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CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to GB 1506656.6 filed Apr. 20, 2015, which is hereby incorporated by reference in its entirety. 
       TECHNICAL FIELD 
       [0002]    The present invention relates to a bump stop assembly for the door of a motor vehicle and is particularly, although not exclusively, concerned with a bump stop assembly that ensures correct closure of an access door of the vehicle. 
       BACKGROUND 
       [0003]    When a door of a vehicle is closed, a latch within the door mechanism engages to prevent the door from opening unintentionally. The latch often allows some movement of the door relative to the body of the vehicle. Because of this freedom of movement, the door may rattle as it is closed and the edges of the door panel may not always be aligned with the surrounding body panels. 
         [0004]    In order to ensure the door of the vehicle is correctly aligned with the surrounding body panels and to ensure the door does not rattle as it is being closed, a bump stop can be fitted to the door or the door frame. The bump stop is often configured such that, when the door is closed and correctly aligned with the surrounding body panels, the bump stop fills the gap between the door and the door frame, preventing the door from closing any further. By restricting the movement of the door in this way, rattling of the door may be reduced. 
         [0005]    Adjustment of the bump stop, to ensure it correctly fills the gap between the door and the door frame, is often performed by hand. The door may be opened and closed several times while the bump stop is being adjusted, until it is judged that the door is correctly aligned with the adjacent panels of the vehicle. 
         [0006]    This process is unreliable and different results are achieved depending on the vehicle and the person adjusting the bump stop. Restricted access to the bump stop when the door is closed prevents the use of many tools or aids which might be used to allow the bump stop to be adjusted consistently. 
         [0007]    With reference to  FIG. 1 , a bump stop  4  for an access door  10  of a vehicle is shown. The bump stop  4  may be coupled to the door  10  via a thread  4   a  on a shaft portion of the bump stop. The bump stop further comprises a stop face  4   c  configured to contact a door frame  12  that surrounds the door when closed. The bump stop  4  may be rotated and axially adjusted with the thread so that the stop face  4   c  engages the door frame  12  when the door is closed. In  FIG. 1 , the bump stop  4  has not been configured correctly and a gap is present between the bump stop  4  and the door frame  12 . This gap may lead to the door panel being misaligned with the surrounding body panels and may allow the door to rattle when it is closed. 
       SUMMARY 
       [0008]    According to a first aspect of the present disclosure, a bump stop assembly is provided for a motor vehicle that is configured to be coupled to an access door or a door frame. A door closure gauge is movably coupled to, e.g. slidably received in, the bump stop. A closure pad is configured to couple to the bump stop to one of the door frame or the access door and engage with the other of the door frame or the access door when the door is closed. The thickness of the closure pad required in the bump stop assembly can be determined from the extent of the protrusion of the door closure gauge relative to the bump stop. 
         [0009]    The door closure gauge may comprise a measurement scale from which the protrusion of the door closure gauge from the bump stop can be determined. The door closure gauge may be color coded, such that the extent that the door closure gauge protrudes from the bump stop can be determined from the color or colors of the protruding part of the door closure gauge. 
         [0010]    The closure pad may be at least partially colored, wherein the color corresponds to the thickness of the closure pad. The color coding of the door closure gauge may correspond to the color of the closure pad. The color or colors of the portion of the door closure gauge protruding from the bump stop indicate the color of the required closure pad. The color of the closure pad may not be visible when assembled into the bump stop assembly. 
         [0011]    The closure pad may comprise a coupling portion configured to couple to the bump stop or the door frame or access door and an engaging portion configured to engage the other of the door frame or door of the vehicle or the bump stop. The coupling portion and the engaging portion of the closure pad may be separate components. 
         [0012]    The coupling portion of the closure pad may be configured to couple with a range of engaging portions ranging in size. The coupling portion of the closure pad may be configured to directly engage the door frame or door of the vehicle or the bump stop. 
         [0013]    The bump stop or the closure pad may be coupled to the access door or the door frame by a thread provided on the respective bump stop or closure pad. 
         [0014]    According to another aspect of the present disclosure, a door closure gauge is provided for use in the bump stop assembly according to any of the above mentioned aspects of the disclosure. 
         [0015]    According to another aspect of the present disclosure, a bump stop is provided for use in the bump stop assembly according to any of the above mentioned aspects of the disclosure. 
         [0016]    According to another aspect of the present disclosure, a closure pad is provided for use in the bump stop assembly according to any of the above mentioned aspects of the disclosure. 
         [0017]    According to another aspect of the present disclosure, a kit of parts is provided that includes two or more closure pads. The closure pads are configured to be coupled to a bump stop or a door or door frame. The closure pads engage the door, door frame, or the bump stop when the access door is closed. Each of the closure pads provided by the kit is a different thickness. 
         [0018]    The kit may comprise a set of closure pads of different thicknesses. The kit may comprise a coupling portion of the closure pad and one or more engaging portions of the closure pad. 
         [0019]    The closure pads may be color coded with the color corresponding to the thickness of the closure pad. The color may not be visible after the closure pad is coupled to the bump stop and the access door or the door frame. 
         [0020]    According to another aspect of the present disclosure, a method is provided of setting the closure of an access door. The method comprises coupling a bump stop to the access door or a door frame. The bump stop is provided with a door closure gauge that is movably coupled to the bump stop. The door is closed until the door latches and is correctly aligned with the body of the vehicle. The door is opened and the extent that the door closure gauge protrudes from the bump stop is determined. A closure pad of appropriate thickness is coupled to the other of the door frame, the access door, or the bump stop, such that it engages with the bump stop, the access door, or door frame when the door is closed. 
         [0021]    The extent that the door closure gauge protrudes from the bump stop may be determined by referring to a measurement scale provided on the door closure gauge. The extent the door closure gauge protrudes from the bump stop may be determined based upon the color or colors of a portion of the door closure gauge protruding from the bump stop. 
         [0022]    The method may further comprise selecting a closure pad of the correct thickness from a set of closure pads of different thicknesses. Each closure pad in the set may be at least partially colored with the color corresponding to the thickness of the closure pad. The closure pad of the correct thickness may be selected by matching the color of the closure pad to the color or colors of the protruding portion of the door closure gauge. 
         [0023]    For a better understanding of the present disclosure, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]      FIG. 1  is a sectional view of a prior art bump stop fitted to a door of a vehicle; 
           [0025]      FIG. 2  is a schematic sectional view of a bump stop assembly according to an example of the present disclosure; 
           [0026]      FIG. 3  shows a method for setting the closure of an access door according to an example of the present disclosure; 
           [0027]      FIGS. 4 a  and 4 b    are schematic sectional views of a bump stop fitted with a door closure gauge according to an example of the present disclosure; and 
           [0028]      FIG. 5  is a sectional perspective view of a set of closure pads according to an example of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts. 
         [0030]    With reference to  FIG. 2 , a bump stop assembly  102  according to an example of the present disclosure comprises a bump stop  104 , a door closure gauge  106  and a closure pad  108 . The bump stop  104  may be coupled to an access door  10  of a vehicle, such as a passenger/driver door, bonnet, boot or any other access panel or hatch. The bump stop comprises a connecting portion  104   a  connected to the door  10  that secures the bump stop in place. The connecting portion  104   a  may comprise a barbed connector, such as a fir tree connector. The fir tree connector is deformable to be passed through a hole in the door  10 . A resilient barb of the fir tree connector prevents the bump stop from detaching from the door  10 . Alternatively, the connecting portion  104   a  may comprise any other connecting means suitable for connecting the bump stop to the access door  10  or the door frame  12 . 
         [0031]    An abutment surface  104   c  of the bump stop  104  may be in contact with the closure pad  108  when the door is closed. The abutment surface  104   c  may contact a closure surface  108   a  of the closure pad. The closure pad  108  may be coupled to a door frame  12 . Alternatively, the closure pad  108  may be coupled to the abutment surface  104   c  of the bump stop  104 . The combined thickness of the bump stop  104  and the closure pad  108  may fill the gap between the door  10  and the door frame  12  when the access door  10  is closed. The thickness of the bump stop  104  and the closure pad  108  may be selected to ensure that there is no gap present between the two components so that the door will not rattle when closed. The combined thickness of the bump stop  104  and the closure pad  108  correctly aligned the door  10  with the body panels of the vehicle adjacent to the door. 
         [0032]    The door closure gauge  106  may be movably coupled to the bump stop  104 . For example, as shown in  FIG. 2 , the bump stop  104  may comprise an axial bore  104   b  that is adapted to slidably receive the door closure gauge  106 . Alternatively, the door closure gauge  106  may be pivotally supported at an axis of the bump stop. 
         [0033]    The door closure gauge  106  may comprise a shaft with a substantially constant cross-section along the length of the shaft. For example, the cross-section of the door closure gauge  106  may be substantially circular. Alternatively, the cross-section may be any other shape such as substantially square or rectangular. In any event, the door closure gauge  106  cross-section may correspond to the shape of the axial bore  104   b  of the bump stop  104 . The door closure gauge may form a tight fit with the axial bore  104   b . The door closure gauge may be ribbed or comprise any other surface feature in order to prevent unwanted movement of the door closure gauge  106  within the axial bore  104   b . The length of the door closure gauge may be greater than a maximum anticipated tolerance or combination of tolerances affecting the gap between the access door  10  and the door frame  12 . 
         [0034]    The door closure gauge may be used, as described below, to determine the correct thickness of closure pad  108  to use within the bump stop assembly  102 . The door closure gauge has a first end  106   a  and a second end  106   b . A measurement scale  120  may be provided at or near the second end  106   b  of the door closure gauge. The measurement scale may indicate a length from the second end  106   b  of the door closure gauge to a point on the measurement scale  120 . In the example shown in  FIG. 2 , the measurement scale  120  comprises three bands of different colors  120   a ,  120   b ,  120   c , which are axially spaced along the door closure gauge. It is also envisaged that the measurement scale may comprise different numbers of bands of different colors. The measurement scale  120  may include a series of graduations indicating a length, for example in millimeters. It will be appreciated that the measurement scale may comprise any other markings or surface features capable of indicating a length. The measurement scale may extend over a length greater than the maximum anticipated tolerance stack-up of the parts forming the gap between the access door  10  and the door frame  12 . 
         [0035]    As depicted in  FIG. 2 , when the bump stop assembly  102  is fully assembled, the second end  106   b  of the door closure gauge  106  may be substantially aligned with the abutment surface  104   c  of the bump stop  104  and may contact the closure surface  108   a  of the closure pad  108  when the door is closed. 
         [0036]    The closure pad  108  may comprise a coupling portion  108   b  and an engaging portion  108   d . As depicted in  FIG. 2 , the closure surface  108   a  of the closure pad may be provided on the engaging portion  108   d . The engaging portion  108   d  and the coupling portion  108   b  of the closure pad may be separate components that are assembled to form the closure pad  108 . As shown in  FIG. 2 , the engaging portion  108   d  may comprise a recess  108   e  with a rim extending circumferentially around its edge. The coupling portion  108   b  may be received within the recess  108   e  and may form an interference fit with the inside surface of the rim. The coupling portion  108   b  may itself comprise a recess configured to receive a portion of the engaging portion  108   d . An adhesive may be used to assemble the coupling portion  108   b  with the engaging portion  108   d . Alternatively, the closure pad  108  may be a single component comprising the coupling portion  108   b  and the engaging portion  108   d.    
         [0037]    The coupling portion  108   b  may comprise a connector  108   c , for example a fir tree connector as described above with reference to the bump stop  104 . The connector  108   c  may connect the coupling portion to the access door  10  or the door frame  12 . Alternatively, the connector  108   c  may connect the coupling portion to the bump stop  104 . For example, the connector  108   c  may be received within the axial bore  104   b  of the bump stop  104 . 
         [0038]    The coupling portion  108   b  of the closure pad used within the bump stop assembly  102  may have a constant thickness regardless of the gap present between the bump stop  104  and the door frame  12  when the door is closed. By contrast, the thickness of the engaging portion  108   d  of the closure pad used within the bump stop assembly  102  may be variable in order to provide a closure pad  108  or closure pad assembly with the desired overall thickness. For example, a range of engaging portions  108   d  may be provided which can be assembled with the coupling portion  108   b  to provide the desired thickness of closure pad  108 . Alternatively, if the thinnest possible closure pad  108  is desired, no engaging portion  108   d  may be provided, and the coupling portion  108   b  may contact the abutment surface  104   c  of the bump stop directly. 
         [0039]    As depicted in  FIG. 2 , the bump stop  104  may be coupled to the access door  10 , and the closure pad  108  may be coupled to the door frame  12 . However, it is equally envisaged that the bump stop  104  may be coupled to the door frame  12  and the closure pad  108  may be coupled to the access door  10 . Alternatively, as mentioned above, the closure pad  108  may be coupled to the bump stop  104 . 
         [0040]    With reference to  FIG. 3 , according to an example of the present disclosure, a method  300  is described for setting the closure of the access door  10 . The method  300  may comprise a first step  302 , in which the bump stop  104  is coupled to the access door  10  or the door frame  12 . In a second step  304 , the access door  10  is closed until the door latches and is correctly aligned with the body of the vehicle. In a third step  306 , the door is opened and the extent of door closure gauge  106  protruding from the bump stop is determined. In a fourth step  308 , the door closure pad  108  of the correct thickness is coupled to the other of the door frame or the access door such that it engages the bump stop when the door is closed. 
         [0041]    In  FIG. 4 a   , the bump stop  104  and door closure gauge  106  are depicted after the first step  302  of the method  300  has been performed. At this point the second end  106   b  of the closure gauge  6  may be protruding from the bump stop  104  and the measurement scale  120  may protrude fully from the axial bore  104   b.    
         [0042]    In  FIG. 4 b   , the bump stop  104  and door closure gauge  106  are shown after the second step  304  of the method  300  has been completed. During this step, the access door  10  is closed and the door closure gauge  106  may be moved relative to the bump stop  104  through contact with the door frame  12  as the access door  10  is closed against it. At this stage in the method  300 , the closure pad  108  has not been provided within the bump stop assembly  102  and hence a gap may be present between the bump stop  104  and the door frame  12 . The gap is spanned by the protruding portion of the door closure gauge  106 . As depicted in  FIG. 4 b   , the measurement scale  120  may be partially received within the axial bore  104   b  of the bump stop  104  and may partially protrude therefrom. The length of the door closure gauge  106  protruding beyond the abutment surface  104   c  may therefore be determined from the protrusion of the measurement scale  120 . 
         [0043]    The position of the second end  106   b  of the door closure gauge relative to the bump stop abutment face  104   c  following the second step  304  may be affected by the manufacturing tolerances of all components in a tolerance stack between the bump stop  104  and the door frame  12 . Additionally, when the door is correctly aligned with the surrounding body panels of the vehicle, tolerances affecting the position of the body panels and the door panels may also affect the gap between the bump stop and the door frame. 
         [0044]    In the third step  306 , the length of door closure gauge protruding from the bump stop  104  may be determined using any measurement process known in the art. For example, a rule, depth gauge, or set of calipers may be used to measure the protruding length. Alternatively, the measurement scale  120  may be used to measure the protruding length. As depicted in  FIG. 4 b   , the first band  120   a  of the measurement scale  120  may now be within the axial bore  104   b  of the bump stop, the second band  120   b  may be protruding partially from the axial bore  104   b  and the third colored band  120   c  may be completely outside the axial bore  104   b . The color of the second band  120   b  may thereby indicate the length of door closure gauge  106  protruding from the bump stop  104 . 
         [0045]    The method  300  may further comprise the additional step  310  of selecting a closure pad  108  of the correct thickness from a set of closure pads of different thicknesses. The thickness of the closure pad  108  may be selected such that the closure pad thickness is substantially the same as the length of protrusion of the door closure gauge  106 , as determined in the third step  306 . 
         [0046]    With reference to  FIG. 5 , a kit of parts  500 , according to an example of the present disclosure, may be assembled that provides a plurality of different closure pads. The thickness of each of the different closure pads may be different than the others. As depicted in  FIG. 5 , the kit may comprise a coupling portion  108   b  and one or more engaging portions, for example first and second engaging portions  504 ,  506 . As described above with reference to  FIG. 2 , the coupling portion  108   b  may be used within the bump stop assembly  102  without an engaging portion  108   d  and hence the kit of parts  500  may be used to provide three different thicknesses of closure pad  108 . 
         [0047]    The different closure pads may have a range of thicknesses between 1.2 mm and 3.4 mm. For example, the coupling portion  108   b  may have a thickness of 1.2 mm, a first engaging portion  504  may have a thickness of 2.3 mm, e.g. at its rim, and a second engaging portion  506  may have a thickness of 3.4 mm, e.g. at its rim. The recess  504   e ,  506   e  provided in the first and second engaging portion is configured to receive the coupling portion  108   b , as described above. The recess may have a depth corresponding to the thickness of the coupling portion. The overall thickness of the closure pad  108  extending proud of the frame/door may be substantially equal to the thickness of the engaging portion. Alternatively, the first and second engaging portions  504 ,  506  may be configured to nest such that the thickness of the closure pad may be increased by coupling successive engaging portions to the coupling portion  108   b.    
         [0048]    Any number of engaging portions may be provided in the kit. The range of thicknesses of closure pad and the increment between closure pad thicknesses may vary. The range of thicknesses may depend on the stack of tolerances between the bump stop and the door frame, as mentioned above. 
         [0049]    The engagement portions  504 ,  506  and coupling portions  108   b  provided in the kit  500  may be color coded. For example, the coupling portion may comprise a colored portion  502   a  and the one or more engagement portions may comprise colored portions  504   a ,  506   a . The color of each colored portion may correspond to the thickness of the coupling portion, engaging portion, or the thickness of the resulting closure pad formed from assembling the engaging portion with the coupling portion  108   b . In each case, the color of the colored portion may match the color of the colored bands of the measurement scale  120  as shown in  FIG. 4 b   . The thickness of the closure pad may be substantially equal to the protrusion of the door closure gauge  106 , as indicated by the color of the measurement scale  120 . 
         [0050]    The engaging portions  504 ,  506  and/or coupling portion  108   b  may be configured such that the colored portion  504   a ,  506   a  of the engagement portions or coupling portion  502   a  is hidden when the closure pad  108  is assembled into the bump stop assembly  102 . For example, as shown in  FIG. 5 , the colored portion  504   a ,  506   a  may be provided on a surface of the engaging portions that is obscured by the coupling portion  108   b  when the closure pad is assembled. 
         [0051]    When the closure pads kit is color coded, the additional step  310  may comprise selecting the engaging portion or coupling portion with a colored portion that matches the color of the measurement scale  120  protruding from the axial bore  104   b  of the bump stop. 
         [0052]    Rather than comprising the coupling portion  108   b  and the one or more engaging portions  504 ,  506 , the kit may instead comprise a plurality of closure pads, each comprise a coupling portion and an engaging portion, with each closure pad being a different thickness. The kit may therefore comprise a set of closure pads of different thicknesses. 
         [0053]    Once the method  300  has been completed, the door closure gauge  106  may be removed from the bump stop assembly  102 . The door closure gauge may then be placed within the axial bore  104   b  of another bump stop  104  which is to be fitted to another door or door frame of a vehicle, e.g. the door closure gauge may be reusable. Alternatively, the door closure gauge  106  may not be removed, and when the door  10  is closed the door closure gauge  106  may be pushed by the closure pad  108  such that the door closure gauge  106  is fully received within the axial bore  104   b  and the second end  106   b  of the door closure gauge is substantially aligned with the abutment surface  104   c , as depicted in  FIG. 2 . The bump stop  104  and the door closure gauge  106  may be configured to retain the door closure gauge  106  within the axial bore  104   b  of the bump stop  104  and cannot subsequently be removed. As shown in  FIG. 2 , the door closure gauge  106  may block the axial bore  104   b  once the bump stop assembly  102  has been fully assembled. The second end  106   b  of the door closure gauge  106  may be configured to be uniform in appearance with the abutment surface of the bump stop. 
         [0054]    The embodiments described above are specific examples that do not describe all possible forms of this disclosure. The features of the illustrated embodiments may be combined to form further embodiments of the disclosed concepts. The words used in the specification are words of description rather than limitation. The scope of the following claims is broader than the specifically disclosed embodiments and also includes modifications of the illustrated embodiments.

Summary:
A bump stop assembly is provided for an access door. The assembly comprises a bump stop configured to couple to the access door or a door frame and a door closure gauge movably coupled to the bump stop. A closure pad couples the bump top to one of the door frame or the access door. The closure pad engages the other side of the access door and door frame when the door is closed. The thickness of a selected closure pad is determined based upon the extent that the door closure gauge protrudes relative to the bump stop.