Method of making a door trim panel assembly

Details Method of making a door trim panel assembly Method of making a door trim panel assembly

1999-05-25

2001-04-03

Kuhns, Allan R. (Department: 1732)

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

Composite article making

C264S046400

Reexamination Certificate

active

06210613

ABSTRACT:

TECHNICAL FIELD
The present invention relates generally to door trim panels for vehicles and, more particularly, to a method of making a door trim panel assembly for an automotive vehicle.
BACKGROUND OF THE INVENTION
It is known to provide a door trim panel assembly for a vehicle such as an automotive vehicle to present an aesthetically pleasing appearance in an occupant compartment of the automotive vehicle. The door trim panel assembly includes a plurality of separate components with each component having a specific function. The components typically include a door trim substrate, sound absorber, water barrier, insert, armrest, and map pocket closeout and side impact blocks. The components are assembled together and attached to a door trim substrate by several different conventional processes including adhesives, heat staking, sonic welding and fasteners. The door trim panel assembly is then mounted to an inner door panel of a door for the automotive vehicle by suitable means such as fasteners.
Although the above door trim panel assembly has worked well, it is desirable to reduce the number of components and costs associated with the purchase and assembly of the door trim panel assembly. It is also desirable to provide a door trim panel assembly with reduced mass, tooling and equipment per vehicle. Therefore, there is a need in the art to provide an improved method of making a door trim panel assembly for attachment to an inner panel of a door for an automotive vehicle.
SUMMARY OF THE INVENTION
It is, therefore, one object of the present invention to provide a new method of making a door trim panel assembly for an automotive vehicle.
It is another object of the present invention to provide a method of making a door trim panel assembly that incorporates many components into a single component for attachment to an inner panel of a door for an automotive vehicle.
It is yet another object of the present invention to provide a method of making a door trim panel assembly that is multi-functional for attachment to an inner panel of a door for an automotive vehicle.
It is still another object of the present invention to provide a method of making a door trim panel assembly that has fewer components and cost.
It is a further object of the present invention to provide a new method of making a door trim assembly that molds a door trim substrate to a door trim panel.
To achieve the foregoing objects, the present invention is a method of making a door trim panel assembly for attachment to an inner panel of a door for an automotive vehicle. The method includes the steps of placing a door trim substrate into a cavity of a mold and placing at least one component into the cavity against the door trim substrate. The method also includes the steps of filling the cavity with a plastic material. The method further includes the steps of introducing steam into the mold to expand the plastic material to form a carrier and bond the carrier against the at least one component and door trim substrate to form a single door trim panel assembly.
One advantage of the present invention is that an improved method of making a door trim panel assembly is provided for an automotive vehicle. Another advantage of the present invention is that the method of making the door trim panel assembly integrates a plurality of components into a single component. Yet another advantage of the present invention is that the method of making a door trim panel assembly reduces the number of separate components, labor, cost and tooling for the same. Still another advantage of the present invention is that the method of making a door trim panel assembly reduces material, mass and costs. A further advantage of the present invention is that the method of making a door trim panel assembly enhances recycling characteristics of the door trim panel assembly.
Other objects, features and advantages of the present invention will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings.


REFERENCES:
patent: 4420447 (1983-12-01), Nakashima
patent: 4519964 (1985-05-01), Rosen
patent: 5340425 (1994-08-01), Strapazzini
patent: 5411688 (1995-05-01), Morrison et al.
patent: 5928776 (1999-07-01), Shioya et al.
patent: 52-27665 (1977-07-01), None
patent: 55-118837 (1980-09-01), None

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