Description:FIELD OF INVENTION
[001] The present invention relates to a field of a door assembly of a vehicle. Particularly, the present invention relates to a method for assembling the door trim in the vehicle to provide the door trim assembly with minimal components and simple mounting strategy, thereby decreasing manufacturing cost.

BACKGROUND OF THE INVENTION
[002] An interior door trim is an aesthetic subassembly consisting of different sub-components like speaker, speaker grilles, window control switches, door opening handle, decorative trims etc. Commonly door trim and its sub-component trims are manufactured by injection molding process to allow specific features to be integrated on them. A common method of joining trims permanently is by use of heat stakes. Some trims are joined by snap fitment. Snaps and heat stakes manufacturing is possible by injection molding.
[003] The complete interior door trim subassembly is mounted on the door inner structure using clips and other fasteners so that mountings are not visible to occupants. Injection molding helps to manufacture areas with grooves, cavities and undercuts on the backside of door trim. Some door trims have recesses with screw bosses or threaded inserts to mount them onto door inner structure.
[004] The door trims use fasteners like clips which are either customized to the door design or readily available in the market. These fasteners need features like a housing, clip carrier, recess for inserting clips etc. which need to be designed as per the clip dimensions, thicknesses of panels to be joined and gap between the panels. These features are integrated to door trim during its manufacturing by injection molding, or they are made separately and attached at precise locations onto door trim and door structure. Injection molding of door trim with integrated features leads to complicated molds and increased costs. Attaching these features separately needs jigs, fixtures for locating and special tools and equipment for attachment. All this adds to the design and manufacturing cost, and makes the door trim a complex assembly.
[005] Door trim often needs to be removed for servicing components like speakers, wires etc. Sometimes door trims are removed for interior customization. Fasteners like clips get damaged or need replacement after a few cycles of unmounting. They are unable to withstand multiple cycles of unmounting.
[006] Some door trims have depressions where screws or bolts are tightened. These depressions do not look aesthetic and are covered using cover trims which snap into the holes. Snaps are small features which can be manufactured by injection molding or additive manufacturing. Such snap-fit cover trims increase overall part count and add to manufacturing cost. Our door trim has 2 bolts at the bottom side which are not visible during normal door operations and eliminates the need of any cover trim.
[007] Door components and accessories are mounted on door trim panel using processes like heat stakes or ultrasonic welding which makes the door trim a subassembly of multiple components. Our door trim panel is a simple one-mold part, with minimal components attached to it directly: speaker bracket with speaker unit, speaker grill and different L-brackets for mounting.
[008] In several prior existing examples, the complete door trim is a complex sub-assembly of small parts like armrest cover, armrest cushion, switch and switch bezel, door handle, map pockets etc. Different trims in different areas have different colors, textures and covering skin. Some decorative trims are attached to the door trim using heat stakes or are mounted by snap fits to improve aesthetic appearance. This makes customization of door trim complex and expensive process.
[009] There are several prior art documents that disclose different designs of clips proposed for attachment of door trim onto door inner body. But they require special housing and retaining features. Some door trims use studs and nuts for panel attachments, coupled with heat caulking method.
[0010] A patent application US20050052050A1 titled “Automobile door structure” discloses an automobile door structure is formed by joining an outer panel and inner panel to each other. The inner panel has an opening portion. A resin-made carrier plate which supports accessories of a door is attached to the inner panel so as to cover the opening portion. An upper trim portion extending to cover a vehicle compartment side of a belt portion of the door is integrally molded on an upper portion of the carrier plate. A trim plate is attached to a portion of the carrier plate which is below the upper trim portion so as to cover the vehicle compartment side of the carrier plate.
[0011] Another patent application US5170586A titled “Trim for a vehicle” discloses a trim for a vehicle having a trim body and a weather strip which is in contact with an inner surface of a window glass in an outer side of an upper end of the trim body. A flange part projecting outwardly and extending along the upper end of the trim body is formed at the trim body. A plurality of boss parts are formed integrally with the trim body under the flange part with proper intervals between the boss parts along the upper end of the trim body. The weather strip is fixed to the boss parts by bolt members, wherein an inner surface of the weather strip contacts with outer ends of the flange part and the boss parts.
[0012] Yet another patent application KR102463200B1 titled “Door for vehicle” discloses a door for a vehicle, a first door module forming a door frame; a second door module coupled to the first door module and forming a door window; the second door module is made of a relatively lightweight material compared to the first door module; The second door module is provided with an impact pad, so that it is possible to reduce the weight and cost of the door of the vehicle.
[0013] One another patent application US5345721A titled “Hook and pin fastener assembly for a door trim panel” discloses a hook and pin fastener assembly for connecting and reliably locating a molded door trim panel to an aperture inner door panel of a motor vehicle without the need for conventional fasteners. A pair of conventional hooks are molded into the upper and lower portions of a molded door trim panel, and a locator pin is molded into a center portion of the molded door trim panel. The pair of hooks extend through corresponding apertures in the inner door panel and slidably engage the inner door panel so that movement of the upper and lower portions of the molded door trim panel is restricted in the lateral direction. The locator pin has a main body and a free end, wherein the free end is integral with and extending from the main body. The free end is slightly smaller than a locating aperture in the inner door panel, and the main body is larger than the locating aperture. The free end of the locator pin extends through the locating aperture to locate and restrict movement of the molded door trim panel in the vertical and fore and aft directions. The main body of the locator pin engages the inner door panel and is interposed between the molded door trim panel and the inner door panel to locate and prevent movement of the molded door trim panel in the lateral direction

[0014] Another patent application JPH06270673A titled “clip attaching seat” discloses a clip attaching seat adapted to beset on the rear side of a core in an interior part, has a two stage structure having a lower stage part and an upper stage part which are connected together by means of a stepped part having a weakened rigidity so as to effectively absorb a shock transmitted to the passenger by an energy loss caused by breaking of the stepped part and an energy loss caused by sliding of the upper stage part into the lower stage part.

[0015] In order to overcome the problem associated with state of arts, there is a need for the development of a modular door trim assembly with simplified mounting strategy that eliminates the need of special mounting features integrated onto door trim like clip housings with undercuts, screw bosses, heat stakes, hooks, snaps etc. which significantly reduces cost of manufacturing with the advantage of easy and cost effective customization.

OBJECTIVE OF THE INVENTION

[0016] The primary objective of the present invention is to provide a door assembly in a vehicle.
[0017] Another objective of the present invention is to provide a modular interior door trim subassembly with minimal components.
[0018] Yet another objective of the present invention is to provide a mounting strategy for door trim subassembly which eliminates need of mounting features like screw bosses, threaded inserts, clip housings.
[0019] Another objective of the present invention is to provide mounting strategy that enables door trim panel to be manufactured as a one mould part without any undercuts or complicated housing features for fasteners.
[0020] Another objective of the present invention is to reduce cost of manufacturing the door trim subassembly of the vehicle.
[0021] Yet another objective of the present invention is to ensure that door trim subassembly is mounted firmly while meeting aesthetic requirements.
[0022] Another objective of the present invention is to enables low-cost interior customization by providing options of door trim panels in multiple colors and textures.
[0023] Yet another objective of the present invention is to provide a modular design and simple mounting strategy that enables quick mounting of door trim subassembly without use of any special tools.
[0024] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

BRIEF DESCRIPTION OF DRAWINGS
[0025] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0026] Figure 1 illustrates an exploded view of a vehicle door assembly with different parts;
[0027] Figure 2 illustrates a front view of a second door module and components in the second door module;
[0028] Figure 3a illustrates exploded view of the modular door trim subassembly;
[0029] Figure 3b illustrates front view and back view of the modular door trim subassembly with assembled parts.
[0030] Figure 4 illustrates perspective view of a first set of L-bracket on top door flange;
[0031] Figure 5 illustrates perspective view of second set of L-bracket with magnets and positioning hole;
[0032] Figure 6 illustrates perspective view of a complimentary plate with cylindrical pin;
[0033] Figure 7 illustrates perspective view of a third set of L-bracket with nut welded;
[0034] Figure 8a illustrates top view of the magnetic L-bracket mounted on the door trim subassembly;
[0035] Figure 8b illustrates top view of the complimentary plate mounted on the second door module;
[0036] Figure 9a illustrates front view of the modular door trim subassembly mounted onto the second door module with simplified section view along section A-A;;
[0037] Figure 9b illustrates section view where the first set of L-bracket is inserted into a weather strip and the door trim subassembly is held at small angle 3-7 degree;
[0038] Figure 10 illustrates an enlarged view of area (200) with upper part of the door trim subassembly where L-bracket inserts into weather strip;
[0039] Figure 11 illustrates an enlarged view of area 300 with bottom of the door trim subassembly where bolts are tightened;
[0040] Figure 12 illustrates top view of area 400, where second set of L-bracket pairs with the complimentary plate attached on second door module.

SUMMARY OF THE INVENTION
[0041] The present invention relates to a door assembly of a vehicle. The vehicle door assembly comprises of a first door module forming an exterior door panel, a second door module attached to the first door module, comprising a housing body for a door frame, a weather strip positioned at upper edge of the second door module, complimentary plates and a set of L-brackets with welded nuts; and a door trim subassembly attached to the second door module through three different sets of L-brackets, magnets, complimentary plates and bolts. The door trim subassembly comprises a door trim panel, two different sets of L-brackets attached to the top and side flanges of door trim panel, bolting holes at the bottom flange of door trim panel for bolting with third set of L-brackets present on second door module, a speaker mounting bracket attached at the backside of door trim panel, a speaker grill attached on the front of door trim panel, and a cutout for routing wires from second door module to the armrest.
[0042] Further, the first set of L-brackets is attached on the top flange of door trim panel which secures the door trim subassembly onto the weather strip of second door module. Furthermore, the second set of L-brackets are attached to the side flanges of the door trim panel, comprising a magnet attached to each of the second set of L-brackets through a screw or adhesive or by any other joining methods and a positioning hole adjacent to the magnet. Each magnet attaches to a corresponding complimentary plate present on second door module. Complimentary plate comprises a cylindrical pin which pairs with positioning hole on second set of L-brackets to enable lateral positioning of door trim subassembly on second door module. Additionally, the third set of L-brackets attached at the bottom portion of the second door module having a hole and a nut aligned with the hole welded on the third set of L-brackets.

[0043] The present invention provides a modular design of the door trim subassembly and does not need complicated mounting features which reduces cost. The door trim panel is capable of being manufactured by thermoforming, thereby enabling low-cost interior customization, although other manufacturing processes like injection molding can also be used.

[0044] The present invention also provides a method for assembling a door trim subassembly in a vehicle. The method comprises steps of: attaching a speaker wire anchored on a second door module to the speaker on door trim subassembly and routing an armrest wiring through a cutout on the door trim subassembly, inserting a first set of L-brackets into a weather strip such that the door trim subassembly is free to move sideways in lateral direction, holding the door trim subassembly at small angle of about 3 to 7 degrees with respect to the second door module, and adjusting the lateral position for aligning a positioning hole on a second set of L-brackets with a cylindrical pin attached on a complimentary plate, releasing the angular position and guiding the door trim subassembly towards the second door module for attaching a magnet to the complimentary plate, bolting the door trim subassembly to a third set of L-brackets comprising welded nuts positioned such that the bolting holes on bottom flange of the door trim subassembly automatically align with nuts on the third set of L-brackets upon attachment of the magnet with the complimentary plate, and mounting an armrest sub assembly after mounting the door trim subassembly .

DETAILED DESCRIPTION OF INVENTION

[0045] The following detailed description and embodiments set forth herein below are merely exemplary out of the wide variety and arrangement of instructions which can be employed with the present invention. The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. All the features disclosed in this specification may be replaced by similar other or alternative features performing similar or same or equivalent purposes. Thus, unless expressly stated otherwise, they all are within the scope of the present invention.

[0046] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0047] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0048] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0049] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof.

[0050] Accordingly, the present invention relates to a field of a door assembly of a vehicle. Particularly, the present invention relates to a method for assembling the door trim subassembly in the vehicle to provide a modular design of door trim subassembly with minimal components and simple mounting strategy, thereby decreasing manufacturing cost and enabling easy customization.

[0051] In an embodiment of the present disclosure, a vehicle door assembly (100) comprises of a first door module (102), a second door module (104), and a door trim subassembly (114) . Further, the second door module (104) comprises of a housing body for attaching a door frame, a weather strip (106) positioned at upper edge of the second door module (104), complimentary plates (122) and a set of L-bracket (112) with welded nuts (140). Furthermore, the door trim subassembly (114) has a cutout (134) for routing wire from second door module to an armrest (136). The second door module (104) may provide housing for window glass, window motor, window seals and wiring.

[0052] The present invention is a novel mounting strategy for mounting a door trim subassembly (114) onto a second door module (104) of a vehicle. The mounting strategy includes 3 types of L-brackets (108, 110, 112), magnet (118), complimentary plate (122) and bolts. The mounting strategy is easily repeatable and does not need any special tools or jigs and fixtures which significantly reduces complexity in the assembling process. The modular door trim subassembly (114) is presented with a simple door trim panel containing minimal subcomponents and eliminating the need of attachment features like heat stakes or snap fits.

[0053] In an embodiment, the door assembly of vehicle (100 ) is provided that eliminates the need of special mounting features onto door trim panel like clip housings with undercuts, screw bosses, heat stakes, hooks, snaps etc. The door trim panel (144) of the present invention is a simple one mold part without complicated mounting features. The door trim panel (144) is manufactured by any general manufacturing process like injection molding, thermoforming, etc. The thermoforming process gives two advantages like the cost of thermoforming on a part is less than that of injection molding and a thermoformed part’s color and texture is changed by simply changing the raw material sheet. This enables low cost interior customization by providing door trim panel (144) options in different colors and textures.
[0054] Figure 1-12 of the present invention illustrates the complete assembly of the present invention including the following components:
[0055] A) First door module (102): A first door module (102) forms an exterior door panel. Figure 1 illustrates a vehicle door assembly (100) with different parts showing the first door module (102). The first door module (102) is attached on the outer side of a second door module (104) while a door trim subassembly (114) is attached on the second door module’s (104) inner side which faces towards the passengers.
[0056] B) Second door module (104): A second door module (104) is attached to the first door module (102) as illustrated in Figure 2. The second door module (104) is the base to which the first door module (102) and the door trim subassembly (114) are attached. The second door module (104) comprises of a housing body for a door frame and also houses window glass, window motor, window seals, wiring etc., a weather strip (106) positioned at upper edge of the second door module (104),complimentary plates (122) and a set of L-brackets (112) with welded nuts (140), positioned at bottom of second door module. The second door module (104) provides anchor points for wire harness powering window motor, window switch, speakers etc.
[0057] The present invention utilizes different types of L-brackets (108, 110, 112) that enables multiple cycles of easy mounting and unmounting of door trim subassembly(114), making the door trim subassembly (114) a modular part with minimal components, as shown in figure 3a and 3b.
[0058] Weather strip (106) is attached on the upper portion of the second door module (104). The weather strip (106) secures the top portion of the door trim subassembly (114) to the second door module (104).
[0059] The first set of L-brackets (108) as shown in Figure 4 , is attached on the top flange of door trim panel (144) using industrial strength adhesive, which secures the door trim subassembly (114) onto the weather strip (106) positioned on second door module. Further, the second set of L-brackets (110) as shown in Figure 5, comprises of a magnet (118) attached to each of the second set of L-brackets (110) through a screw or adhesive or by any other joining methods and a positioning hole (120) provided adjacent to the magnet (118). Each of the second set of L-bracket is paired with a corresponding complimentary plate (122) attached on the second door module. The complimentary plate comprises a cylindrical pin (124), as illustrated in figure 6. Furthermore, the third set of L-brackets (112) is attached at the bottom portion of the second door module (104) having a hole and a nut (140) aligned with the hole welded on the third set of L-brackets (112) as illustrated in Figure 7 .
[0060] Figure 8a and 8b illustrate the top views of second set of L-brackets (110) attached to the side flanges of the door trim panel (144) and the corresponding complimentary plate (122) mounted on the second door module (104) respectively. The positioning hole (120) on L-bracket (110) pairs with the cylindrical pin (124) on complimentary plate.
[0061] In an exemplary embodiment of the present invention, the magnet (118) is made of neodymium. The pull strength of the magnet should be at least 5kg.
[0062] In another exemplary embodiment, the complimentary plate (122) is made with material selected from mild steel, alloy steel, carbon steel and galvanized steel to attract the magnet (118).
[0063] In another exemplary embodiment, the L-brackets and complimentary plates are attached to the panel/module by using industrial strength adhesive, fasteners, rivets etc.
[0064] C) Door Trim Subassembly (114): A door trim subassembly (114) is attached to the second door module (104) through three different sets of L-brackets (108,110,112), magnets, complimentary plates and bolts. The door trim subassembly (114) comprises a door trim panel (144), two different sets of L-brackets (108,110) attached to the top and side flanges of door trim panel, bolting holes (142) at the bottom flange of door trim panel for bolting with third set of L-brackets (112) present on second door module (104), a speaker mounting bracket (116) attached at the backside of door trim panel (144), a speaker grill (138) attached on the front of door trim panel (144), and a cutout (134) for routing wires (130) from second door module (104) to the armrest (136). The door trim subassembly (114) is a major contributor to interior cabin aesthetics. Wires (130) going to the door trim subassembly (114) include speaker wire and wires for window switches which are located in an armrest (136). These wires are anchored on second door module (104) and then routed to their respective components. Wire to armrest (136) is routed through a cutout (134) on the door trim subassembly (114). It is important to mount the door trim subassembly (114) strongly onto the second door module (104), while ensuring that the mounts are hidden from passengers and do not hinder the overall cabin aesthetics. The present invention showcases a modular design of the door trim subassembly (114) with minimal components and a unique mounting strategy which eliminates need of many complicated mounting features.
[0065] In an embodiment, during mounting of the door trim subassembly (114), the magnets (118) on the second set of L-brackets (110) on the door trim subassembly (114) stick to their corresponding complimentary plates (122) fixed onto the second door module (104), thus attaching the door trim subassembly (114) to the second door module (104). Simultaneously the positioning hole (120) on second set of L-bracket (110) engages with cylindrical pin (124) on complimentary plate (122) to help in lateral positioning of door trim subassembly (114) with respect to the second door module (104). When magnets attach to complimentary plates, the bolting holes (142) on bottom flange of the door trim subassembly (114) align with the nuts (140) welded on third set of L-bracket (112) and then bolt is tightened through the door trim subassembly (114) and the nuts (140) welded on the third set of L-brackets ( 112).
[0066] In an embodiment, the diameter of positioning hole (120) on the second set of L-brackets (110) is same as the diameter of the cylindrical pin (124) on complimentary plate (122). The elongation of positioning holes in vertical direction prevents interference between the second set of L-brackets (110) and the cylindrical pin (124) when the door trim subassembly (114) is guided towards the second door module (104). After the magnet (118) sticks, the cylindrical pin (124) is arrested inside positioning hole (120) and restricts any lateral movement of the door trim subassembly (114). The pairing of the cylindrical pin (124) and positioning holes (120) on the second set of L-brackets (110), help in correct positioning of the door trim subassembly (114) with respect to the second door module (104) in lateral direction, without need of any positioning jigs and fixtures.
[0067] D) Speaker mounting bracket (116): A speaker mounting bracket (116) is attached on the backside of the door trim panel (144) using permanent adhesive as illustrated in Figure 3a and 3b.
[0068] In an exemplary embodiment, the speaker mounting bracket (116) may be attached by other methods like ultrasonic welding or visible fasteners like rivets or screws. The speaker (132) unit is screwed to the back of the speaker mounting bracket (116). A speaker grill (138) made up of stamped sheet metal is attached from the front side of the door trim panel (144), which hides any ultrasonic welds, or any rivets or fasteners used to attach the speaker mounting bracket (116) on the door trim panel (144). The speaker grill (138) has metal protrusions which insert into their receiving holes on the door trim panel (144). The protrusions are bent to secure the speaker grill (138) firmly on the door trim panel (144).
[0069] In an embodiment, the present invention also provides a method for assembling a door trim subassembly (114) onto the second door module (104) of a vehicle, comprising the following steps:-

? attaching a speaker wire (130) anchored on a second door module (104) to the speaker (132) attached on a door trim subassembly (114) and routing an armrest wiring through a cutout (134) on the door trim subassembly (114);
? inserting a first set of L-brackets (108) into a weather strip (106) such that the door trim subassembly (114) is free to move sideways in lateral direction;
? holding the door trim subassembly (114) at small angle of about 3 to 7 degrees with respect to the second door module (104), where door trim subassembly (114) is pivoted about the L-bracket (108) inserted into weather strip (106), and adjusting the lateral position of door trim subassembly (114) for aligning a positioning hole (120) on a second set of L-brackets (110) with a cylindrical pin (124) attached on a complimentary plate (122);
? releasing the angular position and guiding the door trim subassembly (114) towards the second door module (104), during which the positioning hole (120) on second set of L-bracket (110) glides through the cylindrical pin (124) on complimentary plate (122), until magnet (118) attaches to the flat surface of complimentary plate (122);
? bolting the bottom flange of door trim subassembly (114) to a third set of L-brackets (112) attached to the bottom of second door module, where the bolting holes (142) on bottom flange of the door trim subassembly (114) automatically align with nuts (140) on the third set of L-brackets (112) upon attachment of the magnet (118); and
? mounting an armrest sub assembly (136) after mounting the door trim subassembly (114).

[0070] In an embodiment the advantages of the present invention are enlisted herein:
o The present invention provides a modular design of a door trim subassembly with minimal components.
o The present invention provides a mounting strategy for door trim subassembly which eliminates need of mounting features like screw bosses, threaded inserts, clip housings.
o The present invention provides mounting strategy that enables door trim panel to be manufactured as a one mould part without any undercuts or complicated housing features for fasteners. This allows manufacturing the door trim panel by the process of thermoforming that is a cheaper option.
o The present invention reduces cost of manufacturing the door trim panel of the vehicle.
o The present invention ensures that door trim subassembly is mounted firmly while meeting aesthetic requirements.
o The present invention enables use of thermoforming for manufacturing the door trim panel, thereby enabling its color and texture to be changed by changing the raw material sheet, resulting in low-cost interior customization.
o The present invention provides a modular design and simple mounting strategy that enables quick mounting of door trim subassembly without use of any special tools, thereby assisting in easy interior customization.
o The present invention provides a mounting strategy which gives provision of positioning the door trim subassembly onto the second door module without additional jigs and fixtures.

[0071] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
, Claims:WE CLAIM:
1. A door assembly of a vehicle (100), comprising:
• a first door module (102) forming an exterior door panel;
• a second door module (104) attached to the first door module (102), comprising a housing body for attaching a door frame, a weather strip (106) positioned at an upper edge of the second door module (104), complimentary plates (122) and a third set of L-brackets (112) with welded nuts (140);
• a door trim subassembly (114) attached to the second door module (104) through three different sets of L-brackets (108, 110, 112), magnets (118), complimentary plates (122) and bolts, wherein the door trim subassembly (114) comprises:
o a door trim panel (144),
o a first set of L-brackets (108) attached to a top flange of the door trim panel (144);
o a second set of L brackets (110) attached to side flanges of the door trim panel (144), each comprising a magnet (118) and a positioning hole;
o a plurality of bolting holes (142) at the bottom flange of door trim panel (144) for bolting with the third set of L-brackets (112);
o a speaker mounting bracket (116) attached at a backside of the door trim panel (144);
o a speaker grill (138) attached on a front of the door trim panel (144); and
o a cutout (134) for routing wires (130) from second door module (104) to the armrest (136).
2. The door assembly (100) as claimed in claim 1, wherein the second door module (104) provides housing for a door frame, window glass, window motor, window seals and wiring.
3. The door assembly (100) as claimed in claim 1, wherein the door trim panel (144) of a door trim subassembly (114) has no undercuts and is manufactured by a thermoforming process.
4. The door assembly (100) as claimed in claim 1, wherein the first set of L-brackets (108) are attached on the top flange of the door trim subassembly (114) using permanent adhesive, and is inserted into weather strip (106) which secures the upper portion of door trim subassembly (114) onto the weather strip (106) of second door module (104).
5. The door assembly (100) as claimed in claim 1, wherein the door assembly (100) comprising:
a. each magnet (118) on the second set of L-brackets (110) is paired with a corresponding complimentary plate (122) attached on the second door module (104);
b. each complimentary plate (122) comprises a flat surface for attachment of the magnet and a cylindrical pin (124) that pairs with the positioning hole (120) on the second set of L-brackets (110); and
c. the cylindrical pin (124) and positioning hole (120) enable positioning of the door trim subassembly on the second door module (104) in a lateral direction.
6. The door assembly (100) as claimed in claim 5, wherein the magnet (118) is made of neodymium.
7. The door assembly (100) as claimed in claim 5, wherein the complimentary plate (122) is made with material selected from ferromagnetic materials like mild steel, alloy steel, carbon steel and galvanized steel.
8. The door assembly (100) as claimed in claim 1, wherein the third set of L-brackets (112) attached at a bottom portion of the second door module (104) using permanent adhesive, rivets or the like, and comprises a hole aligned with a welded nut (140).
9. A method for assembling the door trim subassembly (114) onto the second door module (104) of a vehicle, comprising:
a) attaching a speaker wire (130) anchored on a second door module (104) to the speaker (132) attached on a door trim subassembly (114) and routing an armrest (136) wiring through a cutout (134) on the door trim subassembly (114);
b) inserting a first set of L-brackets (108) into a weather strip (106) such that the door trim subassembly (114) is free to move sideways in lateral direction;
c) holding the door trim subassembly (114) at small angle of about 3 to 7 degrees with respect to the second door module (104), where door trim subassembly (114) is pivoted about the L-bracket inserted into weather strip (106), and adjusting the lateral position of door trim subassembly (114) for aligning a positioning hole (120) on a second set of L-brackets (110) with a cylindrical pin (124) attached on a complimentary plate (122);
d) releasing the angular position and guiding the door trim subassembly (114) towards the second door module (104) during which the positioning hole(120) on second set of L-bracket (110) glides through the cylindrical pin (124) on complimentary plate (122) until magnet (118) attaches to the flat surface of complimentary plate (122);
e) bolting the bottom flange of door trim subassembly (114) to a third set of L-brackets (112) attached to the bottom of second door module (104), where the bolting holes (142) on bottom flange of door trim subassembly (114) automatically align with nuts (140) on the third set of L-brackets (112) upon attachment of the magnet (118); and
f) mounting an armrest sub assembly ( 136) after mounting the door trim subassembly (114).
10. The method as claimed in claim 9, wherein the magnet (118) face towards the second door module (104) where the complimentary plate (122) is attached.