DESC:TECHNICAL FIELD
[001] The present invention relates to a collapsible door trim panel assembly, more particularly a collapsible armrest panel in vehicles which meets ergonomic requirements of an occupant without compromising on safety requirements during an impact.
BACKGROUND
[002] Generally, vehicle doors are constructed with many panels attached to a door frame, including an exterior panel for shielding the occupant compartment from other elements, an inner door panel which provides structural support to the door, and a door trim panel assembly facing the occupant compartment. The door trim panel assembly is usually fastened to the inner door panel appropriately with snap fits, locators, screws, clips and vibration welds and shields the vehicle occupants from internal door components, such as the window, the window regulator, and the door locks. The door trim panel assembly also provides aesthetic qualities to the interior occupant compartment as well as ergonomic features, for example, easily accessible door handles, arm rest, mirror and window controls, and the like.
[003] Crashworthiness of the vehicle is the ability to absorb the crash energy within the structure and transfer as minimum as energies to the occupant and reducing the injury. Some side impacts on the vehicle in a crash involve a vehicle travelling sideways into rigid roadside objects such as trees or poles. Such accidents are severe, and the frequency of death or serious injury is high. It has been observed that vehicle’s interiors are primary source of injuries when occupants interact with them in the event of such accidents. The extent of injuries depends on energy dissipating characteristics of interiors and severity of accidents. Vehicle interior’s energy dissipating characteristic requirements are assessed for the occupant pelvis, abdomen and thorax impacting against door trim panel assembly, thereby assessing the occupant’s protection and impact response provided by the door trim panel assembly, during a side pole impact test. Occupant protection during impact with vehicle interiors e.g., door trim, dashboard, steering wheel etc. has been an important safety parameter in any event of the vehicle crash. Door armrest in the side pole impact collision accident scenarios is most critical region in door trim panel assembly and therefore, deformation behavior and development of the door armrest panel that meets the criteria for side pole impact is critical.
[004] Deformation behavior of door panel assembly at specified impact locations is critical in any side pole impact test. Generally, the door trim panel assembly or the door armrest panel is made of a soft plastic (made from foam) wrapped with soft skin material or the armrest is made completely of a hard plastic. Most of the time when vehicle experiencing side pole impact crash test, it has been observed that the structure of door armrest panel made of hard plastic and its position does not meet the side pole impact crash performance test.
[005] Therefore, there is a need to provide a door trim panel assembly to overcome one or more of the aforementioned problems.
SUMMARY
[006] Accordingly, an aspect of the present invention discloses a collapsible door trim panel assembly comprising a collapsible door armrest panel structure located intermediate of a collapsible mid insert structure and a collapsible door carrier structure; at least a first positive fixation for coupling said collapsible mid insert structure to at least a surface of said collapsible door armrest panel structure, at least said first positive fixation located proximate to said collapsible door armrest panel structure; at least a second positive fixation for coupling said collapsible door carrier structure to at least a surface of said collapsible door armrest panel structure, at least said second positive fixation located proximate to said collapsible door armrest panel structure; a primary singular locator embedded within said collapsible door carrier structure at a surface opposite to at least said first and second positive fixations for fixing said collapsible door armrest panel structure and a plurality of cut-outs located within said collapsible door carrier structure for enabling assembly of at least said first and second positive fixations to absorb energy and distribute a side pole impact force over said collapsible door trim panel assembly.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[007] The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:
[008] Figure 1 illustrates a front view of a collapsible door trim panel assembly and a detailed sectional view of a collapsible door armrest panel according to an aspect of present invention;
[009] Figure 2 illustrates an interior view and an exterior of the collapsible door trim panel assembly, according to an embodiment of the present invention;
[010] Figure 3 illustrates a detailed view of the collapsible door trim panel assembly showing a collapsible door carrier structure having a plurality of cut-outs, and a plurality of positive fixations, according to an embodiment of the present invention;
[011] Figure 4 illustrates a detailed view of the collapsible door trim panel assembly showing a collapsible door carrier structure having a primary singular locator;
[012] Figure 5 illustrates an isometric view of the collapsible door trim panel assembly showing the collapsible door armrest panel structure and a collapsible mid insert structure, according to the embodiment of the present invention; and
[013] Figure 6 illustrates a front view of the collapsible door trim panel with collapsible door armrest panel structure positioned at a predetermined distance from a H-point, according to the present invention.
[014] Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to the other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference signs are used to depict the same or similar elements, features, and structures.

DETAILED DESCRIPTION
[015] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail, a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspects of the invention to the embodiment illustrated. Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention. Embodiments of the present disclosure will now be described with reference to the accompanying drawings. Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to a person skilled in the art. Numerous details are set forth relating to specific components to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
[016] In the following description, for the purpose of explanation, specific details are set forth in order to provide an understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known structures are shown in diagram form to facilitate describing the invention. One skilled in the art will recognize that embodiments of the present invention, some of which are described below, may be incorporated into several applications.
[017] In general, the present invention claims, collapsible door trim panel assembly comprising a collapsible door armrest panel structure located intermediate of a collapsible mid insert structure and a collapsible door carrier structure. At least a first positive fixation and at least a second positive fixation are located proximate to said collapsible door armrest panel structure. A primary singular locator and a plurality of cut-outs are provided for fixing said collapsible door armrest panel structure, and are located within said collapsible door carrier structure for enabling assembly of at least said first and second positive fixations to absorb energy and distribute a side pole impact force over said collapsible door trim panel assembly.
[018] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results. As used in the present disclosure, the forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises,” “comprising,” “including,” “made of” and “having,” are open ended transitional phrases and therefore specify the presence of stated elements, units and/or components, but do not forbid the presence or addition of one or more other elements, components, and/or groups thereof.
[019] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor 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 as defined by the appended claims and their equivalents. The skilled person will be able to devise various structures, shapes of the insulator fender blocker that, although not explicitly described herein, embody the principles of the present invention. All the terms and expressions in the description are only for the purpose of the understanding and nowhere limit the invention. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein may be made without departing from the scope of the invention. Terms plurality, top, bottom, perpendicular, side surfaces, outer surface and the like are used to differentiate between objects having the same terminology and are in no way intended to represent a chronological order, unless where explicitly stated otherwise. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass equivalents thereof. Thus, while particular type of structure, material, size, width, height of H-point, type, thickness of positive fixations, fasteners, number of shell structures, wall thickness, type of deformable shell type mounting structure, it will be appreciated that the embodiments may be manufactured with other design parameters and configurations as well and are not limited to those described herein above. Accordingly, the shape, configuration and materials, are not limited thereto and may be as per operational requirements and nowhere limits the scope of the invention. Terms inner, outer, upper, lower, top, bottom, first, second, at least a surface, primary, and the like are used to differentiate between objects having the same terminology and are in no way intended to represent a chronological order, unless where explicitly stated otherwise. Further, the structure and configuration of the collapsible door trim panel assembly, are provided only for reference and for understating purpose of the invention.
[020] Referring Figures 1-6, a collapsible door trim panel assembly (100), a collapsible door armrest panel structure (110), a first positive fixation (120a), a second positive fixation (120b), a plurality of cut-outs (125), a collapsible door carrier structure (130), a collapsible mid insert structure (140), a primary singular locator (150), protruding heads (155), a plurality of collapsible walls (160), and fasteners (165).
[021] Accordingly, an aspect of the present invention discloses a collapsible door trim panel assembly (100) having a collapsible door armrest panel structure (110). The collapsible door armrest panel structure (110) is made of soft plastic or hard plastic. According to the preferred embodiment, the collapsible door armrest panel structure (110) is made of hard plastic. The collapsible door armrest panel structure (110) is positively attached to the collapsible door trim panel assembly (100) with the aid of positive fixations (120a, 120b) with deformable shell type mounting structure (120a, 120b). The structure is provided to meet a pull strength target test and a side pole impact test. The collapsible door armrest panel structure (110) geometry structure has energy absorbing capability for easy collapse during side impact at arm rest. Conventionally, for fixating the door armrest, primary and secondary locators are required, with a unique deformable shell type mounting structure of the collapsible door armrest panel (110), the present invention eliminates the need for providing secondary locators in the door trim panel assembly (100). The deformable shell type mounting support structure (120a, 120b) of the collapsible door armrest panel structure (110), ensures that gap and flushness of the door armrest and door trim panel is accurately maintained. In the present invention, collapsible door armrest panel structure (110) walls are provided with a lighter thickness (2 mm) at functional area yet meeting 40Kg vertical load requirements. The collapsible door armrest panel structure (110) and the collapsible door trim panel assembly (100) according to the present invention meets the hard door trim meeting side pole impact (ADR 85) test performance. It has been observed that ergonomically, the armrest positioned at the height of Thorax Rib Zone meets the side pole impact (ADR 85) test performance. According to the present invention, the collapsible door armrest panel structure (110) is positioned at a predetermined height of A i.e., 187mm from a H-point at the Thorax Rib Zone. The collapsible door armrest panel structure (110) and the collapsible door trim panel assembly (100) according to the present invention are applicable for both soft and hard plastic arm rest variants of the vehicle meeting ergonomics. A collapsible door carrier structure (130) and a collapsible mid insert structure (140) and are commonized for both soft and hard plastic arm rest variants of the vehicle meeting ergonomics. The collapsible door armrest panel structure (110), the collapsible door carrier structure (130) and the collapsible mid insert structure (140) according to the present invention are made from injection molding. The collapsible door armrest panel structure (110) and the collapsible door trim panel assembly (100) according to the present invention ensures that the impact forces are distributed over a wide area. According to the present invention positive fixations in the form of deformable shell type mounting structure is added to the collapsible door armrest panel structure (110) at desired height and locations to improve fit finish and meet both crash, gap and flushness requirements of the collapsible door trim panel assembly (100).
[022] Referring Figure 1 illustrates a front view of a collapsible door trim panel assembly and a detailed sectional view of a collapsible door armrest panel. Referring Figure 2 illustrates an interior view and an exterior of the collapsible door trim panel assembly. Referring Figures 1-6, illustrates a collapsible door trim panel assembly (100) comprising a collapsible door armrest panel structure (110) located intermediate of a collapsible mid insert structure (140) and a collapsible door carrier structure (130). At least a first positive fixation (120a) is provided for coupling said collapsible mid insert structure (140) to at least a surface of said collapsible door armrest panel structure (110). The first positive fixation (120a) is located proximate to said collapsible door armrest panel structure (110). Further, at least a second positive fixation (120b) is provided for coupling said collapsible door carrier structure (130) to at least a surface of said collapsible door armrest panel structure (110). The second positive fixation (120b) is located proximate to said collapsible door armrest panel structure (110).
[023] Referring Figure 4 illustrates a detailed view of the collapsible door trim panel assembly showing a collapsible door carrier structure having a primary singular locator. The primary singular locator (150) is embedded within said collapsible door carrier structure (130) at a surface opposite to at least said first and second positive fixations (120a, 120b) for fixing said collapsible door armrest panel structure (110).
[024] Referring Figure 3 illustrates a detailed view of the collapsible door trim panel assembly showing a collapsible door carrier structure having a plurality of cut-outs, and a plurality of positive fixations, according to the embodiment of the present invention. The plurality of cut-outs (125) are located within said collapsible door carrier structure (130) for enabling assembly of at least said first and second positive fixations (120a, 120b) to absorb energy and distribute a side pole impact force over said collapsible door trim panel assembly (100).
[025] Referring Figure 5 illustrates an isometric view of the collapsible door trim panel assembly showing the collapsible door armrest panel structure and a collapsible mid insert structure. According to the embodiment of the present invention, each said first positive fixation (120a) is a first deformable shell type mounting support structure and each said second positive fixation (120b) is a second deformable shell type mounting support structure. Each said first and second deformable shell type mounting support structures have heads (155) protruding in a same direction and each said first and second deformable shell type mounting support structures have a plurality of collapsible walls (160) with equal widths and thickness that deform during a side pole impact. The deformable shell type mounting structure (120a, 120b) positively fixed on the collapsible door trim panel assembly (100).
[026] According to the embodiment, each said protruding head (155) of each said first and second deformable shell type mounting support structures have at least a surface for locating at a fastener (165) that includes but not limited to screws.
[027] According to the embodiment, each said first positive fixation (120a) is formed within said collapsible mid insert structure (140) as an injection molded singular structure and each said second positive fixation (120b) is formed within said collapsible door carrier structure (130) as an injection molded singular structure. Each said first positive fixation (120a) is a top mounted structure and each said second positive fixation (120b) is a bottom mounted structure, at least said first and second positive fixations (120a, 120b) are parallel and collinear or at off-set to each other. According to the embodiment, said collapsible door armrest panel (110), said collapsible mid insert structure (140) and said collapsible door carrier structure (130) are flushed with a gap therebetween.
[028] Referring Figure 6 illustrates a front view of the collapsible door trim panel with collapsible door armrest panel structure positioned at a predetermined distance from a H-point, according to the present invention. According to the embodiment, said collapsible door armrest panel (110) is made of a hard plastic and meets requirements of an ADR 85 hard door trim side pole impact standard. The collapsible door armrest panel (110) has a wall thickness of 2 mm and is located at a height of “A” 187mm from a H-point within a thorax rib zone.
[029] There have been described and illustrated herein several embodiments of exemplary indicative implementation of the collapsible door trim panel assembly (100). It will be also apparent to a skilled person that the embodiments described above are specific examples of a single broader invention, which may have greater scope than any of the singular descriptions taught. There may be many alterations made in the description without departing from the scope of the invention. The present invention is simple in construction and design, integrated, cost effective and easy to manufacture and assembly. While particular embodiments of the invention have been described, it is not intended that the invention be limited said configuration disclosed thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise not restrictive to the terminology described herein above. Any discussion of embodiments included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

,CLAIMS:
1. A collapsible door trim panel assembly (100) comprising:
a collapsible door armrest panel structure (110) located intermediate of a collapsible mid insert structure (140) and a collapsible door carrier structure (130);
at least a first positive fixation (120a) for coupling said collapsible mid insert structure (140) to at least a surface of said collapsible door armrest panel structure (110), at least said first positive fixation (120a) located proximate to said collapsible door armrest panel structure (110);
at least a second positive fixation (120b) for coupling said collapsible door carrier structure (130) to at least a surface of said collapsible door armrest panel structure (110), at least said second positive fixation (120b) located proximate to said collapsible door armrest panel structure (110);
a primary singular locator (150) embedded within said collapsible door carrier structure (130) at a surface opposite to at least said first and second positive fixations (120a, 120b) for fixing said collapsible door armrest panel structure (110); and
a plurality of cut-outs (125) located within said collapsible door carrier structure (130) for enabling assembly of at least said first and second positive fixations (120a, 120b) to absorb energy and distribute a side pole impact force.

2. The collapsible door trim panel assembly (100) as claimed in claim 1, wherein each said first positive fixation (120a) is a first deformable shell type mounting support structure and each said second positive fixation (120b) is a second deformable shell type mounting support structure.

3. The collapsible door trim panel assembly (100) as claimed in claim 2, wherein each said first and second deformable shell type mounting support structures have heads (155) protruding in a same direction.

4. The collapsible door trim panel assembly (100) as claimed in claim 2, wherein each said first and second deformable shell type mounting support structures have a plurality of collapsible walls (160) with equal width and thickness that deform during a side pole impact.

5. The collapsible door trim panel assembly (100) as claimed in claim 2, wherein each said protruding head (155) of each said first and second deformable shell type mounting support structures has at least a surface for locating at a fastener (165).

6. The collapsible door trim panel assembly (100) as claimed in claim 1 or 2, wherein each said first positive fixation (120a) is formed within said collapsible mid insert structure (140) as an injection molded singular structure and each said second positive fixation (120b) is formed within said collapsible door carrier structure (130) as an injection molded singular structure.

7. The collapsible door trim panel assembly (100) as claimed in anyone of the preceding claims 1-6, wherein each said first positive fixation (120a) is a top mounted structure and each said second positive fixation (120b) is a bottom mounted structure, at least said first and second positive fixations (120a, 120b) are parallel and collinear or at off-set to each other.

8. The collapsible door trim panel assembly (100) as claimed in anyone of the preceding claims 1-7, wherein said collapsible door armrest panel (110) is made of a hard plastic and meets requirements of an ADR 85 hard door trim side pole impact standard.

9. The collapsible door trim panel assembly (100) as claimed in anyone of the preceding claims 1-8, wherein said collapsible door armrest panel (110) has a wall thickness of 2 mm and is located at a height “A” of 187mm from a H-point within a thorax rib zone.

10. The collapsible door trim panel assembly (100) as claimed in anyone of the preceding claims 1-9, wherein said collapsible door armrest panel (110), said collapsible mid insert structure (140) and said collapsible door carrier structure (130) are flushed with a gap therebetween.