Modular vehicle door assembly

• US 6,823,628 B2
• Filed: 12/16/2002
• Issued: 11/30/2004
• Est. Priority Date: 12/09/1999
• Status: Expired due to Fees

• 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.
• Primary Examiner(s): Strimbu, Gregory J.
• Application Number:
  US10/319,960
• Publication Number:
  US 20030096510A1
• Time in Patent Office: 715 Days
• Field of Search: 495/02, 493/48, 493/49, 493/52, 493/74
• 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: E05F 11/483 by cables
• CPC Class Codes: E05Y 2600/50 Mounting methods; Positioning
• CPC Class Codes: E05Y 2800/692 Temporary use
• 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 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.

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 and providing structural support to the vehicle door frame;

a seal surrounding an entire outer peripheral edge of the elongate body of the carrier and placed between the door frame and the carrier to inhibit the introduction of foreign materials into a passenger compartment of the vehicle;

a door entry system mounted on the carrier, the door entry system including a lock assembly, a latch assembly coupled to the lock assembly, at least one cable connecting an inner door handle disposed on the carrier to the latch assembly, and an outer door handle operatively connected to the lock assembly disposed in the outer surface of the vehicle door frame;

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

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

2. The modular door assembly of claim 1 wherein the at least one cable comprises a pair of cables exending through a pair of apertures in the elongate body of the carrier.

3. The modular door assembly of claim 2 wherein grommets extend about the outer periphery of the pair of cables to seal the apertures in the elongate body of the carrier.

4. The modular door assembly of claim 1 wherein the at least one cable includes a first end attached to the inner door handle and a second end attached to the latch assembly.

5. The modular door assembly of claim 1 further comprising vehicle components disposed on the elongate body of the carrier.

6. The modular door assembly of claim 5 wherein the vehicle components 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.

7. 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 to an electrical system of the vehicle.

8. A module configurable for securement to a vehicle door assembly of a vehicle, the module comprising:

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

a seal mounted on and surrounding an entire outer peripheral edge of the elongate body of the carrier to inhibit the introduction of foreign materials into a passenger compartment of the vehicle;

a door entry system mounted to the carrier, the door entry system including a latch assembly mounted adjacent a rear portion of the elongate body, a lock assembly coupled to the latch assembly adjacent the outer surface of the carrier, an outer door handle operatively connected to the lock assembly, an inner door handle secured to the inner surface of the carrier, 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 latch 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 the carrier and extending toward the passenger compartment of the vehicle;

a wiring harness assembly extending through apertures 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; and

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

9. The module of claim 8 wherein a grommet extends about the outer periphery of the at least one cable operatively connecting the inner door handle and the latch assembly to seal the at least one aperture in the elongate body of the carrier.

10. The module of claim 8 wherein the at least one cable includes a first end attached to the inner door handle, a second end attached to the latch assembly and a grommet extending into the at least one aperture to seal the at least one aperture in the carrier.

11. The module of claim 8 wherein a grommet extends about the outer periphery of the wiring harness assembly to seal at least one of the apertures in the elongate body of the carrier through which said wiring harness assembly extends.

12. The module of claim 8 wherein the vehicle components 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.

13. The module of claim 8 wherein the elongate body of the carrier is a one-piece stamped metal structure.

14. The module of claim 8 wherein the elongate body of the carrier is formed from a polymeric material as a one-piece structure.