Week 12- Final project

DESIGN OF DOOR TRIM PANEL

AIM:

To create a CAD model adhering to OEM and Tier 1 standards, utilizing the Class A surface, maintaining the specified nominal thickness as per master sections, and implementing an optimized attachment strategy to ensure manufacturability, structural integrity, and design feasibility.

INTRODUCTION:

Automotive interior trim:

It encompasses all the components and materials used to improve the aesthetic appeal, comfort, and functionality of a vehicle's interior. These trims are designed to create a visually cohesive and ergonomic environment while protecting the interior surfaces and providing tactile satisfaction for passengers.

Figure from compo_-sil

Door Trim Panels:

a. Definition and Purpose:

Ø Door trim panels cover the internal framework of a vehicle door, enhancing protection, functionality, and aesthetics.

Ø They provide a comfortable resting surface for passengers and integrate various controls and features.

b. Features:

Ø Comfortable armrests to reduce fatigue.

Ø Housing for power window switches, door handles, and storage pockets.

Ø Integration of speaker grilles for audio systems.

Ø Decorative elements like stitching, ambient lighting, or metallic accents.

c. Materials Used:

Ø Surface Materials: Leather, fabric, vinyl, or molded plastics for durability and aesthetics.

Ø Padding: Foam layers for enhanced comfort and noise reduction.

Ø Decorative Components: Wood veneer, carbon fiber, or metal inserts for a premium look.

d. Functions:

Ø Protects the door’s structural components from damage.

Ø Reduces noise and vibration through insulation layers.

Ø Adds to the overall interior appeal with matching colors and textures.

e. Manufacturing Process:

Ø Injection Molding: Creates the base structure with precision.

Ø Foam Padding Application: Provides comfort and sound insulation.

Ø Surface Wrapping: Covers the panel with leather, vinyl, or fabric for a polished finish.

Ø Assembly: Integrates functional elements like switches and handles.

f. Design Considerations:

Ø Ergonomics: Ensures comfort and easy access to controls.

Ø Durability: Materials resist wear, UV exposure, and temperature changes.

Ø Safety: Designed to minimize sharp edges and improve crash performance.

Ø Aesthetics: Matches the interior’s overall theme and style.

Door trim panels combine functionality with style, ensuring a comfortable and visually appealing passenger experience.

Fig from engineer post website

DESIGN OF DOOR TRIM COMPONENTS:

1. Lower Substrate

2. Map Pocket

3. Door Armrest

4. Bottle Holder

---

1. Lower Substrate

• Function: The foundational structure of the door trim panel, supporting all other components.
• Material: Lightweight and durable plastics like polypropylene (PP) or ABS.
• Design Considerations:
• Provides slots or clips for mounting additional components.
• Ensures structural integrity and noise insulation using foam or gaskets.
• Must align with the door's metal framework for a precise fit.

---

2. Map Pocket

• Function: Storage compartment for small items like maps or documents.
• Material: Molded plastic or thermoplastic elastomers (TPE).
• Design Considerations:
• Integrated seamlessly with the lower substrate.
• Adequate size to securely hold items without interfering with other features.
• Smooth edges for ergonomic access and safety.

---

3. Door Armrest

Ø Function: Provides ergonomic support and comfort for passengers’ arms.

Ø Material: Foam padding covered with leather, fabric, or vinyl.

Ø Design Considerations:

Ø Positioned at an ergonomic height for easy use.

Ø Soft-touch surface with durable materials to withstand wear.

Ø May include integrated features like control switches or storage compartments.

---

4. Bottle Holder

• Function: Secure storage space for water bottles or beverages.
• Material: Molded plastic with rubberized inserts to prevent slipping.
• Design Considerations:
• Positioned for easy accessibility.
• Designed to accommodate standard bottle sizes with anti-slip features.
• Includes drainage holes to manage spills or condensation.

---

These components collectively ensure functionality, comfort, and aesthetic appeal, making the door trim panel an integral part of a vehicle's interior design.

DESIGN GUIDELINES FOR DOOR TRIM PANEL :

General Steps

• View the part in all directions (X, Y, Z).
• Draw a reference line in the relevant direction (X, Y, Z) based on the part.

1. Lower Substrate

1. Create the tooling axis in the Y-direction based on the surface.

2. Create the B-class surface.

3. Create the C-class surface:

o If the edge surface is parallel to the tooling axis, create it on the reference surface.

o Otherwise, create it in the draft direction.

2. Door Arm Rest

1. Create the tooling axis in the Z-direction using the bisecting method.

2. Create the B-class surface.

3. Create the C-class surface:

o If the edge surface is parallel to the tooling axis, create it on the reference surface.

o Otherwise, create it in the draft direction.

3. Map Pocket

1. Create the tooling axis in the Y-direction based on the surface.

2. Create the B-class surface.

3. Create the C-class surface:

o If the edge surface is parallel to the tooling axis, create it on the reference surface.

o Otherwise, create it in the draft direction.

4. Bottle Holder

1. Create the tooling axis in the Y-direction using the bisecting method.

2. Create the B-class surface.

3. Create the C-class surface:

o If the edge surface is parallel to the tooling axis, create it on the reference surface.

o Otherwise, create it in the draft direction.

Draft Analysis

1. Maintain a draft angle of 3° for the door trim panel.

2. Maintain a draft angle of 0.5° for heat stakes and locators.

3. Maintain a draft angle of 1.5° for doghouses.

DRAFT ANALYSIS OF LOWER SUBTRATE:

A CLASS SURFACE

SOLID SURFACE:

DRAFT ANALYSIS OF DOOR ARM REST:

A CLASS SURFACE

SOLID SURFACE

we have to put a side core for this.

DRAFT ANALYSIS OF MAP POCKET:

A CLASS SURFACE

SOLID SURFACE

DRAFT ANALYSIS OF BOTTLE HOLDER:

A CLASS SURFACE

we have to use side core

minimum degree is 0.5

SOLID SURFACE:

DRAFT ANALYSIS OF HEATSTAKES,LOCATOR AND DOGHOUSE:

PIN ATTACHEMENT:

DOOR PANEL ATTACHEMENT:

thus fore completed the door panel design.