Modular vehicle door and method of assembly

• US 20030096510A1
• Filed: 12/16/2002
• Published: 05/22/2003
• Est. Priority Date: 12/09/1999
• Status: Active Grant

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: Lear Corporation
• Inventors: Duff, Lewis B., Hoisington, Eric, Drew, Iris, Ventimiglia, James F., Morrison, Gerald O.
• Granted Patent: US 6,823,628 B2
• Time in Patent Office: Days
• US Class Current: 439/34
• CPC Class Codes: B60J 5/0416 Assembly panels to be installed in doors as a module with components, e.g. lock or window lifter, attached thereto
• CPC Class Codes: E05F 11/483 by cables
• CPC Class Codes: E05Y 2600/50 Mounting methods; Positioning
• CPC Class Codes: E05Y 2800/692 Temporary use, e.g. removable tools
• CPC Class Codes: E05Y 2900/55 Windows
• CPC Class Codes: Y10T 29/4984 Retaining clearance for motion between assembled parts
• CPC Class Codes: Y10T 29/49902 by manipulating aligning means
• CPC Class Codes: Y10T 29/53974 having means to permit support movement while work is thereon

Abstract

A modular door assembly for a vehicle is disclosed having a door frame and a carrier secured to the door frame. A door entry system is secured to the carrier to operate the vehicle door. A window carrier assembly includes a window regulator and motor secured to the carrier. A window pane is attached to the window regulator and is adjustable relative to the carrier in the vehicle door frame. A method of assembling the modular door assembly for a vehicle is also disclosed.

Claims

1. A modular door assembly for a vehicle comprising:

a vehicle door frame having an inner surface and an outer surface;

a carrier having an elongate body secured to the inner surface of the vehicle door frame providing structural support to the vehicle door frame;

a door entry system mounted to the carrier, the door entry system including a lock assembly, a latch assembly in communication with the lock assembly, an outer handle disposed in the outer surface of the vehicle door frame connected to the lock assembly and an inner handle mounted to the carrier connected to the latch assembly by at least one cable extending through the carrier;

a window carrier assembly mounted to the carrier, the window carrier assembly including a window regulator secured to the carrier having a pair of spaced apart rails, a support arm extending between the rails and a motor in communication with the support arm to adjust the position of the support arm on the spaced apart rails; and

a window pane secured to the support arm of the window regulator which is adjustable in a channel in the door frame.

2. The modular door assembly of claim 1 further comprising a seal extending about the outer periphery of the elongate body of the carrier placed between the door frame and the carrier to inhibit the introduction of foreign materials into a passenger compartment of a vehicle.

3. The modular door assembly of claim 1 wherein the inner door handle and latch assembly are operatively connected by a pair of cables extending through an aperture in the elongate body of the carrier.

4. The modular door assembly of claim 3 wherein at least one grommet extends about the outer periphery of each of the pair of cables to seal the aperture in the elongate body of the carrier.

5. The modular door assembly of claim 1 wherein the at least one cable is a quick-connect cable having a first end attached to the inside door handle and a second end attached to the latch assembly.

6. The modular door assembly of claim 1 wherein the window regulator further comprises a pair of vertically spaced apart rails mounted to the elongate body of the carrier and a generally horizontal support arm extending between the vertically spaced apart rails.

7. The modular door assembly of claim 1 further comprising vehicle components disposed on the elongate body of the carrier extending into the passenger compartment of the vehicle.

8. The modular door assembly of claim 7 wherein the vehicle components mounted to the carrier include a speaker assembly mounted in an aperture formed in the elongate body of the carrier and switches which operatively control the door entry system.

9. The modular door assembly of claim 1 further comprising a wiring harness assembly extending through an aperture in the elongate body of the carrier to connect the motor of window carrier assembly and the vehicle components to an electrical system of the vehicle.

10. A module for a vehicle door assembly comprising:

a carrier formed of an elongate body having an outer surface and an inner surface;

a door entry system mounted to the elongate body, the door entry system including a latch assembly mounted adjacent a rear portion of the elongate body, a lock assembly in communication with and extending from the latch assembly adjacent the outer surface of the carrier, an outer door handle connected to the lock assembly, an inner door handle secured to the inner surface of the elongate body and at least one cable extending through at least one aperture in the elongate body of the carrier to operatively connect the inner door handle and the lock assembly;

a window carrier assembly mounted to the elongate body of the carrier, the window carrier assembly including a window regulator having a pair of spaced apart generally vertical rails mounted to the outer surface of the carrier, a generally horizontal support arm extending between the rails and a motor operatively connected to the support arm;

vehicle components mounted to apertures formed in the vehicle carrier extending toward a passenger compartment of the vehicle;

a wiring harness assembly extending through apertures in the elongate body to connect the motor of window carrier assembly and vehicle components mounted on the carrier to an electrical system of the vehicle; and

a window pane mounted to the generally horizontal support arm of the window carrier assembly vertically adjustable relative to the elongate body of the carrier.

11. The vehicle door module of claim 10 wherein a grommet extends about the outer periphery of the at least one cable operatively connecting the inner handle and the latch assembly to seal the aperture in the elongate body of the carrier.

12. The vehicle door module of claim 10 wherein the at least one cable is a quick-connect cable having a first end attached to the inside door handle and a second end attached to the latch assembly.

13. The vehicle door module of claim 10 wherein a grommet extends about the outer periphery of the wiring harness assembly to seal the aperture in the elongate body of the carrier.

15. The vehicle door module of claim 10 further comprising a seal extending about the outer periphery of the elongate body to inhibit the introduction of foreign materials into a passenger compartment of a vehicle.

16. The vehicle door module of claim 10 wherein the elongate body of the carrier is a one-piece stamped metal structure.

17. The vehicle door module of claim 10 wherein the elongate body of the carrier is formed from a polymeric material as a one-piece structure.

18. A method of assembling a modular vehicle door, the method comprising the steps of:

providing a vehicle door frame having inner surface and an outer surface;

placing the outer surface of the vehicle door frame on a substantially horizontal planar surface;

providing a carrier having an elongate body having an inner surface and an outer surface, the carrier including a door entry system and a window carrier assembly secured to the elongate body of the carrier;

securing a window pane to a support arm of the window carrier assembly to operatively connect the window pane and carrier;

engaging the window pane and carrier with a loading device;

positioning the window pane and carrier parallel to and adjacent the inner surface of the door frame;

inserting the window pane into a cavity formed by the inner surface of the door frame;

positioning the window pane into a channel formed in the door frame to receive the window pane;

aligning the carrier to the door frame; and

securing the carrier to the inner surface of the door frame.

14. The vehicle door module of claim 19 wherein the vehicle components mounted to the carrier include a speaker assembly mounted in an aperture formed in the elongate body of the carrier and switches which operatively control the door entry system.

19. The method of claim 18 further comprising the step of placing a window assembly tool about the outer periphery of the window pane prior to loading the window pane into the cavity in the inner surface of the door frame.

20. The method of claim 18 further comprising the step of placing the carrier and assembled window pane on a substantially horizontal planar surface prior to engaging the carrier and window pane with the loading device.

21. The method of claim 18 wherein the loading device comprises a first arm having suction cups at each end of the first arm to engage an inner surface of the carrier, a lifting mechanism extending vertically from the first arm to support the carrier, adjustment arms extending away from the receiving arm to position the loading device and a second arm disposed adjacent the first arm, the second arm having an adjustable extension finger terminating at a suction cup extending through an aperture in the elongate body to engage the window pane to adjust the window pane as it is inserted into the channel in the door frame.

22. The method of claim 18 further comprising the step of securing the modular door assembly to the frame of the vehicle.

23. A method of assembling a modular vehicle door, the method comprising the steps of:

providing a vehicle door frame having inner surface and an outer surface;

placing the outer surface of the vehicle door frame on a substantially horizontal planar surface;

inserting a window pane through a cavity formed by the inner surface of the door frame into a channel in the door frame;

providing a carrier having an elongate body having an inner surface and an outer surface, the carrier including a door entry system and a window carrier assembly secured to the elongate body of the carrier;

engaging the carrier with a loading device;

positioning the carrier parallel to and adjacent the inner surface of the door frame;

securing the window pane to a support arm of the window carrier assembly; and

securing the carrier to the inner surface of the door frame.

24. The method of claim 23 further comprising the step of placing the carrier on a substantially horizontal planar surface prior to engaging the carrier with the loading device.

25. The method of claim 23 wherein the loading device comprises a receiving arm having suction cups at each end of the receiving arm to engage an inner surface of the carrier, a lifting mechanism extending vertically from the receiving arm to support the carrier and planar adjustment arms extending away from the receiving arm to position the loading device.

26. The method of claim 23 further comprising the step of securing the modular door assembly to the frame of the vehicle.