Trim door hardware carrier and methods of assembling vehicle door

• US 6,979,047 B2
• Filed: 02/06/2004
• Issued: 12/27/2005
• Est. Priority Date: 01/07/2002
• Status: Active Grant

• Current Assignee: Intier Automotive Closures, Inc.
• Original Assignee: Intier Automotive Closures, Inc.
• Inventors: Broadhead, Douglas G., Kirejczyk, Juliusz, Fritsch, Manfred, Buening, Dennis John, Legault, David, Regnier, Luc R., Wenglinski, Daniel E., Bokun, Radoslav, Lin, Jih Cheng, Krysiak, David J.
• Primary Examiner(s): ENGLE, PATRICIA LYNN
• Application Number:
  US10/774,195
• Publication Number:
  US 20040155483A1
• Time in Patent Office: 690 Days
• Field of Search: 296/146.1, 296/146.2, 296/146.5, 296/146.6, 296/146.7, 296/152, 495/02, 493/52, 493/49
• US Class Current: 296/146.7
• 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: B60J 5/0468 Fixation or mounting means specific for door components fasteners in general F16B21/00
• CPC Class Codes: B60R 13/0206 Arrangements of fasteners and clips specially adapted for attaching inner vehicle liners or mouldings devices for fastening or securing F16B
• CPC Class Codes: B60R 13/0243 Doors
• CPC Class Codes: B60R 13/0275 comprising removable or hinged parts for accessing storage compartments B60R7/04; for airbag deployment B60R21/215
• 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

Abstract

A door module assembly for a motor vehicle door has a plate-like carrier holding a plurality of door hardware components in a pre-configured orientation, including one or more window regulator rails. The carrier seals the motor vehicle door and includes a flap that provides at least partial access to the window regulator rails. A first trim panel is pre-fixed to the carrier. A second trim panel articulates with respect to the first trim panel between an initial position generally parallel to the first trim panel and an installed position generally in-line with the first trim panel. With the carrier storing substantially all of the hardware required for the door and the trim panels covering substantially the entire surface area of the door, handling and assembly operations are minimized.

Claims

1. A door module assembly for a motor vehicle door, comprising:

a carrier holding a plurality of door hardware components in a pre-configured orientation;

a first trim panel, connected to the carrier; and

at least a second trim panel, joined to the first trim panel and articulated therewith, and moveable between a position generally distanced from the carrier plate and an installed position generally flush with the first trim panel and overlapping the carrier plate.

2. A door module assembly according to claim 1, wherein the first and at least second trim panels are hinged together.

3. A door module assembly according to claim 2, wherein the first and at least second trim panels cover substantially the entire surface area of the motor vehicle door.

4. A door module assembly according to claim 3, wherein the first trim panel is a lower trim panel and the at least second trim panel is an upper trim panel.

5. A door module assembly according to claim 4, wherein the upper and lower trim panels are articulated together.

6. A door module assembly according to claim 5, wherein the carrier provides a secondary trim component and at least one of the upper and lower trim panels include an opening co-operating with the secondary trim component.

7. A door module assembly according to claim 5, wherein the carrier provides a map pocket shelf and at least one of the upper and lower trim panels include a co-operating opening to thereby define a map pocket.

8. A door module assembly according to claim 5, wherein the carrier is formed from plastic and includes at least one hinge so as to provide at least one moveable flap.

9. A door module assembly according to claim 6, wherein the carrier holds at least one window regulator rail, at least a portion of said rail being accessible behind the at least one flap.

10. A door module assembly according to claim 5, wherein the lower trim panel includes a plurality of hooks that snap-fit into a plurality of corresponding receptacles located on the carrier.

11. A door module assembly according to claim 5, wherein the lower trim panel and the carrier are at least partially interconnected by a plurality of hooks that snap-fit into a plurality of corresponding-shaped receptacles.

12. A door module according to claim 5, wherein the upper and lower trim panels are interconnected by a plurality of lugs which seat into a plurality of corresponding-shaped receptacles.

13. A door module according to claim 12, wherein the lugs located on the upper trim panel and have frusto-pyramidical shaped end portions which seat into correspondingly shaped receptacles located on the lower trim panel.

14. A door module assembly according to claim 1, wherein the carrier holds all of the plurality of door hardware components required for the door.

15. A method of assembling a motor vehicle door including a structural door body comprising inner and outer sheet metal layers joined together at their peripheries to define a cavity therebetween, wherein the inner sheet metal layer includes at least one relatively large opening providing access to the cavity, the method including:

provisioning a door module assembly comprising;

a carrier holding a plurality of door hardware components in a pre-configured orientation, including at least one window regulator rail;

a lower trim panel, connected to the carrier; and

an upper trim panel, articulated to the lower trim panel, and moveable between a position generally distanced from the carrier and an installed position generally flush with the lower trim panel and overlapping the carrier;

hanging the at least one rail on the inner sheet metal layer, thereby suspending the door module from the structural door body;

fastening the at least one rail to the inner sheet metal layer;

installing various hardware components to the structural door body; and

moving the upper trim panel into the installed position, wherein the upper and lower trim panels cover substantially the entire surface area inner sheet metal layer.

16. A method according to claim 15, wherein the carrier is formed from plastic and includes at least one hinge so as to provide at least one moveable flap, the at least one window regulator rail being accessible behind the at least one flap.

17. A method according to claim 16, wherein the carrier is substantially un-perforated and includes a sealing bead adjacent its periphery which co-operates with the inner sheet metal layer in order to seal the door from the external environment.

18. A method according to claim 17, wherein the carrier provides a secondary trim component and at least one of the upper and lower trim panels include an opening co-operating with the secondary trim component.

19. A method according to claim 17, wherein the carrier provides a map pocket shelf and at least one of the upper and lower trim panels include a co-operating opening to thereby define a map pocket.

20. A method according to claim 17, wherein the lower trim panel includes a plurality of hooks that snap-fit into a plurality of corresponding receptacles located on the carrier.

21. A method according to claim 17, wherein the lower trim panel and the carrier are at least partially interconnected by a plurality of hooks that snap-fit into a plurality of corresponding-shaped receptacles.

22. A method according to claim 17, wherein the upper and lower trim panels are interconnected by a plurality of lugs which seat into a plurality of corresponding-shaped receptacles.

23. A method according to claim 22, wherein the lugs located on the upper trim panel and have frusto-pyramidical shaped end portions which seat into correspondingly shaped receptacles located on the lower trim panel.

24. A method according to claim 17, wherein the carrier holds substantially all of the hardware components required for the door.

25. A method according to claim 17, including rigidly connecting the lower trim panel to the inner sheet metal layer.

26. A method according to claim 17, including rigidly connecting the upper trim panel to the inner sheet metal layer.

27. A method according to claim 17, wherein the rail is suspended from the structural door body by inserting a bolt through an aperture in the inner sheet metal layer and the rail.

28. A door module assembly for a motor vehicle door, wherein the door includes a structural door body having inner and outer sheet metal layers which define a cavity therebetween and the inner sheet metal layer includes at least one access opening to the cavity, the door module assembly comprising:

a carrier plate having a plurality of door hardware mounted thereon, the carrier plate being formed from a substantially water-impervious material and sized to cover and seal the at least one access opening when the carrier plate is mounted against the inner sheet metal layer;

a first trim panel pre-assembled to the carrier plate prior to installation of the door module to the structural door body; and

at least a second trim panel, pre-joined to the first trim panel prior to installation of the door module to the structural door body, the second trim panel being moveable between a non-installed position which is distanced from the carrier plate and an installed position generally flush with the first trim panel and overlapping the carrier plate.

29. A door module assembly according to claim 28, wherein the carrier plate includes at least one integral hinge defining at least one flap section moveable about the corresponding hinge in order to provide access to the cavity without removal of the carrier plate from the door.

30. A door module assembly according to claim 29, wherein the carrier plate holds at least one window regulator rail and a fastening point for attaching the at least one window regulator rail to the inner sheet metal layer is accessible behind the at least one flap.

31. A door module assembly according to claim 28, wherein the first and second trim panels substantially cover up the carrier plate.

32. A door module assembly according to claim 31, wherein the carrier plate provides a map pocket shelf and at least one of the trim panels include a co-operating opening to thereby define a map pocket.

33. A door module assembly according to claim 28, where the first and second trim panels are articulated together, the second trim being moveable approximately 180 degrees between a shipping position co-located with and parallel to the first trim panel to the installed position.