Door module with electrical wires and connectors

Abstract

A method of producing components, such as door modules with electrical wires and connectors, is provided. The door module includes a substrate material with conductor tracks arranged therein. Electrical wires, which preferably have connectors at the ends, are placed into the conductor tracks. The substrate is then placed in a mol and filled with foamed plastic to encase the wires and form the door module. The connectors protrude from the door module to permit electrical component to be attached to the connectors.

What is claimed is:  
     
         1 . A method of producing components comprising the steps of: 
 a) providing a substrate having conductor tracks with a connector lying in a component boundary;    b) placing the substrate into a component mold; and    c) filling the component mold with foamed plastic to encase the conductor tracks with a portion of the connector protruding from the component boundary.    
     
     
         2 . The method according to  claim 1 , wherein the substrate is constructed from plastic.  
     
     
         3 . The method according to  claim 1 , further including the step of providing a thermoformed film having a channel for receiving and routing the conductor tracks.  
     
     
         4 . The method according to  claim 3 , wherein the conductor tracks include individual wires.  
     
     
         5 . The method according to  claim 3 , wherein the conductor tracks include a wiring harness having a plurality of individual wires.  
     
     
         6 . The method according to  claim 3 , wherein the conductor tracks include a ribbon having individual wires.  
     
     
         7 . The method according to  claim 1 , further including the step of stamping the conductor tracks onto the substrate.  
     
     
         8 . The method according to  claim 7 , further including the step of connecting electrical components to the conductor tracks.  
     
     
         9 . The method according to  claim 8 , further including the step of supporting the electrical components on the substrate.  
     
     
         10 . The method according to  claim 1 , wherein the foamed plastic is a thermoplastic resin.  
     
     
         11 . The method according to  claim 10 , wherein the foamed plastic is reinforced with glass fibers.  
     
     
         12 . The method according to  claim 1 , wherein the component is a door module.  
     
     
         13 . An interior trim component comprising: 
 a substrate for providing structural support;    conductor tracks supported on the substrate, said conductor tracks including a connector;    a foam cover defining a component boundary, said foam cover formed over said conductor tracks with a portion of said connector protruding from said foam cover.    
     
     
         14 . The component according to  claim 13 , wherein said substrate further includes a thermoformed film having a channel for receiving and routing said conductor tracks.  
     
     
         15 . The component according to  claim 14 , wherein said conductor tracks include individual wires.  
     
     
         16 . The component according to  claim 14 , wherein said conductor tracks include a wiring harness having a plurality of individual wires.  
     
     
         17 . The component according to  claim 14 , wherein said conductor tracks include a ribbon having individual wires.  
     
     
         18 . The component according to  claim 13 , wherein said conductor tracks are stamped into said substrate.