Patent Publication Number: US-2005115155-A1

Title: Door for a motor vehicle

Description:
TECHNICAL FIELD  
      The present invention relates to a door for a motor vehicle.  
     BACKGROUND ART  
      As is known, the side door of a motor vehicle comprises a metal skeleton which in turn comprises an upper frame which delimits a window which can be closed by a sliding window pane, and a lower box-shaped portion formed by an inner wall and an outer wall joined together along an edge. The inner and outer walls delimit between them a compartment which houses the window pane when it is lowered, and certain operating and control devices, such as the window regulator device and the lock of the door.  
      During the assembly of the door, these devices are inserted into the compartment through corresponding apertures formed in part of the surface of the inner wall, and are connected integrally to the skeleton. Subsequently, these apertures are closed by means of a shaped trim panel which is generally made from plastic material and is joined integrally to the inner wall to delimit the passenger compartment of the motor vehicle.  
      The doors of the known type described above are unsatisfactory in terms of assembly time and costs, since it is relatively inconvenient to insert the various devices into the apertures of the inner wall and permanently connect the devices to the skeleton by operating through these apertures.  
      To overcome these disadvantages, there is a known way of making a module which comprises a supporting panel, generally made from plastic material, and the various operating and control devices, which are connected integrally to the supporting panel. During the assembly of the door, the module is pre-assembled and then conveyed to a station where it is connected integrally to a skeleton which normally does not have the inner wall.  
      The doors of the known type described above have the disadvantage that the supporting panel is relatively complex, bulky and expensive, since it must be more rigid than the trim panels of the conventional type in order to support the operating and control devices without becoming deformed in transit from one station of the assembly line to another.  
     DISCLOSURE OF INVENTION  
      The object of the present invention is to provide a door for a motor vehicle which enables the above problems to be overcome in a simple and economical way, and, in particular, makes it possible to simplify the assembly of at least the window regulator device by using a trim panel of the conventional type.  
      According to the present invention, a door for a motor vehicle is provided, comprising a supporting skeleton comprising a frame forming a window and a box-shaped portion forming an inner compartment and comprising an outer wall and an inner wall, and a window regulator device housed in the compartment and capable of moving a window pane for closing the window. The inner wall has at least one aperture formed in part of its surface for fitting the window regulator device into the compartment. This aperture is covered by a trim panel connected integrally to the box-shaped portion. An assembly module comprises the window regulator device, the trim panel, and means of relative positioning and support to join the window regulator device, at least in a temporary way, to the trim panel. Fixing elements are provided to connect the assembly module integrally to the box-shaped portion. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The invention will now be described with reference to the attached drawings, which illustrate a non-restrictive example of embodiment of the invention, in which:  
       FIG. 1  shows, partially and in lateral elevation, a first preferred embodiment of the door for a motor vehicle made according to the present invention;  
       FIGS. 2 and 3  show corresponding details of the door of  FIG. 1 ;  
       FIGS. 4 and 5  are sections, on an enlarged scale and with parts removed for the sake of clarity, taken along the line IV-IV and the line V-V respectively in  FIG. 1 ;  
       FIGS. 6, 7  and  8  are figures similar to  FIGS. 1, 2  and  3  respectively, illustrating a second preferred embodiment of the door for a motor vehicle made according to the present invention;  
       FIG. 9  is a section, on an enlarged scale and with parts removed for the sake of clarity, taken along the line IX-IX in  FIG. 8 ; and  
       FIG. 10  is a section, with parts removed for the sake of clarity, taken along the line X-X in  FIG. 6 . 
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION  
      In  FIG. 1 , the number  1  indicates, as a whole, a side door for a motor vehicle (not illustrated), this door comprising a metal supporting skeleton  2  (partially illustrated) of a known type, which in turn comprises an upper frame (not illustrated) delimiting a window which can be closed by a movable window pane  3 .  
      With reference to  FIGS. 1 and 2 , the skeleton  2  also comprises a lower box-shaped portion  5  formed by two walls  7  and  8  or sheets opposite each other, which face the interior and exterior of the motor vehicle respectively, and which are joined together along the perimetric edge of the wall  8 . The walls  7  and  8  delimit between them an inner compartment  9 , which houses a window pane  3 , at least when the window pane  3  is lowered, and has a plurality of access apertures formed in part of the surface of the wall  8  and, in particular, an essentially triangular aperture  11  and an essentially trapezoidal aperture  12  (shown in dashed lines in  FIG. 1 ).  
      With reference to FIGS.  1  to  5 , the apertures  11  and  12  are closed by a shaped trim panel  14  ( FIGS. 1 and 3 ) which partially covers the wall  8  externally and delimits the passenger compartment of the motor vehicle, and is made in one piece, preferably by moulding from a plastic material.  
      The wall  8  and the panel  14  are joined together by a connecting system  15  which comprises a plurality of screws  16  located along a perimetric portion of the panel  14 , and a plurality of centring portions  17  formed in one piece with the panel  14  and engaging in corresponding reference seats  18  formed in the wall  8  ( FIG. 4 ).  
      The system  15  comprises three joining devices  19  for connecting integrally and also providing fastening points to the wall  8 , the panel  14  and a plate  21 , which comprises an intermediate portion  22  with an essentially triangular profile extending through the aperture  11 , and three terminal fastening appendages  23 .  
      Each of the appendages  23  comprises a flattened annular portion  24  parallel to, and interposed between, the wall  8  and the panel  14  along the periphery of the aperture  11 , and an intermediate stud  25 , which projects from the corresponding portion  24  along an axis A orthogonal to the portion  24 , is shaped in the form of a collar to form a corresponding axial through hole  26 , and engages in a through seat  27  formed through the panel  14 .  
      Each stud  25  and the corresponding seat  27  form part of a device  19 , which additionally comprises an internally threaded nut  31  connected integrally to the wall  8  and coaxially with the corresponding stud  25 , and one of the screws  16  comprising a head  33  bearing on an outer surface  34  of the panel  14 , and a threaded shank  35  engaging in the corresponding hole  26  and locked by the corresponding nut  31 .  
      With reference to  FIG. 1 , the plate  21  forms part of a window regulator device  37 , shown schematically, which is housed in the compartment  9  and comprises an arm  38  for moving the window pane  3 , this arm being hinged, at one end, to the portion  22  so that it rotates about an axis  39  which is essentially orthogonal to the walls  7  and  8  and to the plane of  FIGS. 1 and 3 . The arm  38  has an integral pushing stud  41  projecting from its other end, parallel to the axis  39 , and coupled slidably to an essentially horizontal rectilinear guide  42  fixed to the base of the window pane  3 . The arm  38  comprises a sector  44 , which extends about the axis  39  in an intermediate position between the ends of the arm  38 , delimits a slot  45 , is internally toothed, and engages with a pinion  46  driven by a gear motor unit  47  (shown schematically). The unit  47  is operated to rotate the arm  38  and thus to raise or lower the window pane  3 , and comprises, in the particular example described, an electric motor and a transmission of the worm and helical gear type.  
      With reference to  FIGS. 1 and 3 , the panel  14  comprises a terminal portion  51 , at the opposite end to the device  37 , and an intermediate aperture  52  which provides access to the aperture  12  and is closed by a snap-on hatch  53 , which is made in one piece with the panel  14  and is joined to the portion  51  by means of a virtual hinge.  
      With reference to  FIGS. 1, 3  and  5 , a bracket  55  extends in one piece from the portion  51  and projects into the compartment  9  through the aperture  12 , and carries a lock  56  housed in a terminal area  57  of the compartment  9  delimited by a rear side  58  of the box-shaped portion  5 . The lock  56  is fixed to the side  58  by means of a pair of screws  59  and is joined to the bracket  55  with the interposition of an elastic element  60 , preferably accordion-shaped, which allows the lock  56  to move with respect to the panel  14  in a plane which is essentially horizontal and orthogonal to the portion  51 . In a variant which is not illustrated, the element  60  is made in one piece with the bracket  55  and therefore with the panel  14 .  
      During the assembly of the door  1 , after the skeleton  2  has been assembled, the lock  56  is connected to the bracket  55 , while the fastening plate  21  of the device  37  is joined movably to the panel  14  by the forcing of the studs  25  into the corresponding seats  27 . Thus the plate  21  is placed in a fixed position with respect to the panel  14  and supported, in a temporary way, by the panel  14  during the assembly, thus forming a pre-assembled module  61  comprising the panel  14 , the device  37  and the lock  56 .  
      At the same assembly station, the module  61  is placed in a position facing the wall  8  and is then joined to the box-shaped portion  5  by insertion of the lock  56  into the aperture  12  and movement of the module  61  with respect to the skeleton  2  in an essentially horizontal direction from the left to the right with reference to FIGS.  1  to  3 , in such a way that the lock  56  is introduced into the rear area  57  of the compartment  9 . The device  37  is then inserted through the aperture  11 , while the module  61  continues to be moved in the aforesaid direction, until the lock  56  bears against the side  58 , and until the stud  41  moves beyond the guide  42 , compressing the elastic element  60  if necessary. At this point, the module  61  is made to withdraw horizontally towards the left so that the stud  41  is made to enter the guide  42 , and is placed in a fixed position with respect to the wall  8  by insertion of the centring portions  17  into the corresponding reference seats  18 .  
      Finally, the screws  16  are screwed in to secure the module  61  to the wall  8 , and the lock  56  is positioned manually through the apertures  52  and  12  in such a way that the screws  59  can be tightened through the side  58 , by working from the exterior of the door  1 .  
      Finally, the hatch  53  is closed, and other trim panels (not illustrated) are applied to completely cover the wall  8 , providing fluid-tight joints between the panels and the skeleton  2 .  
      FIGS.  6  to  10  show a door  70  whose components are identified, where possible, by the same reference numbers as those used for the corresponding parts of the door  1 .  
      The wall  8  is joined to a module  71  comprising a trim panel  74  which has constructional characteristics similar to those of the panel  14 , faces the wall  8  and is joined to the box-shaped portion  5  by a connecting system  75  comprising the screws  16  and a set of centring portions (not illustrated) interacting with the wall  8 . The module  71  comprises the lock  56  and a window regulator device  77  ( FIGS. 6, 8 ), which differs from the device  37  in the different shape of the plate  21  and the arm  38  and in that it has no collar-shaped portions  26 , while the holes  26  are delimited by the portions  24 .  
      The device  77  is carried by the panel  74  in a temporary way by means of a pair of studs  78  ( FIG. 9 ), which are made in one piece with the panel  74 , project along corresponding axes A towards the wall  8 , and are snap-fitted into corresponding holes  26  formed in one of the appendages  23  of the plate  21 . In a variant which is not illustrated, the studs  78  are separate from the panel  74  and from the plate  21 , and are connected integrally to the panel  74 . The plate  21  is connected integrally to the box-shaped portion  5  by means of three fixing screws  79 , which engage in corresponding holes  26  and are screwed into corresponding nuts  31  ( FIG. 7 ) which are integral with the wall  8 , to secure the appendages  23 .  
      In the panel  74  there are formed an aperture  80  for a loudspeaker (not illustrated) which can be housed in the compartment  9 , and an intermediate aperture  82 , which has dimensions greater than those of the aperture  52  of the panel  14 , provides access both to the device  72  and to the lock  56  through the apertures  11  and  12 , and is closed by a panel  83  ( FIGS. 8, 10 ) connected releasably to the panel  74 , preferably by a snap-fitting method. The panel  83  delimits the passenger compartment together with the panel  74 , and is covered externally with fabric or other finishing material with a pleasing appearance.  
      With reference to  FIGS. 6 and 8 , the module  71  comprises an interior handle  84  which is carried directly by the panel  74  and which, in turn, comprises a lever  85 , which can be operated from inside the passenger compartment to operate the lock  56  and is connected to the lock  56  by a lever mechanism  86  (partially illustrated) interposed between the panel  74  and the wall  8 .  
      Also with reference to  FIGS. 6 and 8 , the module  71  comprises a guide  87  which enables the window pane  3  to slide in the compartment  9  and is carried by the panel  74  by means of the lock  56 , to which it is connected integrally, preferably by a snap fitting.  
      The module  71  also comprises electrical wiring (not illustrated) connected to the electrical system of the motor vehicle and certain elements  88  (shown schematically) which form the inner parts of an outer handle of the door  70 . These elements  88  are housed in the compartment  9  and comprise, in particular, a protective or anti-theft wall carried by the guide  87 , the lock operating lever mechanisms  56  and a drum or block for a key to open the door  70 , connected to the guide  87  by means of an elastic bracket  89 , which projects from the guide  87  on the side opposite the lock  56 .  
      With reference to  FIG. 10 , the module  71  comprises, finally, sealing elements  90  for excluding water and dust, interposed between the panel  74  and the wall  8 , and a gasket element  91 , commonly known as a “window seal”, connected integrally to the panel  74  in a position facing the window pane  3  and delimiting the window of the door  70  to interact by sliding with the window pane  3 .  
      With reference to FIGS.  6  to  10 , during the assembly of the door  70 , by contrast with the assembly of the door  1 , the plate  21  is snap-fitted to the studs  78 , which have a rigidity and resistance such that the device  77  is supported at least in a temporary way, in other words such that the device  77  is kept joined to the panel  74  at least for the time required for the module  77  to be positioned against the wall  8 , by operations carried out at the same assembly station.  
      The module  71  is initially joined to the box-shaped portion  5  by the insertion of the bracket  89  and the elements  88  into the aperture  12 , followed by the insertion of the lock  56 , by means of a slight rotation of the module  71  in the anti-clockwise direction according to FIGS.  6  to  8 , so that the lock  56  is positioned in the area  57 .  
      The module  71  is then simply pushed towards the wall  8  in order to insert the arm  38  into the aperture  11  and to position the appendages  23  so that they bear against the wall  8 . The panel  74  is positioned on the wall  8  by means of the centring portions, and the screws  16  and  79  are then tightened to secure the panel  74  and the device  77  to the wall  8 . Finally, by operations carried out from outside the box-shaped portion  5 , the lock  56  is fixed to the side  58  by means of the screws  59 , the elements  88  are secured to the wall  7  by means of screws which are not illustrated, and the window pane  3  is made to slide into the compartment  9  along the guide  87  until the edge of the window pane  3  is snap-fitted into the guide  42 .  
      On completion of the assembly operations, the panel  83  is fitted to close the apertures  80 ,  82 .  
      It will be clear from the above that the devices  19  and the studs  78  make it extremely simple to fit the device  37  to the door  1  by using trim panels  14 ,  74  of the conventional type, in other words those having a pleasing appearance and not having any special stiffening portions.  
      In particular, the studs  25  and the seats  27  for the door  1  and the studs  78  and the holes  26  for the door  70  enable the plate  21  to be placed in a fixed reference position with respect to the panel  14  and to connect the plate  21  to the panel  14 , at least in a temporary way, during assembly. The assembly operations are therefore simplified by comparison with the known solutions, since the modules  61 ,  71  make it possible to eliminate manual operations through the aperture  11  for positioning and connecting the window regulator devices  37 ,  77  in the compartment  9 .  
      At the same time, the modules  61 ,  71  make it possible to use a skeleton  2  of conventional type, in other words one which has a structure, a rigidity, and apertures  11  and  12  of the wall  8  which are identical to those of the skeletons normally used and which have apertures formed in only a part of the surface of the wall  8 .  
      Moreover, the fact that the pre-assembled modules  61 ,  71  comprise other devices carried by the panels  14 ,  74 , and in particular the lock  56 , the handle  84 , the guide  87  and the elements  88 , further simplifies the operations of assembling the doors  1 ,  70 , since, by contrast with the known solutions, these devices are placed in the corresponding positions in the compartment  9  by a single assembly operation, instead of being fitted one after another, and do not require the use of complex fitting equipment. As regards the lock  56 , the apertures  12  and  52 ,  82  are used only for positioning, while the fixing of the lock  56  is carried out by working from the outside of the compartment  9 .  
      Furthermore, the elasticity of the studs  78 , of the element  60  and of the bracket  89  makes it possible to compensate automatically, on the one hand, the thermal deformations of the components of the door  1 ,  70 , and, on the other hand, relatively minor errors of machining and/or positioning of the components.  
      With reference to the door  70 , since the fastening points formed by the studs  78  are independent of the fastening points formed by the fixing screws  79 , the reactive forces caused by the operation of the device  77  are discharged directly to the skeleton  2  and not to the panel  74 , which is therefore not subject to displacement, deformation or vibration when in use.  
      Moreover, the module  71  also provides the panel  74  with a water and dust seal function with respect to the box-shaped portion  5  and the window pane  3 , and enables the window pane  3  to be fitted in an extremely simple way, without the need to make complex adjustments of the position of the guide  87  with respect to the device  77 , since both the guide  87  and the device  77  are carried by the panel  74  and placed in fixed relative positions.  
      Additionally, the possibility of removing the panel  83 , which forms a kind of “plug” for the aperture  82 , enables all the devices carried by the panel  74  to be inspected without the complete dismantling of the module  71 , while the components of the door  74  can be dismantled in a simple way by disengaging the snap fittings through the aperture  82 . In particular, the device  77  can be disconnected from the door  70  simply by slackening the screws  79  and disengaging the studs  78  from the holes  78 .  
      Finally, it is clear from the above that modifications and variations can be applied to the described door  1 ,  70  without departure from the scope of protection of the present invention.  
      In particular, the window regulator device could be different from that described, and/or the functions of support and relative positioning between the plate  21  and the panel  14  could be at least partially provided by the screws  16  of the devices  19 .