Patent ID: 8763308
Filing Date: 2014-07-01
Classification: B60J

Abstract:
1. A structural door module for a motor vehicle door body, comprising, a carrier plate extending longitudinally between a hinge end for securing the door body to the motor vehicle and a latch end for selectively latching the door body to the motor vehicle and including a dryside surface facing the interior of the motor vehicle and an opposed wetside surface facing the exterior of the motor vehicle; a plurality of door hardware components mounted to at least one of the dryside or wetside surfaces in a pre-configured orientation; an armrest support integrally foamed with the carrier plate and projecting outwardly from the dryside surface thereof and into a passenger compartment of the motor vehicle; and an energy absorption block integrally formed from the carrier plate, the energy absorption block formed from a plurality of terraced portions extending outwardly from the wetside surface of the carrier plate to form a hollow in the dryside surface of the carrier plate wherein at least some of the terraced portions collapse into the hollow when subjected to compression forces greater than a predefined force and wherein said energy absorption block is positioned between the armrest support and the latch end of the carrier plate to collapse inwardly into the hollow prior to protruding into the passenger compartment of the vehicle; wherein the plurality of terraced portions are spaced apart and interconnected by wall portions arranged so that the plurality of terraced portions connected by the wall portions form the hollow on the dryside surface of the carrier; and wherein adjacent wall portions are connected to each other by web portions, the web portions being thinner than the terraced portions and the wall portions whereby at least some of the web portions shear when subjected to the compression forces.