A-surface’, which is opposed to a concealed or ‘B-surface’ that attaches directly to the door. [0034] The vehicle door panel 102 provides an armrest 108 extending from the external surface 106 to provide a support for an arm of a passenger within the vehicle. The vehicle door panel 102 also includes a plurality of receptacles 110 formed into the substrate 104. The receptacles 110 are each sized to receive a media device, such as a speaker assembly 112. The speaker assemblies 112 are each installed in the receptacles 110 so that an enclosure and a cone speaker of the speaker assemblies 112 are oriented between the external surface 106 and the door.

[0035] The vehicle door panel assembly 100 includes a first door panel as a knit layer 114 that is manufactured from a digitally knit fabric. Digital knitting is modular and flexible, and may be modified by modifications in the CAD files and/or programming.

[0036] The first door panel knit layer 114 alone, or in combination with other knit layers, may replace a traditional trim layer, such as leather, vinyl, or the like. The first door panel knit layer 114 includes a first region 116 of digitally knit fabric that is sized to be displaced partially on the external surface 106 of the of the vehicle door panel 102. The material of the layer 114 may be polyester, or a suitable flexible and structural thread material. The first region 116 has a first thread concentration. Digital knitting permits variations of threads, and therefore the thread concentration can be determined by a thread diameter. Digital knitting also permits variations of thread patterns. Therefore, thread concentration can also be determined by a quantity of threads within the region 116. For the depicted embodiment, the region 116 may have a sufficient concentration to provide comfort padding to the door panel assembly 100, thereby eliminating a foam layer. Alternatively, an additional cushion layer may be provided between the first region 116 and the door panel 102.

[0037] Digital knitting also permits knitting of the panel layer 114 with various thread materials. The first region 116 may be fabricated from a thread with an enlarged diameter. The first region 116 may also be fabricated with a thread with elastically deformable properties. Additionally, the first region 116 may be fabricated from a heat expandable thread. After knitting, a heating process may be employed to expand the thread of the first region 116. According to another embodiment, the thread material may be a thermoset material to maintain an orientation after heat treatment. According to another embodiment, a heat expandable thread may be woven into the first region 116 in a secondary process after the knitting process of the first region 116. [0038] The first door panel layer 114 also includes a second region 118 of digitally knit fabric. The second region 118 is interrelated with the first region 116. For efficiency, modularity, and quality, the interrelation of the first region 116 and the second region 118 is provided by digitally knitting the second region 118 to the first region 116 integrally. According to other embodiments, the second region 118 may be intertwined or interwoven to the first region 116. The second region 118 is also displaced partially over the external surface 106 of the vehicle door panel 102. The second region 118 is sized to be displaced over the speaker assemblies 112 in the receptacles 110 in the substrate 104 of the vehicle door panel 102.

[0039] The second region 118 has a second thread concentration that is less concentrated than the first thread concentration. The second thread concentration is sufficiently thin and/or fine such that the second region 118 is at least partially, acoustically transparent to permit an acoustic output from the speaker assemblies 112 to egress the door panel 102 without audibly obstructing the acoustic output.

[0040] The acoustically transparent region 118 is designed to allow sound to pass through with minimal attenuation, to complement the speaker assemblies 112. The acoustically transparent region 118 has gaps in the knitted material, such as holes, or knitted fabric, that allow sound waves to pass through without interference. According to one example, the gaps are 0.3 millimeters in diameter or width. Of course, any thread concentration that permits a suitable air permeability for egress of sound is contemplated. The digitally knit acoustically transparent region 118 may also visually reduce the chance of a moire effect associated with conventional speaker grilles or screens. According to an embodiment, the second region 118 has a thread concentration of approximately forty percent to seventy percent to provide openings within the second region of thirty to sixty percent. According to another embodiment, the second region 118 provides openings of approximately fifty to fifty-five percent of the region 118 to maximize acoustic vibrations while maintaining structural integrity of the region 118. The threads and/or gaps may vary in size and/or spacing to provide the desired acoustic transparency. In other words, the acoustic transparency may vary across the second region 118. If the second region 118 is open thirty to sixty percent, then an acceptable decibel loss is obtained to qualify as acoustically transparent. [0041] The door panel layer 114 may also include piping 120 provided in the second region 118, or another region of the layer 114, such as a third region 122. The piping 120 may be formed from a thread or threads of a different diameter and interrelated with the door panel layer 114 during the digitally knitting process. Alternatively, the piping 120 may be woven into a piping opening 120 in the door panel layer 114 in a subsequent process after the digital knitting. The piping 120 may provide an additional ornamental or stylized aesthetic to the door panel assembly 100.

[0042] According to another embodiment, the piping 120 may include a light source to provide an illumination effect along the piping 120. The light source 120 may be a fiber optic material or refractive piping 120 that is digitally knitted or interwoven into the panel layer 114. For example, a fiber optic thread of one to two millimeters, may embody the piping 120. In another embodiment, the piping 120 may be hollow and translucent for receipt of the light source within the piping 120. To the extent that the piping 120 is partially covered by the second region 118 and/or the third region 122, these regions 118, 122 may be at least partially optically transparent for transmission of light from the vehicle door panel assembly 100.

[0043] The first door panel knit layer 114 may also include a fourth region 124 that is sized to be displaced upon, and adjacent to, the armrest 108. The fourth region 124 may be formed from a thread concentration greater than that of the other regions 116, 118, 122 to provide cushioning support to the passenger upon and adjacent to the armrest 108. Alternatively, an additional thread or yam may be woven into the fourth region 124 in a secondary operation to provide cushioning to the fourth region 124. The additional thread or yam may be an expandable thread or yam that is expanded by a subsequent operation, such as heating.

[0044] The digitally knit layer 114 may be formed with a join 126 formed around a periphery of the layer 114. The join 126 may be formed from a seam 126 or any suitable knitting edge termination along the periphery of the layer 114. By knitting the layer 114 to the join 126 at the edge, no additional scrap is generated beyond the periphery. By avoiding scrap, materials are conserved, and an additional cutting operation is omitted. Additionally, a clean edge is provided along the join 126. The join 126 may also be knitted with hooks, loops, straps, or any suitable fastener for attaching the knit layer 114 to the door panel 102. [0045] Figure 1 illustrates a digitally knit pattern 128 that may be formed into the first layer 114. The knit pattern 128 may vary in color, patterns, aesthetics, or the like. The knit pattern 128 may be knitted digitally and integrally with the knit layer 114.

[0046] The vehicle door panel assembly 100 may include any number of knit layers 114. According to another embodiment, a second door panel digitally knit layer 128 may be provided to enhance an ornamental appearance of the door panel assembly 100. Further, the second knit layer 128 may provide additional patterns and/or colors to the door panel assembly 100. The second knit layer 128 can be installed to the door panel 102 at least partially over the first knit layer 114.

[0047] The second door panel layer 128 includes a first region 130, which is displaced at least partially over the first region 116 of the first layer 114. The first layer 114 may be dedicated to structural support, and consequently, the second layer 128 can be directed to appearance.

[0048] Likewise, the second door panel layer 128 also includes a second region 132 that is displaced at least partially over the second region 118 of the first layer 114, and consequently over the speaker assemblies 112 and receptacles 110. The second region 132 of the second layer 128 may also be formed from a reduced thread concentration for acoustic transparency of the second region 132. The second region 132 may be formed integrally and interrelated with the first region 130 of the second layer 128. Alternatively, the first region 130 and the second region 132 of the second layer 128 may be formed as separate subpanels that are each individually attached to the first layer 114 and the door panel 102.

[0049] The second layer 128 may be provided with one or more join(s) 134 formed around the periphery (or peripheries) of the second layer 128. The join 134 provides a clean terminal edge and minimizes waste, cost, and manufacturing time. Alternatively, the second layer 128 may be digitally interrelated with the first layer 114.

[0050] According to the depicted embodiment, a third layer 136 of a digitally knit fabric can be provided. The third layer 136 may attach to the second region 132 of the second layer 128 and the second region 118 of the first layer 114. The third layer 136 includes a thread concentration that is acoustically transparent. The third layer 136 may be digitally knitted and interrelated with the first and/or second layers 114, 128. The third layer 136 may employ a thread pattern that is conducive to gaps such as a pointelle pattern. Other suitable stitching patterns may include lace stitch, eyelet stitch, openwork stitch, mesh stitch, daisy stitch, honeycomb stitch, or the like. The digitally knit, acoustically transparent, fabric layer regions 118, 132, 136 offer enhanced structural integrity over conventional acoustic fabrics.

[0051] The digitally knit door panel layers 114, 128, 136 may include logos 138, branding, design cues, ornamental indicia, instructional indicia, or the like woven or knitted directly into the layers 114, 128, 136. The third layer 136 may also include a peripheral join 140 for a clean edge and attachment to the other layers 114, 128 and the door panel 102.

[0052] The design and features of door panel assemblies 100 vary depending on the make and model of the vehicle, as well as the trim level. The flexibility of the digital knitting permits flexibility in modification of the design with minimal retooling. The door panel assemblies 100 may accommodate other common features, such as door handles, controls (e.g., window, locks, etc.), storage pockets, or the like.

[0053] The digitally knit door panel layers 114, 128, 136 permit integration of other components into the door panel assembly 100. For example, conductive wire may be woven, knitted, or threaded into the door panel layers 114, 128, 136 for providing a heating function of the vehicle trim assembly 100. Interactive surfaces for controls, entertainment, or the like may also be integrated into the door panel assembly 100.

[0054] Overall, the vehicle door panel assembly 100 provides comfort, convenience, haptic engagement, tactile engagement, and visual appeal to the interior of the vehicle, while also contributing to overall structural integrity and safety. The digital knitting of the trim panel layers 114, 128, 136 provides versatility and sustainability to the door panel assembly 100. The design and associated manufacturing processes reduce part count, simplify supply chain management, improve part performance, improve user experience, and improve sustainability. [0055] The vehicle trim assembly 100 provides a "seamless" and "minimal" interior expression, while concealing or ornamentally integrating speaker screens 136, 132, 118, lighting 120, branding or the like. The vehicle trim assembly 100 eliminates otherwise unwanted breaks, parting lines, and visual obfuscation on the interior.

[0056] The panel trim layers 114, 128, 136 can be knit specifically to a defined shape to match the interior, while eliminating or minimizing off-cut waste at the factory. Application specifications, such as acoustic transparency, durability, and brand requirements from the factoiy, can be integrated while eliminating feedback loops between various stakeholders. The integration of technology, such as lighting, conductive/heating wire/thread, and interactive surfaces provides a compelling avenue to a new generation of in-cabin vehicle experiences. The trim panel assembly 100 teachings may be applied to other vehicle subassemblies, such as head restraints, instrument panels, pillars, or the like.

[0057] Figure 2 illustrates an exploded view of a vehicle door panel assembly 160 according to another embodiment. The vehicle door panel assembly 160 includes a vehicle door panel 162. The door panel 162 includes a substrate 164 with a surface 166 that faces an interior of the vehicle and therefore, is an external surface 166 relative to the vehicle door. The vehicle door panel 162 provides an armrest 168 extending from the external surface 166 to provide a support for an arm of a passenger within the vehicle.

[0058] The vehicle door panel 162 also includes a receptacle 170 formed into the substrate 164. The receptacle 170 is sized to receive a speaker assembly 172. The speaker assembly 172 includes an enclosure 174 and a plurality of cone speakers 176 received in openings 178 of the enclosure 174. The speaker assembly 172 is installed in the receptacle 170 so that the enclosure 174 and the plurality of cone speakers 176 of the speaker assembly 172 are oriented between the external surface 166 and the door. The door panel assembly 160 also includes a light source 180 for providing an illumination effect. The light source 180 can be a light pipe, a light panel, a lens, or a light guide received in the receptacle 170.

[0059] The vehicle door panel assembly 160 includes a first door panel knit layer 182 that is manufactured from a digitally knit fabric. The first door panel knit layer 182 includes a first region 184 of digitally knit fabric that is sized to be displaced partially on the external surface 166 of the of the vehicle door panel 162. The first region 184 has a first thread concentration. For the depicted embodiment, the region 184 may have a sufficient concentration to provide comfort padding to the door panel assembly 160.

[0060] A second door panel layer 186 includes a second region 188 of digitally knit fabric. The second region 188 may be interwoven, or digitally knit integrally with the first region 184. The second region 188 is also displaced partially over the external surface 166 of the vehicle door panel 162. The second region 188 is sized to be displaced over the speaker assembly 172 in the receptacle 170 in the substrate 164 of the vehicle door panel 162.

[0061] The second region 188 has a second thread concentration that is less concentrated than the first thread concentration. The second thread concentration is sufficiently thin and/or fine such that the second region 188 is acoustically transparent to permit an acoustic output from the speaker assembly 172 to egress the door panel 162 without audibly obstructing the acoustic output. According to another embodiment, the light source 180 may be light piping that is woven or knitted into the second region 188.

[0062] The digitally knit layer 182 may be formed with a join 190 formed around a periphery of the layer 182. The join 190 may be formed from a seam 190 or any suitable knitting edge termination along the periphery of the layer 182. By knitting the layer 182 to the join 190 at the edge, no additional scrap is generated beyond the periphery. By avoiding scrap, materials are conserved, and an additional cutting operation is omitted. Additionally, a clean edge is provided along the join 190. The join 190 may also be knitted with hooks, loops, straps, or any suitable fastener for attaching the knit layer 182 to the door panel 162.

[0063] The vehicle door panel assembly 160 may include any number of knit layers 182. For example, the second door panel digitally knit layer 186 may enhance an ornamental appearance of the door panel assembly 160. Further, the second knit layer 186 may provide additional patterns and/or colors to the door panel assembly 160. The second layer 186 may be provided with a join 192 formed around the periphery of the second layer 186. The join 192 provides a clean terminal edge and minimizes waste, cost, and manufacturing time. Alternatively, the second layer 186 may be digitally interrelated with the first layer 182.

[0064] Figures 3 and 4 illustrate a vehicle interior 210 according to another embodiment. The vehicle interior 210 includes a pair of vehicle door assemblies 212, 214 attached to a vehicle body 216. Each vehicle door assembly 212, 214 includes a vehicle door panel assembly 218, 220.

[0065] Each vehicle door panel assembly 218, 220 includes a vehicle door panel. Each door panel includes a substrate with a surface that faces an interior of the vehicle and therefore, is an external surface relative to the vehicle door. Each vehicle door panel provides an armrest 222, 224 extending from the external surface to provide a support for an arm of a passenger within the vehicle.

[0066] Each vehicle door panel assembly 218, 220 includes a first door panel knit layer 226, 228 that is manufactured from a digitally knit fabric. Each first door panel knit layer 226, 228 includes a first region 230, 232 of digitally knit fabric that is sized to be displaced partially on the external surface of the of the vehicle door panel. The first region 230, 232 has a first thread concentration. For the depicted embodiment, the region 230, 232 may have a sufficient concentration to provide comfort padding to the door panel assembly 218, 220.

[0067] Each vehicle door panel assembly 218, 220 includes a second region 234, 236 of digitally knit fabric. The second regions 234, 236 may be interwoven, or digitally knit integrally with the first regions 230, 232. The second regions 234, 236 are also displaced partially over the external surface of the vehicle door panel. The second regions 234, 236 are sized to be displaced over the corresponding speaker assembly in the receptacle in the substrate of the vehicle door panel.

[0068] Each second region 234, 236 has a second thread concentration that is less concentrated than the first thread concentration. The second thread concentration is sufficiently thin and/or fine such that the second region 234, 236 is acoustically transparent to permit an acoustic output from the speaker assembly to egress the door panel without audibly obstructing the acoustic output.

[0069] The first door panel knit layers 226, 228 may also include a third region 238, 240 that is sized to be displaced upon, and adjacent to, the corresponding armrest 222, 224. The third regions 238, 240 may be formed from a thread concentration greater than that of the other regions 230, 232, 234, 236 to provide cushioning support to the passenger upon and adjacent to the armrests 222, 224.

[0070] Figure 5 illustrates a vehicle interior 260 according to another embodiment. The vehicle interior 260 includes a pair of vehicle door assemblies 262, 264 attached to a vehicle body 266. Each vehicle door assembly 262, 264 includes a vehicle door panel assembly 268, 270.

[0071] Each vehicle door panel assembly 268, 270 includes a vehicle door panel. Each door panel includes a substrate with a surface that faces an interior of the vehicle and therefore, is an external surface relative to the vehicle door. Each vehicle door panel provides an armrest 272, 274 extending from the external surface to provide a support for an arm of a passenger within the vehicle.

[0072] Each vehicle door panel assembly 268, 270 includes a first door panel knit layer 276, 278 that is manufactured from a digitally knit fabric. Each first door panel knit layer 276, 278 includes a first region 280, 282 of digitally knit fabric that is sized to be displaced partially on the external surface of the of the vehicle door panel. The first region 280, 282 has a first pattern. For the depicted embodiment, the region 280, 282 may have a sufficient concentration to provide comfort padding to the door panel assembly 268, 270.

[0073] Each vehicle door panel assembly 268, 270 includes a second region 284, 286 of digitally knit fabric. The second regions 284, 286 may be interwoven, or digitally knit integrally with the first regions 280, 282. The second regions 284, 286 are also displaced partially over the external surface of the vehicle door panel. The second regions 284, 286 offer a second pattern.

[0074] The first door panel knit layers 276, 278 may also include a third region 288, 290 that are sized to be displaced upon, and adjacent to, the corresponding armrest 272, 274. The third regions 288, 290 may be formed from a thread concentration greater than that of the other regions 280, 282, 284, 286 to provide cushioning support to the passenger upon and adjacent to the armrests 272, 274. The third regions 288, 290 may provide another pattern. [0075] A light source 292, 294 may be provided in each vehicle door panel assembly 268, 270. The light sources 292, 294 may be integrated into the digitally knit panels 276, 278 of each door panel assembly 268, 270 as described with prior embodiments.

[0076] Figure 6 illustrates a vehicle interior 310 according to another embodiment. The vehicle interior 310 includes a vehicle door assembly 312 attached to a vehicle body 314. The vehicle door assembly 312 includes a vehicle door panel assembly 316.

[0077] The vehicle door panel assembly 316 includes a vehicle door panel. The door panel includes a substrate with a surface that faces an interior of the vehicle and therefore, is an external surface relative to the vehicle door. The vehicle door panel provides an armrest 318 extending from the external surface to provide a support for an arm of a passenger within the vehicle.

[0078] The vehicle door panel assembly 316 includes a first door panel knit layer 320 that is manufactured from a digitally knit fabric. The first door panel knit layer 320 includes a first region 322 of digitally knit fabric that is sized to be displaced partially on the external surface of the of the vehicle door panel. The first region 322 has a first pattern. For the depicted embodiment, the region 322 may have a sufficient concentration to provide comfort padding to the door panel assembly 316.

10079] The vehicle door panel assembly 316 includes a second region 324 of digitally knit fabric. The second region 324 may be interwoven, or digitally knit integrally with the first region 322. The second region 324 is also displaced partially over the external surface of the vehicle door panel. The second region 324 offers a second pattern.

[0080] The first door panel knit layer 320 may also include a third region 326 that is sized to be displaced upon, and adjacent to, the corresponding armrest 318. The third region 326 may be formed from a thread concentration greater than that of the other regions 322, 324 to provide cushioning support to the passenger upon and adjacent to the armrest 318. The third region 326 may provide another pattern. [0081] A light source 328 may be provided in the vehicle door panel assembly 316. The light source 328 may be integrated into the digitally knit panel 320 of the door panel assembly 316 as described with prior embodiments.

[0082] Figure 7 illustrates a vehicle door panel assembly 350 according to another embodiment. The vehicle door panel assembly 350 includes a vehicle door panel. The door panel includes a substrate with a surface that faces an interior of the vehicle and therefore, is an external surface relative to the vehicle door. The vehicle door panel provides an armrest 352 extending from the external surface to provide a support for an arm of a passenger within the vehicle.

[0083] The vehicle door panel assembly 350 includes a first door panel knit layer 354 that is manufactured from a digitally knit fabric. The first door panel knit layer 354 includes a first region 356 of digitally knit fabric that is sized to be displaced partially on the external surface of the of the vehicle door panel. The first region 356 has a first pattern. For the depicted embodiment, the region 356 may have a sufficient concentration to provide comfort padding to the door panel assembly 350.

[0084] The vehicle door panel assembly 350 includes a second region 358 of digitally knit fabric. The second region 358 may be interwoven, or digitally knit integrally with the first region 356. The second region 358 is also displaced partially over the external surface of the vehicle door panel. The second region 358 offers a second pattern.

[0085] The first door panel knit layer 354 may also include a third region 360 that is sized to be displaced upon, and adjacent to, the corresponding armrest 352. The third region 360 may be formed from a thread concentration greater than that of the other regions 356, 358 to provide cushioning support to the passenger upon and adjacent to the armrest 352. The third region 360 may provide another pattern.

[0086] A light source 362 may be provided in the vehicle door panel assembly 350. The light source 362 may be integrated into the digitally knit panel 354 of the door panel assembly 350 as described with prior embodiments. [0087] While various embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.

Claims

WHAT IS CLAIMED IS:

1. A panel comprising: a first region of knit fabric with a first thread concentration, the first region sized to be displaced at least partially on a vehicle door panel; and a second region of knit fabric, interrelated with the first region, wherein the second region is sized to be displaced at least partially on the vehicle door panel, wherein the second region comprises a second thread concentration that is less than the first thread concentration.

2. The panel of claim 1 further comprising a join formed by the knit fabric about a periphery of the first region for attachment to the vehicle door panel.

3. The panel of claim 1 further comprising indicia woven or knitted into the second region.

4. A vehicle trim assembly comprising: a vehicle door panel comprising a substrate with an external surface; and the panel according to claim 1, wherein the first region is displaced over the external surface of the substrate.

5. The vehicle trim assembly of claim 4 wherein the vehicle door panel is provided with a receptacle formed in the substrate, sized to support and receive a media device; and wherein the second region of the panel is displaced over the receptacle.

6. The vehicle trim assembly of claim 4 further comprising a cushioning panel displaced at least partially over the substrate and oriented between the substrate and the first region of the panel.

7. The vehicle trim assembly of claim 6 wherein the cushioning panel further comprises a knit fabric.

8. A panel comprising: a first region of knit fabric with a first thread concentration, the first region sized to be displaced at least partially on a vehicle trim member; and a second region of knit fabric, interrelated with the first region, wherein the second region is sized to be displaced at least partially over a media device, wherein the second region comprises a second thread concentration that is less than the first thread concentration.

9. The panel of claim 8 wherein the second region is at least partially acoustically transparent.

10. The panel of claim 8 wherein the second region is at least partially optically transparent.

11. A panel assembly comprising: the panel according to claim 8; and a light source provided in the second region.

12. The panel assembly of claim 11 wherein the light source is woven or knitted into the second region.

13. The panel assembly of claim 11 wherein the light source further comprises a light pipe.

14. A panel assembly comprising: the panel according to claim 8; and a speaker assembly provided in the second region.

15. The panel assembly of claim 14 wherein the speaker assembly comprises an enclosure with an opening; and a speaker oriented in the enclosure facing out of the opening.

16. The panel assembly of claim 15 wherein the opening of the enclosure is covered by the second region of the panel.

17. A vehicle trim assembly comprising: a vehicle trim member comprising a substrate with an external surface; and the panel according to claim 8, wherein the first region is displaced over the external surface of the substrate; wherein the vehicle trim member is provided with a receptacle formed in the substrate, sized to support and receive the media device; and wherein the second region of the panel is displaced over the receptacle.

18. A method comprising: digitally knitting a first region of a panel with a first thread concentration, and sized to be displaced at least partially on a vehicle trim member; and digitally knitting a second region of the panel with a second thread concentration that is less than the first thread concentration, and sized to be displaced at least partially over the vehicle trim member.

19. The method of claim 18 further comprising: knitting the panel to a periphery of the panel without cutting waste from the panel.

20. The method of claim 18 further comprising: knitting the panel from expandable thread; and heating the expandable thread to expand the thread.