Door Panel Molding
Door Panel Design Requirement
A great door panel trim design will bring twice result with half effort for trial & mass production and commodification.
1 Interior Styling Design
First according to basic dimensions and shape defined by general layout design, to make and release conception sketch, effect drawing, 3D model and 1:1 tape drawing, and then clay model made for inspection and modification till design idea is well expressed and boundary design conditions fulfilled.
2 Engineering Design
2.1 Determine Design Tasks
To set up a design TOR, for example, by reference from styling and class of bench-marking model and based on own market position and requests like reality sense, texture, color and function, subdividing the tasks. Design source may from marketing positioning consist of marketing forecast, target user, general styling, pricing and grade.
2.2 Door Panel Assembly
Due to different styling, grade and process, there are different trims for assembly like upper trim, switch, handle, armrest, center trim, loudspeaker mesh, body trim, map pocket,etc, which could be connected by uses of ultrasonic welding, heat stake, tapping screws, clips.etc.
2.3 Parts Design Requirement
As design is going on, that process for interior parts including door panel molding process, cost, ergonomics, security, smell, environment protection and so on should be taken in consideration.
2.3.1 Energy Absorb Block
Anti-collision should be considered in design, e.g., to design foam absorbent and door panel stick together, by mating gaps as in followed table:
|
No. |
Items |
Datum |
|
A |
with window glass |
10mm |
|
B |
with sheet metal surface |
5mm |
|
C |
with sheet metal hole |
10mm |
|
D |
with door trim |
2mm |
2.3.2 Inner Handle Bezel
It is a trim mostly made of ABS and processed plating, fixing to the door panel by screw or clip, the boundary requirement is as followed:
|
No. |
Item |
Datum |
Remark |
|
1 |
I/S |
<685mm |
Max.760mm |
|
2 |
From open point |
>480mm |
Min.420mm |
|
3 |
Distance to grip inside edge |
120~140mm |
|
|
4 |
Around gap with mating part (L/R) |
2mm |
|
|
5 |
Around connect with mating part(L/R) |
3mm |
|
|
6 |
Around gap with mating part (U/D) |
1mm |
|
|
7 |
Around connect with mating part(U/D) |
2mm |
|
|
8 |
Connect mating gap |
0 |
|
2.3.3 Electrical Control Button Layout
Ergonomics should be abided by, requiring tidy distribution, easy operation, and proper position, angle and distance.
|
No. |
Item |
Datum |
Remark |
|
1 |
Layout to shoulder turning point |
625~715mm |
|
|
2 |
Distance to grip inside edge |
>140mm |
|
|
3 |
Angle with grip inside edge |
<18° |
|
|
4 |
Front & Back incline angle |
0~10° |
Front up to 10° |
|
5 |
Left & Right incline angle |
0~5° |
Grip surface |
|
6 |
Distance to interior surface |
≥25mm |
|
2.3.4 Armrest Design
Armrest can be made individually by injection molding, slush molding and foam molding or together with door trim panel molding by low pressure injection or compression.
|
No. |
Item |
Datum |
Remark |
|
1 |
Necessary conditions for facing collision in cabinet |
>60mm |
Vertical surface incline within 15° |
|
2 |
Necessary conditions for facing protuberance in cabinet |
R>3 |
See graph above |
|
3 |
Fillet between armrest surface & trim inner side wall |
R>4mm |
Applicable for molding with trim panel |
|
No. |
Item |
Datum |
Remark |
|
1 |
Height above armrest (H) |
Calculated by formula |
Begin from SRP(JM95%) |
|
2 |
Armrest length ( front of SRP) L1 |
170±20mm |
HP(JM50%) |
|
3 |
Armrest length ( front of SRP) L1 |
110±20mm |
|
|
4 |
Front & Back inclination |
5~6° |
|
|
5 |
Left & Right inclination |
0~5° |
|
|
6 |
Width above armrest |
35~70mm |
|
2.3.5 Loudspeaker Mesh Design
|
No. |
Item |
Datum |
Remark |
|
1 |
Mesh area open rate |
40% |
Open shape prior to be circular hole, rib up to styling surface(visible) |
|
2 |
High pitch mesh area open rate |
50% |
|
2.3.6 Handle Design
The function is just for switch and when design the main factors to consider are ergonomics, convenience of operation and space for hand.
|
No. |
Item |
Datum |
Remark |
|
1 |
Handle length |
100~120mm |
|
|
2 |
Handle width |
30~40mm |
|
|
3 |
Box depth |
>35mm |
|
|
4 |
Open type handle width b |
25~35mm |
|
|
5 |
Open type handle depth h |
20~25mm |
|
|
6 |
Box angle |
8° |
Boundary 13° |
|
7 |
Handle rigidity |
6kg/1mm |
|
|
8 |
Handle position |
50~150mm |
|
|
9 |
Handle outer edge R corner |
>0.5mm |
|
|
10 |
Gap between cover & housing |
>0.5mm |
|
3 Engineering Design Output
As all definitions and designs need to be finally transformed to engineering, preliminary designs including BOM, 3D/2D data and technique conditions should be engineering output.
|
BOM Sheet |
3D Data |
2D Data |
Technique Conditions |
|
Items |
Entity Data |
Key Construct Section(gap/segment difference) |
Color |
|
Part Number |
Main Draft Angle |
Control Points Coordinate |
Texture |
|
Assembly Hierarchy |
Slider Direction |
Assembly Drawing |
Glossiness |
|
Material Name |
Parting Line Info. |
2D Drawing |
Surface Treatment |
|
Thickness |
Draft Analysis |
|
Assembly |
|
|
Special Parts Instruction |
|
Utility Conditions |
|
|
Main Locating Hole |
|
Technique Description |
|
|
Modification Info. |
|
|
|
|
3D Breakdown Drawing |
|
|
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