Door module having structural carrier

• US 6,536,164 B1
• Filed: 09/10/2001
• Issued: 03/25/2003
• Est. Priority Date: 03/11/1999
• Status: Expired due to Term

• Current Assignee: Atoma International Corp.
• Original Assignee: Atoma International Corp.
• Inventors: Kirejczyk, Juliusz
• Primary Examiner(s): REDMAN, JERRY E
• Application Number:
  US09/936,274
• Time in Patent Office: 561 Days
• Field of Search: 495/02, 493/48, 493/49, 493/52, 296/146.5, 296/146.7
• 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: B60R 11/0217 for loud-speakers
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• CPC Class Codes: B60R 13/0243 Doors
• CPC Class Codes: B60R 13/0846 for duct, cable or rod passages, e.g. between engine and passenger compartments
• CPC Class Codes: B60R 13/0892 for humidity insulation sealing strips B60R13/06
• CPC Class Codes: B60R 16/0207 Wire harnesses
• CPC Class Codes: B60R 2013/0281 made of a plurality of visible parts
• CPC Class Codes: B60R 2013/0287 integrating other functions or accessories
• CPC Class Codes: B60R 2013/0293 Connection or positioning of adjacent panels
• CPC Class Codes: E05F 11/488 with two cable connections to the window glass
• CPC Class Codes: E05Y 2400/654 by electrical cables
• CPC Class Codes: E05Y 2800/342 Deformable
• CPC Class Codes: E05Y 2900/55 Windows

Abstract

A vehicle door module has a hardware sub-module and a trim sub-module. The hardware sub-module includes a structural carrier plate containing hardware mounting surfaces. The carrier plate has an upper body panel and a bifurcated lower body portion comprising two legs extending from the upper body panel in opposite directions. The door hardware is mounted on the mounting surfaces. A window regulator assembly is mounted on the structural carrier plate. The trim sub-module is mounted to the hardware sub-module. The trim sub-module has a trim panel, a water barrier film and a wiring harness. The water barrier film is contoured to extend about and seal a periphery of the trim panel. A portion of the wire harness is sealed to the water barrier and connectors of the wiring harness extend from the trim sub-module at predetermined locations. The carrier plate is sized to be fitted in both a long low profile door and a short high profile door while the trim sub-module is customized to fit onto one of the door styles.

Claims

1. A vehicle door module (10) comprising:

a hardware sub-module (14, 114) including a structural carrier plate (54) containing hardware mounting surfaces, the carrier plate (54) having an upper body panel (62) and a bifurcated lower body portion comprising two legs (64, 66) extending from the upper body panel in opposite directions, door hardware (56, 58) mounted on said mounting surfaces, and a window regulator assembly (60) mounted on said structural carrier plate (54), and

a trim sub-module (12) mounted to said hardware sub-module, said trim sub-module (12) comprising a trim panel (18), a water barrier (24) film and a wiring harness, said water barrier film contoured to extend about and seal a periphery of the trim panel (18), a portion of said wire harness (26) being sealed to the water barrier (24) and said wiring harness having connectors extending from said trim sub-module (12) at predetermined locations.

2. A vehicle door module according to claim 1 wherein said trim sub-module (12) further comprises a speaker mount bracket (20) attached to said trim panel (18), a speaker (22) mounted to said bracket (20) and operatively connected to said wiring harness (26), said speaker mount bracket (20) positioning said speaker (22) in a juxtaposition to a speaker grill (30) in said trim panel and connected to said carrier plate (54) after the trim sub-module (12) is mounted to said hardware sub-module (14, 114).

3. A vehicle door module according to claim 2, wherein said water barrier (24) has an opening (40) for receiving said speaker (22) and said water barrier (24) is sealed about said opening (40).

4. A vehicle door module according to claim 3, wherein said trim sub-module (12) further comprises a courtesy light (36) mounted to said trim panel (18) and operatively connected to said wiring harness (26).

5. A vehicle door module according to claim 4, wherein said two legs (64, 66) are L-shaped and support a lower portion of said trim sub-module (12).

6. A Vehicle door module according to claim 5, wherein said window regulator assembly (60) includes a pair of spaced parallel rails (74, 76) and said two L-shaped legs (64, 66) support lower ends of said parallel rails (74, 76).

7. A vehicle door module according to claim 6, wherein said carrier plate (54) is a stamped sheet metal.

8. A vehicle door module according to claims 1 or 6 wherein said carrier plate (54) is cast from a magnesium alloy and said pair of spaced parallel rails (74, 76) are integrally formed to said carrier plate (54).

9. A vehicle door module according to claim 8 further including an upper trim panel (92) mounted to said carrier plate (54) and positioned to cover a peripheral area of the carrier plate (54).

10. A vehicle door module according to claim 8, wherein said door hardware comprises a door latch (58) operatively connected to an inside release handle (56) and said wiring harness.

11. A vehicle door module according to claim 8, wherein said wiring harness is sealed to the water barrier by an impermeable cover sheet (52).

12. A vehicle door module according to claim 8, wherein said module further comprises a glass panel (16) mounted to said window regulator assembly (60).

13. A vehicle door module according to claim 2, wherein said trim sub-module (12) further comprises a switch (34) mounted on said trim panel (18) and operatively connected to said wiring harness (26).