Abstract:
A motor vehicle door module assembly in a motor vehicle door structure, the assembly including a module plate, a bracket, and a door handle pivotally mounted on the bracket. Coacting mounting structures are provided on the module plate and on the bracket which are operative in response to linear sliding movement of the bracket relative to the module plate to mount the bracket on the module plate while permitting a limited degree of linear play to facilitate the installation of the module assembly on the door structure. The coacting mounting structures take the form of a plurality of tabs on the module plate and a respective plurality of keyways in the bracket.

Description:
BACKGROUND 
   This invention relates to motor vehicle door assemblies and more particularly to a door module for use in forming a motor vehicle door assembly. 
   In the assembly of a present day motor vehicle door the inner panel of the door is typically provided with an opening and a door module, typically from a supplier, is fastened in the opening by the OEM on the assembly line. The door module typically carries door accessory items such as the window regulator mechanism. Following installation of the door module the inside door handle mechanism is installed. Alternatively, the inside door handle mechanism is installed on the door module by the supplier and shipped to the OEM. Whereas these procedures are generally satisfactory, they are labor intensive and therefore rather costly. 
   SUMMARY 
   This invention is directed to the provision of an improved method and apparatus for forming a motor vehicle door assembly. 
   The invention methodology relates to a method of mounting a motor vehicle door module in a motor vehicle door structure, the module including a module plate and inside door handle. According to the invention, the method comprises pivotally mounting the handle on a bracket; mounting the bracket on the module plate in a manner to retain the bracket on the module plate while allowing limited adjustment of the bracket relative to the module plate; positioning the module plate in the door structure and fixing the module plate to the door structure; and fixedly securing the bracket to the door structure. This methodology allows the handle to be shipped to the manufacturer as part of the module plate assembly whereafter the bracket may be adjusted relative to the module plate on the assembly line to facilitate the installation of other door accessory items on the door structure. 
   According to a further feature of the invention methodology, the step of mounting the bracket on the module plate further comprises snappingly latching the bracket to the module plate in response to the sliding movement while allowing a limited amount of play between the bracket and the module plate to provide the desired limited adjustment. 
   According to a further feature of the invention methodology, the step of mounting the bracket on the module plate further comprises providing a plurality of tabs on one of the bracket and module plate and providing a respective plurality of keyways on the other of the bracket and module plate for respective sliding receipt of the tabs. This arrangement provides a convenient means of mounting the bracket on the door module plate to provide the desired limited adjustment. 
   The invention apparatus is directed to a motor vehicle door handle assembly including a module plate positionable within the vehicle door structure, a door handle bracket mounted on the module plate, and an inside door handle pivotally mounted on the bracket. According to the invention, the assembly includes coacting mounting structures on the module plate and on the bracket operative in response to sliding movement of the bracket relative to the module plate to mount the bracket on the module plate. 
   According to a further feature of the invention apparatus, the coacting mounting structures are operative to mount the bracket on the module plate while allowing limited adjustment of the bracket relative to the module plate. 
   According to a further feature of the invention apparatus, the coacting mounting structures are operative in response to the sliding movement to snap the bracket in place relative to the mounting plate. 
   According to a further feature of the invention apparatus, the coacting mounting structures comprise a plurality of tabs on one of the mounting plate and bracket coacting with a respective plurality of keyways in the other of the mounting plate and bracket. In the disclosed embodiment of the invention, the tabs are provided on the module plate and the keyways are provided in the bracket. 
   According to a further feature of the invention apparatus, the tabs have a “T” cross-sectional configuration including a relatively narrow stem portion outstanding from the module plate or bracket and a relatively wide horizontal bar portion on the free end of the stem portion, and each keyway includes a relatively wide entry portion sized to pass the bar portion of a respective tab and a relatively narrow home portion sized to accommodate the stem portion of a respective tab. 
   According to a further feature of the invention apparatus, one of the keyways includes a snap structure whereby the stem portion of a tab passing into the home portion of the keyway is snappingly engaged by the keyway snap structure. 
   According to a further feature of the invention apparatus, each keyway includes a throat between the entry portion and the home portion and the keyway snap structure comprises cantilevered resilient fingers terminating at the throat of the keyway, resiliently yielding in response to movement of the tab stem portion into the keyway throat, and snapping back following movement of the tab stem portion into the keyway home portion to latchingly engage the tab stem portion and preclude inadvertent withdrawal of the tab from the keyway home portion. 
   According to a further feature of the invention apparatus, the sliding movement of the bracket is a linear movement and the latching engagement of the tab stem portion allows a limited amount of linear movement of the bracket relative to the module plate to facilitate the installation of other door accessory items on the door structure. 
   Although the invention method and apparatus are illustrated and described herein in association with a door module, features of the invention allow the disclosed handle mounting structure to be utilized in the mounting of a handle assembly directly to a door structure rather than to a module plate positionable within a door structure. 
   Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
       FIG. 1  is a somewhat schematic exploded view of a motor vehicle door structure; 
       FIG. 2  is a view of an inside door handle assembly shown in exploded association with a module plate; 
       FIG. 3  is a perspective view of an inside door handle assembly; 
       FIG. 4  is a perspective view of a inside door handle bracket; 
       FIG. 5  is a perspective view of an inside door handle lock button; 
       FIG. 6  is an exploded perspective view of the inside door handle assembly; 
       FIG. 7  is a fragmentary perspective view showing the inside door handle assembly installed on the module plate; 
       FIG. 8  is a fragmentary perspective view showing details of the portion of the module plate receiving the inside door handle assembly; 
       FIG. 9  is a schematic view illustrating the mounting coaction of the inside door handle assembly and the module plate; 
       FIG. 10  is a cross-sectional view showing details of the mounting of the inside door handle assembly on the door structure; and 
       FIG. 11  is a fragmentary view showing a detail of the mounting of the inside door handle to the inside door handle bracket. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The motor vehicle door seen schematically and fragmentarily in  FIG. 1  includes a door structure  10  and a door module  11  including a module plate  12  and an inside door handle assembly  14 . 
   Door structure  10  includes a frame portion  16  defining a window opening  18  and an inner panel  20  defining a module opening  20   a  and a plurality of apertures  22  in spaced surrounding relation to the opening  20   a . Door structure  10  is typically formed as a metal fabrication. 
   Module plate  12  is typically formed of a plastics material in a molding operation, has a size and shape generally conforming to the size and shape of the door inner panel opening  20   a , and is secured to the door inner panel within the dash lines seen in  FIG. 1  and utilizing suitable fasteners passing though apertures  23  in the module plate and inner door panel apertures  22 . 
   Inside door handle assembly  14  ( FIGS. 2-6 ) includes a bracket  24 , an inside handle  26 , and a lock button  28  all preferably formed of a suitable plastics material. 
   Bracket  24  includes a main body portion  24   a , an arm portion  24   b , an arm portion  24   c  and a trunnion structure  24   d.    
   Main body portion  24   a  includes an arcuate flange portion  24   e  and a floor portion  24   f  defining an aperture  24   g.    
   Arm portion  24   b  extends radially outwardly from flange  24   e  in general alignment with aperture  24   g  and includes a base portion  24   h  reinforced by gussets  25 . A keyway  24   i  is formed in base portion  24   h . Keyway  24   i  ( FIG. 9 ) includes a relatively wide generally rectangular entry portion  24   j , a relatively narrow home portion  24   k  and a funneled throat portion  24   l  interconnecting the portions  24   j  and  24   k . 
   Arm portion  24   c  extends generally at right angles to a line passing through aperture  24   g  and keyway  24   i  and defines a keyway  24   m . Keyway  24   m  includes a relatively wide generally rectangular entry portion  24   n  and a pair of cantilevered resilient fingers  24   p  defining a relatively narrow home portion  24   q  and having free ends  24   r  terminating at and defining a throat between the wide entry portion  24   n  and the narrow home portion  24   q.    
   Trunnion structure  24 d defines aligned trunnions  24   s ,  24   t ,  24   u  and a cylindrical journal  24   v . 
   Handle  26  includes a main body portion  26   a  and an actuator arm portion  26   b.    
   Main body portion  26   a  defines a generally rectangular handle opening  26   f , a circular lock button opening  26   c , and aligned pivot pin openings  26   d . 
   Actuator arm  26   b  extends generally radially downwardly with respect to the associated pivot opening  26   d  and terminates in a linkage opening  26   e . 
   Lock button  28  includes a generally circular main body portion  28   a  sized to fit within lock button opening  26   c  of the handle and defining aligned pivot pin openings  28   b , and an actuator arm  28   c  extending downwardly from the main body portion and terminating in a linkage opening  28   d.    
   In the assembled relation of the inside door handle assembly  14 , the door handle  26  and the lock button  28  are pivotally mounted on the bracket  24  by a pivot pin  30  passing though an aperture  26   d , though journal  24   v , though trunnion  24   u , though trunnion  24   t , though trunnion  24   s , and though the other aperture  26   d . The handle and the lock button are thus pivotally mounted on the pivot axis defined by the pivot pin  30  for pivotal movement relative to each other and relative to the bracket. A coil spring  32  positioned around journal  24   v  provides resilient resistance to the pivotal movement of the handle relative to the bracket. 
   The handle assembly is mounted on module plate  12  utilizing the keyways  24   i ,  24   m  in coaction with tabs molded integrally with the module plate. Specifically, a first tab  34  is formed integral with the module plate for coaction with keyway  24   i  and a second tab  36  is formed integral with the module plate for coaction with keyway  24   m.    
   Tab  34  is formed on a module plate pad  12   a  and has a “T” cross-sectional configuration including a relatively narrow stem portion  34   a  upstanding from the pad  12   a  and a relatively wide horizontal, generally rectangular bar portion  34   b  on the free upper end of the stem portion. 
   Tab  36  upstands from a pad  12   b  of the module plate and has a “T” cross-sectional configuration including a relatively narrow stem portion  36   a  upstanding from the pad and a relatively wide, horizontal, generally rectangular bar portion  36   b  on the free upper end of the stem portion. The module pads and the tabs are configured such that the tops of the pads  12   a  and  12   b  are at the same height and the tops of the bar portions  34   b  and  36   b  are at the same height. 
   Module plate  12  further includes an aperture  12   c  defined in a module plate pad  12   d . Aperture  12   c  and tabs  34  and  36  have a geometrical inter-relationship generally corresponding to the geometrical inter-relationship between aperture  24   g  and keyways  24   i  and  24   m.    
   In use, the door module is typically produced by a supplier organization and thereafter is shipped to an OEM manufacturer where the door module is assembled onto the door structure during the vehicle assembly procedure. According to the method and apparatus of the invention, the module plate and inside door handle assembly are produced by the supplier organization, the inside door handle assembly is mounted on the module plate in a manner to retain the bracket on the module plate while allowing limited adjustment of the door handle assembly relative to the module plate, the module plate and the door handle assembly are shipped to the OEM, the module plate is positioned on the door structure and fixedly secured to the door inner panel, the limited adjustability of the door handle assembly relative to the module plate is utilized to adjust the door handle assembly relative to the module plate to facilitate the installation of other motor vehicle door accessory items, and the door handle assembly is fixedly secured to the door structure. 
   Specifically, at the supplier location, the keyways  24   i  and  24   m  of a door handle assembly are positioned proximate the tabs  34  and  36  of a module plate; the bar portions  34   b ,  36   b  of the tabs are passed through the entry portions  24   j ,  24   n  of the keyways to position the base member  24   h  of arm  24   b  against the top of pad  12   a  and position the arm  24   c  against the top of pad  12   b ; and the door handle assembly is slid linearly relative to the module plate to pass the tab stem portions  34   a ,  36   a  into the keyway home portions  24   k ,  24   q . As the stem portion  36   a  passes from the keyway entry portion  24   n  into the keyway home portion  24   q , the fingers  24   p  yield resiliently to allow the stem portion to move into the home portion as defined by the fingers whereafter the fingers snap back following movement of the tab stem portion into the keyway home portion to latchingly engage the tab stem portion and preclude inadvertent withdrawal of the tab from the keyway home portion. The height of stem portions  34   a ,  36   a  is slightly greater than the thickness of floor  24   j  and arm  24   c  so that the bar portions  34   b ,  36   b  closely and snugly overlie the floor  24   j  and arm  24   c  with the stem portions in the home position. 
   The tabs, keyways and fingers are dimensioned such that, with the stem portions positioned in the keyway home portions, a limited amount of linear adjustment movement of the inside door handle assembly relative to the module plate is permitted. Specifically, as best seen in  FIGS. 9 and 11 , the keyway home portion defined by the fingers  24   p  is somewhat longer than the length of the tab stem portion  36   a  so that the inside door handle assembly is free to move linearly relative to the module plate a limited amount without detaching the door handle assembly from the module plate. Following the mounting of the door handle assembly on the module plate, a door latch cable  40  is secured to actuator arm  26   b  and a door lock cable  42  is secured to actuator arm  28   c . The mounting of the cables on the module plate is facilitated by lugs  12   e  formed integrally with the module plate coacting with cable end connector members  44 . 
   After the module plate has been installed on the inner panel  22  of the door structure the limited amount of adjusting movement of the inside door handle assembly relative to the module plate may be utilized to facilitate the installation of related door accessory items on the door structure. For example, the limited amount of adjusting movement may be utilized to facilitate the precise positioning of the cables  40  and  42  and this limited amount of adjusting movement also facilitates the installation of the interior trim panel (not shown) on the door structure. With respect to the door trim panel, manufacturing tolerance build-ups make it convenient to be able to move the inside door handle assembly in a limited manner relative to the door module to install the door trim panel on the door in surrounding relationship to the inside door handle assembly. 
   After the limited amount of linear adjusting movement of the inside door handle assembly relative to the module plate has been utilized to facilitate the installation of the various door accessory items, and with reference to  FIG. 10 , a screw  50  is passed downwardly through aligned apertures  24   g ,  12   c  and  22  for engagement with a weld nut  52  positioned in surrounding relation to aperture  22  whereby to complete the securement of the door module assembly to the door inner panel. Screw  50  preferably has a smooth shank with a dog tip lead  50   a  so that it may search for and locate the threaded opening of the weld nut  52  irrespective of the final position of lateral adjustment of the inside door handle assembly relative to the module plate. In this regard, the apertures  24   g ,  12   c  and  22  are all oversized with respect to the shank  50   b  of the screw  50  to accommodate this lateral adjustment. 
   The method and apparatus of the invention will be seen to provide many important advantages. Specifically, the invention design allows for positive retention of the door handle assembly on the module plate during shipping between the supplier facility and the OEM facility; allows controlled adjustment of the door handle assembly relative to the module plate during vehicle assembly to facilitate the installation of door accessory items irrespective of tolerance build ups; reduces the number of fasteners (and potential water entry paths) for the door module assembly; allows the handle assembly to be used in multiple door applications including full window door frame door constructions and door constructions without a window frame; and provides a strong, positive mounting of the door handle assembly on the door structure by virtue of the triangulated mounting provided by the final fastener  50  and the spaced tabs  34  and  36 . Further, the snap mounting of the door handle assembly provides universal mounting capability for the handle assembly and specifically allows the door handle assembly to be used in a door module application or in a conventional application where the door handle assembly is mounted directly to the door structure. 
   While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.