Method of making a door trim assembly

#The present invention relates generally to door trims for vehicles and, more particularly, to a door trim assembly and method of making the same for an automotive vehicle.

#It is known to provide a door trim 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 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 the door trim substrate by several different conventional processes including adhesives, heat staking, and sonic welding. The door trim 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 assembly has worked well, it is desirable to reduce the number of components and cost associated with the purchase and assembly of the door trim assembly. It is also desirable to provide a door trim assembly with reduced mass and tooling per vehicle. Therefore, there is a need in the art to provide an improved door trim assembly and method of making same which includes a single component with multi-functions for attachment to an inner panel of a door for an automotive vehicle.

#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.

#FIG. 1 is a perspective view of a door trim assembly, according to the present invention, illustrated in operational relationship with an automotive vehicle.

#FIG. 2 is an exploded view of the door trim assembly of FIG. 1.

#Referring to the drawings and in particular FIGS. 1 and 2, one embodiment of a door trim assembly 10, according to the present invention, is shown mounted to a door 12 of a vehicle 14 such as an automotive vehicle. It should be appreciated that, in this example, the door trim assembly 10 is mounted to an inner panel 16 of the door 12 as illustrated in FIG. 3. It should also be appreciated that the door trim assembly 10 may be an assembly mounted to other panels of the vehicle 14.

#Referring to FIGS. 1 through 3, the door trim assembly 10 includes a carrier 20 extending longitudinally and vertically and having a generally rectangular shape. The carrier 20 is made of a plastic material such as polypropylene. Preferably, the carrier 20 is made of expanded polypropylene. The carrier 20 is formed by a method, according to the present invention, to be described. The carrier 20 has an inner side 21 and an outer side 22. The outer side 22 is attached to the inner panel 16 of the door 12 by suitable means such as fasteners (not shown).

#The door trim assembly 10 also includes a plurality of components incorporated or integrated into the carrier 20. The components may include an insert 24. The insert 24 extends longitudinally and vertically. The insert 24 is made of a fabric or cloth, vinyl, TPO (Thermal Plastic Polyolefin), leather or carpet material. The insert 24 is bonded to the inner side 21 of the carrier 20 by the plastic material of the carrier 20. It should be appreciated that the insert 24 is a separate piece or component.