Integrated door module

A door assembly includes a carrier panel attachable to a vehicle door outer structure such that the carrier panel substantially covers an opening of the door outer structure. The carrier panel is configured to function as a water shield between the door outer structure and a vehicle occupant compartment. The carrier panel also includes an upper portion and a lower portion, and the lower portion defines a lower appearance surface. The assembly further includes a hardware component mounted to and supported by the carrier panel, and an upper trim panel arrangement that is attachable to the carrier panel after the carrier panel has been attached to the door outer structure. The upper trim panel arrangement is configured to substantially cover the upper portion of the carrier panel and defines an upper appearance surface.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a door assembly for use with a motor vehicle having a door outer structure and an interior occupant compartment.

2. Background Art

Various door assemblies have been developed for use with motor vehicles. Such door assemblies are configured to be mounted onto a vehicle door outer structure, which may include an outer panel and an inner panel or frame. Examples of prior door assemblies are disclosed in U.S. Pat. Nos. 4,648,208, 4,882,842 and 5,095,659.

Another prior door assembly includes a carrier panel made of foamed polypropylene and a trim panel made of injection molded polypropylene. The carrier panel is attachable to a door outer structure of a vehicle, and the trim panel is attachable to the carrier panel with fasteners, after the carrier panel has been attached to the door outer structure. Furthermore, the trim panel defines the entire appearance surface of the door assembly.

SUMMARY OF THE INVENTION

Under the invention, a door assembly is provided for use with a motor vehicle having a door outer structure and an interior occupant compartment, wherein the door outer structure has an opening. The assembly includes a carrier panel adapted to be attached to the door outer structure such that the carrier panel substantially covers the opening. The carrier panel has a first side adapted to face toward the interior compartment and a second side adapted to face the door outer structure. Furthermore, the carrier panel is configured to function as a water shield between the door outer structure and the occupant compartment for inhibiting water from passing from the second side to the first side. The carrier panel also includes an upper portion and a lower portion. The lower portion defines a lower, finished appearance surface that is adapted to face the occupant compartment. The assembly further includes a vehicle door hardware component mounted to and supported by the carrier panel, and an upper trim panel that is attachable to the carrier panel after the carrier panel has been attached to the door outer structure. The upper trim panel is configured to substantially cover the upper portion of the carrier panel and having an upper, finished appearance surface that is adapted to face the occupant compartment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

FIGS. 1 and 2show a door assembly10according to the invention for use with a vehicle having a door outer structure12and an interior occupant compartment. The door outer structure12may be a metallic structure and includes an outer panel14and an inner panel16attached to the outer panel14. The door outer structure12may also include a reinforcing member, such as lateral support18, attached to the outer panel14and/or inner panel16. Furthermore, the inner panel16has an opening20for receiving the door assembly10, and the opening20has a maximum height h and a maximum width w.

The door assembly10includes an integrated door module or carrier module22that is attachable to the door outer structure12, and an upper trim panel arrangement24that is attachable to the carrier module22and/or door outer structure12. Referring toFIGS. 2-4, the carrier module22includes a carrier panel26that is adapted to be attached to the door outer structure12such that the carrier panel26substantially covers the opening20. In other words, the carrier panel26is adapted to span the height h and width w of the opening20. The carrier panel26has a first side28adapted to face toward the interior compartment, and a second side30adapted to face the door outer structure12. In addition, the carrier panel26is configured to function as a water shield between the interior compartment and the door outer structure12for inhibiting water from passing from the second side30to the first side28. The carrier panel26further includes an upper portion32and a lower portion34, and the lower portion34defines a lower, finished appearance surface36. The lower appearance surface36may comprise approximate 20 to 40 percent, for example, of the entire appearance surface of the door assembly10. As shown inFIGS. 2 and 4, the lower portion34may also include a projecting section or projection37that extends inwardly beyond the upper portion32.

Still referring toFIGS. 2-4, the carrier panel26includes a carrier panel body38that is adapted to span the height h and width w of the opening20. The carrier panel body38may include a main portion40and a lower back portion42that is attached to the main portion40so as to define a map pocket44. With this configuration, the main portion40defines the upper portion32, including the first and second sides28and30, respectively, of the upper portion32. The main portion40also defines the projection37of the lower portion34. Furthermore, the back portion42defines the remainder of the lower portion34, including the first and second sides28and30, respectively, of the lower portion34. Alternatively, the carrier panel body38may be formed as a single piece, or multiple pieces that are attached together. The carrier panel body38may also include one or more access apertures, such as holes46and48and slot50, for providing access to components of the door assembly10and/or door outer structure12, as explained below in greater detail.

The carrier panel body38may be made in any suitable manner and may comprise any suitable material or materials such that the carrier panel body38has sufficient strength to support, at least temporarily, one or more vehicle door hardware components, as explained below in greater detail. For example, the main portion40and/or the back portion42may be formed of injection molded or compression molded plastic, such as polypropylene. Furthermore, the plastic may be reinforced with natural and/or synthetic fibers or other particles. As another example, the main portion40and/or back portion42may be formed of foamed plastic material, such as foamed polypropylene, foamed polyethylene and foamed urethane. Such foamed plastic material is formed with a resin rich exterior surface and a foam interior. Other suitable materials for the carrier panel body38include acrylanitrile butadiene styrene (ABS) and glass-fiber mat reinforced thermoplastic material (GMT).

In the embodiment shown inFIG. 3, the main portion40is made of a structural, moisture impermeable material, such as one or more of the materials described above, and the back portion42is made of a flexible, moisture impermeable material such as expanded polypropylene. With such a configuration, the back portion42may also include one or more integrally formed energy management members, such as impact blocks51.

The carrier panel body38may also define a portion or all of the lower appearance surface36. For example, the lower appearance surface36may be provided as a painted surface or an integrally molded colored and/or grained surface of the main portion40. Alternatively, the carrier panel26may include a cover material52that is attached to the carrier panel body38and that defines a portion or all of the appearance surface36. The cover material52may comprise any suitable material, such as vinyl, carpet, leather, etc.

The carrier panel26may also include a seal53disposed about an outer periphery of the carrier panel body38. The seal53is adapted to mate with the inner panel16so as to seal the carrier panel26against the inner panel26when the carrier panel is mounted to the door outer structure12.

The carrier module22further includes one or more vehicle hardware components mounted to the carrier panel26. In the embodiment shown inFIGS. 3 and 4, for example, the carrier module22includes a door latch assembly54, a window regulator or lift mechanism56, a conductive assembly58and a speaker60mounted to the carrier panel26. The door latch assembly54includes a door latch62mounted in any suitable manner on second side30of the carrier panel26. The door latch assembly54further includes an interior handle mechanism64mounted on first side28of the carrier panel26, and actuating cables or links66and68extending between and connected to door latch62and handle mechanism64.

The window lift mechanism56includes a motor70mounted on the first side28or the second side30of the carrier panel26, and a pair of window regulator arms72mounted on the second side30for supporting an associated door window74for vertical movement. The motor70and regulator arms72may be mounted to the carrier panel26in any suitable manner, such as with fasteners. Alternatively, the motor70may be attached to one of the regulator arms72. In the embodiment shown inFIG. 3, each regulator arm72is fixedly mounted to the carrier panel26in a substantially vertical use position, such that the regulator arms72are unable to rotate with respect to the carrier panel26. With such a configuration, the regulator arms72may be fully supported by the carrier panel26after the door assembly10has been fully assembled to the door outer structure12. Alternatively, the regulator arms72may be pivotally mounted to the carrier panel26such that the regulator arms72may be rotated into use positions after the carrier panel26has been attached to the door outer structure12. With such a configuration, the regulator arms72may also be attached to the inner panel16of the door outer structure12after the regulator arms72have been rotated into the use positions.

The window lift mechanism56also includes a cable76that extends along each regulator arm72between ends thereof, and between the regulator arms72in a crossing manner. The cable76has a pair of window connectors78respectively associated with the regulator arms72to provide connection to the door window74. Each window connector78is movable along a respective regulator arm72to enable vertical movement of the door window74.

Alternatively, the window lift mechanism56may have any suitable configuration and include any suitable components. For example, the window lift mechanism56may include only one regulator arm.

The conductive assembly58may be a wire harness that includes various conductive elements, such as wires80, and associated electrical connectors82,83and84for operating electrical components of the door assembly10, such as door latch assembly54, window lift mechanism56, speaker60, a vehicle seat control, a mirror control, etc. In the embodiment shown inFIG. 4, the electrical connectors83and84are configured to be self-docking, as explained below in greater detail. A plurality of jumper wires86may also be connected between the conductive assembly58and the electrical components. Each jumper wire86may include one or more wires88and associated electrical connectors90.

The carrier module22may also include one or more additional vehicle door hardware components mounted to the carrier panel26. For example, the carrier module22may include a side impact restraint, such as air bag92, connected to the main portion40and/or back portion42and disposed between the main portion40and back portion42. Additional details regarding components that may be attached to carrier panel26are disclosed in co-pending application Ser. No. 09/690,635, which is hereby incorporated by reference.

Referring toFIG. 2, the upper trim panel arrangement24is attachable to the carrier panel26and/or door outer structure12after the carrier panel26has been attached to the door outer structure12. For example, the upper trim panel arrangement24may be snap fit and/or attached with fasteners to the carrier panel26and/or door outer structure12. The upper trim panel arrangement24is configured to substantially cover the upper portion32of the carrier panel26, and has an upper, finished appearance surface93that is adapted to face the interior compartment. Furthermore, the upper trim panel arrangement24may include multiple upper trim panel portions, such as arm bolster portion94and top portion96that are attachable together. Alternatively, the upper trim panel arrangement24may be provided as a single panel or module. In any case, the configuration and materials of the upper trim panel arrangement24may be varied from vehicle to vehicle so as to provide aesthetic flexibility and brand-identification flexibility.

The arm bolster portion94defines a first or lower surface portion97of the upper appearance surface93, and may include a bolster portion body98and one or more cover materials, such as cover material100, attached to the bolster portion body98. The bolster portion body98may comprise any suitable material, such as one or more of the materials described above with respect to the carrier panel body38. The cover material100may define some or all of the lower surface portion97, and may comprise any suitable cover material, such as cloth, carpet, vinyl, leather, etc. Alternatively, the arm bolster portion94may be provided without a cover material attached to the bolster portion body98. With such a configuration, the bolster portion body98defines the entire lower surface portion97.

The arm bolster portion94may further include a control unit, such as a switch pack102, attached to the bolster portion body98such as by a snap fit. The switch pack102may include controls or switches104for controlling various vehicle components, such as window lift mechanism56, a power door lock mechanism, a vehicle seat, an automatic mirror, etc. The switch pack102may also include a self-docking connector that mates with the connector83of the connector assembly58.

The top portion96defines a second or upper surface portion105of the upper appearance surface93, and may include a top portion body106and one or more cover materials, such as cover material108, attached to the top portion body106. The top portion body106may comprise any suitable material, such as one or more of the materials described above with respect to the carrier panel body38. Furthermore, the cover material108may define some or all of the upper surface portion105, and may comprise, for example, cloth, carpet, vinyl, leather, or any other suitable cover material. Alternatively, the top portion96may be provided without a cover material attached to the top portion body106. With such a configuration, the top portion body106defines the entire upper surface portion105.

Referring toFIGS. 2-4, a method according to the invention of manufacturing door assembly10will now be described. As mentioned above the carrier panel body38may be made in any suitable manner and may comprise any suitable material. In one embodiment of the invention, the main portion40is made of foamed plastic material using a gas-injection molding process. Such a process may include, for example, injecting polypropylene or other suitable plastic material into a mold, and then injecting a gas, such as nitrogen, into the plastic material so as to create a foam interior portion surrounded by a resin rich surface. The resin rich surface forms a solid plastic shell or layer around the foam interior portion. With such a configuration, the foamed plastic material is strong yet light weight.

In one embodiment of the invention, the back portion42is formed of expanded polypropylene. The back portion42is then heat staked or otherwise attached to the main portion40. The air bag92may also be attached to the main portion40and/or back portion42, prior to attaching the back portion42to the main portion40.

Next, the conductive assembly58may be attached to the first side28or second side30of the main portion40such as with adhesive and/or fasteners. The conductive assembly58may be a preassembled wire harness structure as described above, or the conductive assembly58may be integrated with the carrier panel26. For example, the conductive assembly58may include a conductive element or trace pattern, such as a metal trace pattern, that may be attached to the main portion40. A plasma layer may then be sprayed over the trace pattern so as to insulate the traces from each other as well as the surroundings. The connectors82,83and84may then be connected to the trace pattern, and the jumper wires86may be connected to the connectors82,83and84.

Next, the door latch assembly54is attached to the carrier panel26For example, a projecting portion of the door latch62may be slid into a channel110integrally formed on the second side30of the main portion40, and one or more fasteners may be used to secure the door latch62in a desired position. The actuating links66and68may be routed through integrally formed clamp features112of the main portion40, and then into holes114of a handle receptacle116of the main portion40. Seals associated with the actuating links66and68are then seated in the holes114.

The regulator arms72and cable76of the window lift mechanism56may also be mounted to the second side30of the main portion40and/or back portion42of the carrier panel26. If the regulator arms72are fixedly mounted to the carrier panel26, then the access slot50may be eliminated from the carrier panel26. If the regulator arms72are pivotally mounted to the carrier panel26, then the access slot50may provide access to the regulator arms72after the carrier panel26has been mounted to the door outer structure12. As mentioned above, the window lift mechanism56may be provided with only one regulator arm. With such a configuration, the window lift mechanism56may also include two glass guides (not shown) mounted to the carrier panel on opposite sides of the regulator arm.

Next, the motor70may be mounted on the first side28of the main portion40and/or back portion42such that the motor70is in driving relationship with the cable76. For example, a rotatable shaft118may be positioned between the motor70and the cable76.

The speaker60may also be mounted on the carrier panel76. In addition, one or more of the jumper wires86may be used to connect the conductive assembly58to the speaker60, as well as other electrical components such as the door latch62and motor70.

The bolster portion body98of the arm bolster portion94may be manufactured in any suitable manner, such as by an injection molding process or compression molding process. Furthermore, the cover material100, if used, may be molded with the bolster portion body98, or subsequently attached to the formed bolster portion body98. The switch pack102is then attached to the bolster portion body98.

The top portion96may be manufactured in a similar manner as the arm bolster portion94. Alternatively, as mentioned above, the upper trim panel arrangement24may be formed as a single panel, or any number of panels that are attachable together and/or to the carrier module22.

Referring toFIGS. 1 and 2, a method of assembling the door assembly10to the door outer structure12will now be described. First, a connector arrangement120may be positioned in the door outer structure12. The connector arrangement120is configured to electrically connect the conductive assembly58with vehicle body wiring, such as a body harness (not shown), and includes first and second connectors122and124, respectively. The first connector122is attachable to the body harness (not shown), and the second connector124, which may be a self-docking connector, is attachable to the conductive assembly58.

Next, the carrier module22is positioned proximate the opening20of the door outer structure12so that the connector84is positioned proximate the second connector124. The carrier module22is then attached to the door outer structure12such that such that the connector84mates with the second connector124, and such that the carrier panel26substantially covers the opening20.

If the carrier module22includes one or more regulator arms72that are pivotally connected to the carrier panel26, the method may also include inserting a tool, such as a screwdriver, through the slot50after the carrier panel26has been attached to the door outer structure12. The tool may then be used to rotate the regulator arms72with respect to the carrier panel26and into substantially vertical use positions. Next, the regulator arms72may be secured to the inner panel16with fasteners.

The holes46and48and slot50, as well as any other apertures in the carrier panel body38, may then be covered with patches126. The patches126may comprise any suitable material, such as closed-cell foam, and may be attached to the carrier panel body38in any suitable manner, such as with adhesive.

Next, the arm bolster portion94is attached against the upper portion32such that the self docking connector of the switch pack102mates with the connector83of the conductive assembly58. The top portion96is then positioned above the arm bolster portion94and attached against the upper portion32, such that the arm bolster portion94and top portion96cooperate to substantially cover the first side28of the upper portion32. The arm bolster portion94and top portion96also cooperate to define the upper appearance surface93. A door handle bezel128may then be positioned around the door handle67.

Under the invention, a common carrier module may be used for a variety of vehicles. Advantageously, different upper appearance surfaces and brand identifications may be achieved by using different upper trim panel arrangements. Furthermore, an upper trim panel arrangement, or portion thereof, may be replaced if damaged.