An automobile door is a complex module, which consists of various fixed and movable subassemblies and components. Parameters such as safety, vehicle dynamics, aesthetic and strength are critical while designing the door assembly. Apart from the above, the design of door trim should minimize BSR (buzz squeak and rattle) at vehicle running conditions. Stiffness is one of the key engineering requirements which if not optimized will result in higher BSR levels and failure of the door trim components.
In this study, more importance is given to optimize the stiffness of door trim. As per DVP (design verification and planning) standards of the OEMs, the range of deflection for the plastic trim parts is defined considering the conditions, comfort level and location of use. If stiffness is higher than the requirement, the door trim plastic parts are harder and will violate the quality and safety norms. If it is lower, then trim parts will not meet the functional requirements and safety norms. To achieve the optimized stiffness within the range, various design proposals capturing different structural concepts are constructed and analyzed.