Automobile door modular assembly

• US 5,095,659 A
• Filed: 05/02/1989
• Issued: 03/17/1992
• Est. Priority Date: 05/02/1989
• Status: Expired due to Term

• Current Assignee: Atoma International, Inc.
• Original Assignee: Atoma International Of America, Corp.
• Inventors: Benoit, Dominique, Vinden, Jonathan
• Primary Examiner(s): Smith, Gary L.
• Assistant Examiner(s): REDMAN, JERRY E
• Application Number:
  US07/346,882
• Time in Patent Office: 1,050 Days
• Field of Search: 49/502, 49/503, 49/501, 49/460, 49/374, 49/351, 49/294, 49/394, 292/141, 292/357, 292/336.3, 292/DIG. 31, 292/DiG. 53, 292/DIG. 54, 292/DIG. 64, 16/124, 296/146, 362/80, 362/145
• US Class Current: 49/502
• 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: Y10S 292/31 Lever operator, flush
• CPC Class Codes: Y10T 292/1017 Flexible

Abstract

A vehicle door comprising a door shell, a module, and door hardware components attached on the door module. The door shell comprises an outer belt reinforcement, an outer panel and an inner panel having a hinge and a latch member. The module comprises a core member having two metal plates thereby to receive the hardware components. The hardware components which are attached to the module are an exterior door release, an interior door release, a latch mechanism, a window regulator mechanism, and a trim panel. Thus, the module is adapted to permit pre-assembly and pre-testing of major sub-assemblies.

Claims

1. An automobile door comprising:

a door shell comprising;

an outer belt reinforcement member, an outer panel, an inner panel member including a hinge member, and a latch member;

a module containing door hardware comprising;

an inner belt reinforcement member;

a core comprising two overlapping metal plates having receptables to receive the hardware components, each said plate having a partial box section inverted and opposed to the other to form the inner belt reinforcement member;

the hardware components comprise an exterior door release an interior release;

a latch mechanism;

window regulator mechanism; and

a trim panel;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door.

2. An automobile door comprising:

a door shell, comprising;

an outer belt reinforcement member,

an outer panel,

an inner panel member including a hinge member, and

a latch member; and

a module containing door hardware, comprising;

an inner belt reinforcement member,

an exterior door release,

an interior release,

a latch mechanism,

window regulator mechanism, and

a trim panel;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door;

wherein the outer panel has an opening for receiving the exterior release and the outer panel is reinforced about the opening by a flange extending from the door shell, the flange providing a base upon which the exterior release is fastened;

wherein the exterior release is contained in a housing, comprising;

a first portion inserted under a first portion of the flange,

a second portion fastened to a second portion of the flange to secure the exterior release in the opening;

an upward extension inserted under a depending lip of the flange; and

an inward extension fastened onto an inward extending ledge of the flange to secure the exterior release in the opening;

wherein the module further comprises;

a downwardly biased ratchet cam rotatably mounted on the second portion of the housing, the cam being adapted to rotate into and to connect with an edge of an opening in the inward extending ledge of the flange to secure the exterior release in the opening.

3. An automobile door comprising:

a door shell, comprising;

an outer belt reinforcement member,

an outer panel,

an inner panel member including a hinge member, and

a latch member; and

a module containing door hardware, comprising;

an inner belt reinforcement member,

an exterior door release,

an interior release,

a latch mechanism,

window regulator mechanism, and

a trim panel,

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door;

wherein the module further comprises;

a core, comprising;

two overlapping metal plates having adapted receptables to receive the hardware components, each said plate having a partial box section inserted and opposed to the other to form the inner belt reinforcement member;

wherein the exterior door release comprises;

a separate exterior door release installed from inside the door shell and being connected by actuating cables to a latch mechanism mounted on the module;

wherein the outer panel has an opening for the exterior release and the outer panel is reinforced about the opening by a flange extending from the door shell, the outer panel being bent about the opening to form an inward extending rim, the rim being bounded by a gasket receiving the exterior release and to separate same from the outer panel, the flange providing a base upon which the exterior release is fastened, the exterior release being contained in a housing having an upward extension inserted under a depending lip of the flange and having a lower, inward extension fastened by a downwardly biased ratchet cam rotatably mounted thereon, the cam being adapted to rotate into and to connect with an edge of an opening in the inward extending ledge of the flange to secure the exterior release in the opening.

4. An automobile door, comprising:

a door shell, comprising;

an outer belt reinforcement member,

an outer panel,

an inner panel member including a hinge member, and

a latch member; and

a module containing door hardware comprising;

an inner belt reinforcement member,

an exterior door release,

an interior release,

a latch mechanism,

window regulator mechanism, and

a trim panel;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door;

wherein the outer panel has an opening for receiving the exterior release and the outer panel is reinforced about the opening by a flange extending from the door shell, the flange providing a base upon which the exterior release is fastened;

wherein the exterior release is contained in a housing, comprising;

a first portion inserted under a first portion of the flange;

a second portion fastened to a second portion of the flange to secure the exterior release in the opening;

an upward extension inserted under a depending lip of the flange; and

an inward extension fastened to an inward extending ledge of the flange to secure the exterior release in the opening;

wherein the flange depends from the outer belt reinforcement member and is bonded to the inside of the outer panel about the opening for the exterior release.

5. An automobile door, comprising:

a door shell, comprising;

an outer belt reinforcement member,

an outer panel,

an inner panel member including a hinge member, and

a latch member; and

a module containing door hardware comprising;

an inner belt reinforcement member,

an exterior door release,

an interior release,

a latch mechanism,

window regulator mechanism, and

a trim panel;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door;

wherein the outer panel has an opening for receiving the exterior release and the outer panel is reinforced about the opening by a flange extending from the door shell, the flange providing a base upon which the exterior release is fastened;

wherein the exterior release is contained in a housing, comprising;

a first portion inserted under a first portion of the flange;

a second portion fastened to a second portion of the flange to secure the exterior release in the opening;

an upward extension inserted under a depending lip of the flange, and

an inward extension fastened onto an inward extending ledge of the flange to secure the exterior release in the opening;

wherein the outer panel has an opening for the exterior release and is bent about the opening to form an inward extending rim, the rim being bounded by a gasket receiving the exterior release and to separate same from the outer panel,

wherein the outer belt reinforcement member has a depending flange bonded to the inside of the outer panel about the opening for the exterior release, the flange providing a base upon which the exterior release can be fastened, and

wherein the module has a core, comprising;

two overlapping metal plates, each such pate having a partial box section inverted and opposed to the other to form an inner belt reinforcement member,

wherein the core contains receptacles to receive all door hardware including;

the exterior door release installed from inside the door shell and being connected by actuating cables to the latch mechanism mounted on the module, the exterior release being contained in a housing having an upward extension inserted under a depending lip of the flange and having a lower, inward extension fastened by a downward biased ratchet cam rotatably mounted thereon, the cam rotating into and connecting with an opening in the inward extending ledge of the flange to secure the exterior release in the opening, the module being installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door.

6. An automobile door comprising:

a door shell comprising;

an outer belt reinforcement member;

an outer panel;

an inner panel member including a hinge member; and

a latch member;

a module containing door hardware comprising;

an inner belt reinforcement member;

a latch mechanism;

a separate exterior door release, installed from inside the door shell and being connected by actuating cables to said latch mechanism mounted on the module;

an interior release;

window regulator mechanism; and

a trim panel;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door.

7. An automobile door comprising:

a door shell comprising;

an outer belt reinforcement member;

an outer panel, having an opening receive the exterior release and the outer panel is reinforced about the opening by a flange extending from the door shell, the flange providing a base upon which the exterior release is fastened;

an inner panel member including a hinge member; and

a latch member;

a module containing door hardware comprising;

an inner belt reinforcement member;

an exterior door release;

an interior release;

a latch mechanism;

window regulator mechanism; and

a trim panel;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door.

8. The apparatus of claim 7 in which the exterior release is contained in a housing comprising:

a first portion inserted under a first portion of the flange, and

a second portion fastened to a second portion of the flange to secure the exterior release in the opening.

9. The apparatus of claim 8 in which the housing further comprises:

an upward extension inserted under a depending lip of the flange, and

an inward extension fastened onto an inward extending ledge of the flange to secure the exterior release in the opening.

10. An automobile door comprising:

a door shell comprising;

an outer belt reinforcement member;

an outer panel;

an inner panel member including a hinge member; and

a latch member;

a module containing door hardware comprising;

an inner belt reinforcement member;

an exterior door release;

an interior release;

a latch mechanism;

window regulator mechanism;

a trim panel;

a receptacle surrounded by a first sealing surface; and

a sealing membrane fitted to the first sealing surface and a second sealing surface of an inner panel of the door shell substantially to prevent transmission of water vapor from the door shell into the receptacle while allowing communication between the interior of the automobile and the receptacle through trim panel means;

said receptacle housing components of the module which are susceptible to damage from exposure is water vapor;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door.

11. An automobile door comprising:

a door shell comprising;

an outer belt reinforcement member;

an outer panel;

an inner panel member including a hinge member; and

a latch member;

a module containing door hardware comprising;

an inner belt reinforcement member;

an exterior door release;

an interior release;

a latch mechanism;

window regulator mechanism;

a receptacle surrounded by a first sealing surface;

a trim panel fitted to the first sealing surface of the receptacle and a second sealing surface of an inner panel of the door shell substantially to prevent transmission of water vapor from the door shell into the receptacle; and

a bezel fitted over the receptacle to permit communication between the interior of the automobile and the receptacle through the bezel, said receptacle being adapted to house components of the module which are susceptible to damage from exposure to water vapor;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door.

12. An automobile door comprising:

a door shell comprising;

an outer belt reinforcement member;

an outer panel;

an inner panel member including a hinge member; and

a latch member;

a module containing door hardware comprising;

an inner belt reinforcement member;

an exterior door release;

an interior release;

a latch mechanism;

window regulator mechanism;

a trim panel, comprising a lens and a reflector of a courtesy lamp;

a bulb; and

a socket mounted in the hardware module, said lens and reflector fitting over the bulb and socket as the trim panel is assembled onto the door shell;

wherein the module is installed, from the inside, into the door shell and fastened therein to locate all the hardware components in the door.

13. The automobile door of claim 12 having an over sized hole in the reflector receiving the bulb and accommodating reasonable dimensional tolerances of the hardware module and the trim panel, wherein the door further comprises:

a resilient pad located about the bulb on the socket with reflective material on the bulb side abutting against the inside surface of the reflector to reduce the intrusion of dust and moisture into the courtesy lamp.