Patent Publication Number: US-2022219513-A1

Title: Door module

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application Ser. No. 63/141,936, filed Jan. 26, 2021, and the benefit of U.S. Provisional Application Ser. No. 63/135,010, filed Jan. 8, 2021, which are both incorporated herein by way of reference in their entirety. 
    
    
     FIELD 
     The present disclosure relates to door modules of the type installed in doors associated with motor vehicles, and more particularly, to door modules having an outside handle assembly fixed thereto. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     It is known to install pre-assembled door modules within the interior of a closure assembly associated with a motor vehicle. It is further known to fix an outside door handle assembly and a latch assembly to a mount member, sometimes referred to as presenter, of the pre-assembled door modules in advance of assembling the pre-assembled door module to the closure assembly of the motor vehicle. Unfortunately, complications can arise when assembling pre-assembled door modules to closure assemblies due to misalignment of components fixed to the pre-assembled door modules with associated mount locations of the closure assemblies, such as providing desired alignment of a carrier of the pre-assembled door modules, while at the same time providing desired alignment of the outside door handle assembly and latch assembly with associated mount locations of the closure assembly. 
     In view of the above, there is a need to provide a pre-assembled door module and a latch/outside handle subassembly therefor, wherein the latch/outside handle subassembly allows a latch assembly and outside handle assembly of the pre-assembled door module to be readily aligned with respective mount locations of the closure assembly, such that the pre-assembled door module enhances economies of manufacture and assembly of the closure assembly, while at the same time optimizing functionality of the latch assembly, the outside door handle assembly and other features associated with the pre-assembled door module. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     It is an object of the present disclosure to provide a door module that overcomes at least the complications presented by known door modules discussed above. 
     It is an aspect of the present disclosure to provide a door module that embodies the inventive concepts set forth in the following illustrations. 
     It is a further aspect of the present disclosure to provide a method of installing the door module within the cavity of a vehicle door that embodies the inventive concepts set forth in the following illustrations. 
     It is a further aspect to provide a door module that facilitates assembly of a carrier having an outside handle assembly coupled thereto to a door panel structure of a door assembly. 
     In accordance with these and other aspects of the disclosure, a door module is provided including, a carrier module, a handle chassis, and an arm operably coupled to the carrier module, wherein the arm extends outwardly from the carrier module. The handle chassis is operably coupled to the arm for movement relative to the carrier module to facilitate assembly of the carrier module to the door module. 
     In accordance with another aspect of the disclosure, a main body is connected to the carrier module, wherein the arm is connected to the main body. The main body can be formed as a monolithic piece of material with the arm or as a separate piece of material from the arm. 
     In accordance with another aspect of the disclosure, the arm is cantilevered from the main body, with the arm being flexible to allow the handle chassis to move toward the main body and the carrier module along a first axis and away from the main body and the carrier module along the first axis. 
     In accordance with another aspect of the disclosure, the arm extends to a free end, with the handle assembly being operably coupled to the free end for movement along a second axis, the second axis extending in inclined relation to the first axis. 
     In accordance with another aspect of the disclosure, the second axis extends generally transversely to the first axis. 
     In accordance with another aspect of the disclosure, a handle mount body is connected to the free end of the arm, with the handle chassis being connected to the handle mount body. 
     In accordance with another aspect of the disclosure, the handle chassis is fixed against movement relative to the handle mount body. 
     In accordance with another aspect of the disclosure, the handle mount body is configured to move relative to the arm along the second axis to facilitate locating the handle chassis relative to an outer panel of the door module during assembly. 
     In accordance with another aspect of the disclosure, the handle mount body has at least one of a projection and a slot and the arm has at least one of the other of the projection and the slot, the projection of one of the handle mount body and/or the arm being received for sliding movement in the slot of the other of the handle mount body and/or the arm along the second axis. 
     In accordance with another aspect of the disclosure, the arm has a first portion extending outwardly from the main body and a second portion extending in inclined relation from the first portion to the free end, such that the second portion is laterally spaced from the main body and extends generally parallel to the main body. 
     In accordance with another aspect of the disclosure, the arm first portion extends generally transversely from the main body and the second portion extends generally transversely from the first portion to the free end. 
     In accordance with another aspect of the disclosure, the second portion is generally planar and generally L-shaped as viewed looking transversely to the plane along which the second portion extends. 
     In accordance with another aspect of the disclosure, the carrier module can be provided having an outer periphery configured for attachment to an inner panel of a door panel structure of a motor vehicle. 
     In accordance with another aspect of the disclosure, the carrier module can be configured to close off an opening in the inner panel. 
     In accordance with another aspect of the disclosure, a presenter assembly for a door module of a door panel structure of a motor vehicle is provided. The presenter assembly includes a main body configured for attachment to a carrier module the door module. An arm extends outwardly from the main body, and a handle chassis is operably coupled to the arm. The handle chassis is moveable relative to the main body to facilitate assembly and enhance functionality in use. 
     In accordance with another aspect of the disclosure, the arm of the presenter assembly is cantilevered from the main body to enhance flexibility of the arm, thereby allowing the handle chassis to move toward the main body along a first axis during initial stages of assembly to a door structure and away from the main body along the first axis during completion of assembly. 
     In accordance with another aspect of the disclosure, the arm of the presenter assembly extends to a free end, wherein the handle chassis is operably coupled to the free end for movement along a second axis, wherein the second axis extends generally transversely to the first axis, thereby providing multiple degrees of freedom for adjustment of the handle chassis during assembly. 
     In accordance with another aspect of the disclosure, the presenter assembly further includes a handle mount body connected to the free end of the arm, the handle chassis being connected to the handle mount body. 
     In accordance with another aspect of the disclosure, the handle chassis of the presenter assembly is fixed against movement relative to the handle mount body. 
     In accordance with another aspect of the disclosure, the handle mount body of the presenter assembly is configured to move relative to the arm along the second axis. 
     In accordance with another aspect of the disclosure, the handle mount body of the presenter assembly has at least one of a projection and a slot and the arm has at least one of the other of the projection and the slot, the projection of at least one of the handle and/or arm being received for sliding movement in the slot of the other of at least one of the handle and/or arm for movement along the second axis. 
     In accordance with another aspect of the disclosure, the arm of the presenter assembly has a first portion extending outwardly from the main body and a second portion extending in inclined relation from the first portion to the free end. 
     In accordance with another aspect of the disclosure, the arm first portion extends generally transversely from the main body and the second portion extends generally transversely from the first portion to the free end. 
     In accordance with another aspect of the disclosure, the second portion of the presenter assembly arm extends along a plane, with the second portion being generally L-shaped, as viewed looking along an axis extending generally transversely to the plane along which the arm extends. 
     In accordance with another aspect of the disclosure, a method of installing a door module within a cavity of a vehicle door is provided, wherein the door module has an expanded state and a collapsed state. The method includes the following steps: inserting the door module into the cavity of the vehicle door, and during the inserting, causing the door module to transition from the expanded state to the collapsed state through abutting contact of the door module with the vehicle door. Further, aligning the door module into a final assembled position relative to the vehicle door, whereat the door module is automatically caused to expand from the collapsed state to the expanded state via an internal spring bias within the door module. 
     In accordance with another aspect of the disclosure, the method further includes recognizing that the door module is not in the intended final assembly position until the door module transitions from the expanded state to the collapsed state. Accordingly, the assembler has a direct visual and tactile indicator that the position of the door module is not correct until the door module returns from the collapsed state to the expanded state. 
     In accordance with another aspect of the disclosure, the method further includes recognizing that the door module is in the intended final assembly position when the door module automatically transitions from the expanded state to the collapsed state under the force of the internal spring bias. 
     In accordance with another aspect of the disclosure, the method further includes automatically causing a handle chassis of the door module to snap into an opening of an outer panel of the vehicle door as the door module expands from the collapsed state to the expanded state. 
     In accordance with another aspect of the disclosure, a door module for mounting within a cavity of a vehicle door includes a carrier module, where the carrier module is configured to flex during mounting within the cavity. 
     In a related aspect, a portion of the carrier module is configured to flex during mounting within the cavity. 
     In a related aspect, the carrier module would not be able to be inserted into the vehicle cavity without undergoing a flexure. 
     In a related aspect, the flexure of the carrier module is a result of a portion of the carrier module being forced against an inner surface of the vehicle during assembly of the carrier into the cavity. 
     In a related aspect, the carrier module is configured to return to an unflexed state after having been installed in the cavity of the vehicle door. 
     In a related aspect, the portion of the carrier module configured to flex during mounting within the cavity is a protruding arm supporting a vehicle component, such as for example a door handle. 
     In accordance with another aspect of the disclosure, a vehicle door having an aperture in one of the inner sheet metal and outer sheet metal defining an inner cavity for receiving a portion of a door module for mounting within a cavity of a vehicle door includes a carrier module, where the carrier module is configured to flex during mounting within the cavity and the carrier module is configured to be unflexed when the portion of the door module is aligned with the aperture. 
     In a related aspect, the carrier module has a living hinge to allow the carrier module to flex. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  illustrates a side view of a vehicle equipped with a vehicle door having a door module constructed according to the present disclosure. 
         FIG. 2  is an inside plan view of a portion of the vehicle door of the vehicle of  FIG. 1  illustrating a door module constructed according to the present disclosure; 
         FIG. 3  illustrates an inside plan view of the door module of  FIG. 2 ; 
         FIG. 4  illustrates an outside plan view of a presenter assembly of the door module of  FIG. 2 ; 
         FIG. 4A  illustrates a side elevation view of the presenter assembly of  FIG. 4 ; 
         FIG. 4B  illustrates an inside perspective view of the presenter assembly of  FIG. 4 ; 
         FIG. 5  illustrates a side elevation view of a portion of the presenter assembly of  FIG. 4 , with a handle chassis of the presenter assembly, shown on the left, in an expanded state associated with a “pre-assembled state” and a “fully assembled state,” and on the right, in a collapsed state associated with an “intermediate assembly state”; 
         FIG. 6  illustrates an outside perspective view of the presenter assembly with the handle chassis disassembled therefrom; 
         FIG. 6A  illustrates an outside side plan view of the presenter assembly of  FIG. 6  with the handle chassis disassembled therefrom; 
         FIG. 6B  illustrates an outside plan view of a handle mount body and a free end of an arm of the presenter assembly of  FIG. 6 , with the handle mount body being configured for adjustment along an axis relative to the free end of the arm; 
         FIG. 7  illustrates a main body of the presenter assembly and the arm extending therefrom, with the handle mount body decoupled from the free end of the arm; 
         FIG. 7A  illustrates a perspective view of the main body and arm of  FIG. 7  with the arm shown being deflected along an axis; 
         FIG. 8  illustrates a perspective view of the handle mount body with the handle chassis attached thereto; 
         FIG. 8A  illustrates a side view of the handle mount body with the handle chassis attached thereto shown from an opposite side of  FIG. 8 ; 
         FIG. 9  illustrates an initial stage of assembly of the presenter assembly of the door module into an internal cavity of a door panel structure of the vehicle door with the handle chassis of the presenter assembly shown in the expanded state; 
         FIG. 10  illustrates an intermediate stage of assembly of the presenter assembly of the door module into the internal cavity with the handle chassis of the presenter assembly shown in the collapsed state; 
         FIG. 11  illustrates an advanced intermediate stage of assembly of the presenter assembly of the door module into the internal cavity with the handle chassis of the presenter assembly shown in the collapsed state; 
         FIG. 12  illustrates a fully assembled stage of assembly of the presenter assembly of the door module into the internal cavity with the handle chassis of the presenter assembly shown in the expanded state; 
         FIG. 13A  illustrates an outside side view of the presenter assembly of the door module showing the handle chassis in a position associated with the intermediate stage of assembly of  FIG. 10 , whereat the handle chassis is misaligned with an opening in an outside panel of the vehicle door configured for receipt of the handle chassis; 
         FIG. 13B  is a view similar to  FIG. 13A  showing the handle chassis in a position associated with the advanced intermediate stage of assembly of  FIG. 11 , whereat the handle chassis is misaligned with the opening in the outside panel of the vehicle door; 
         FIG. 13C  is a view similar to  FIG. 13A  showing the handle chassis in a position associated with the fully assembled stage of assembly of  FIG. 12 , whereat the handle chassis is aligned with the opening in the outside panel of the vehicle door and received therein; and 
         FIG. 14  illustrates a flow diagram of a method of installing a door module having an expanded state and a collapsed state within a cavity of a vehicle door. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
     The present disclosure is directed to one or more embodiments of a door module configured for installation with an internal cavity of a vehicle door. The door modules of the present disclosure and methods of installing/assembling such door modules are clearly illustrated in the appended drawings and those skilled in the art will fully comprehend all aspects, features and improvements associated therewith. 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 
     Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     Reference is made to  FIG. 1 , which shows a closure panel, illustrated as a front passenger door  11 , by way of example and without limitation, having a pre-assembled door module  10  ( FIGS. 1-3 ), with front passenger door  11  being mounted to a vehicle body  12  of a motor vehicle  14 . Front passenger door  11  includes an outer panel  16  an inner panel  18  defining an internal door cavity  24  therebetween ( FIG. 2 ). Door module  10  includes a main door module, also referred to as main module, carrier assembly or carrier module  20 . Carrier module  20  includes a carrier  21  configured to close and seal off an opening  26  in inner panel  18  against passage of water and debris. Carrier  21  is configured to support various components, including, but not limited to, a latch assembly  30  and an outside handle chassis, also referred to as outside handle housing or assembly  31 . The latch assembly  30  and outside handle assembly  31  are provided as unitized components of a unitized mini-module, also referred to as mount body assembly or presenter assembly  33 . The presenter assembly  33  is configured to be attached to carrier  21 , thereby being fixedly integrated as a component of door module  10 . Presenter  44  is an example of a first section of the door module  10 . Accordingly, door module  10  can be handled as a single component in assembly, with carrier module  20  and presenter assembly  33  being pre-assembled to one another. It is contemplated herein that presenter assembly  33  can be fixed to carrier module  20  prior to assembling presenter assembly  33  in internal door cavity  24  or after, as desired. In addition to unitizing the handle assembly  31 , as illustrated in  FIG. 4B , latch assembly  30  and carrier module  20 , presenter assembly  33  functions as an anti-theft member by covering any rods and/or cables that enter and exit latch assembly  30 . Accordingly, known tools used by vehicle thieves are prevented from actuating the latch assembly  30  to open the vehicle closure panel  11 ,  13 . 
     The manufacture, assembly, and performance of the vehicle door  11  are enhanced directly as a result of the unitized structure of the door module  10 , and in particular, the unitization of latch assembly  30  and outside handle assembly  31  of presenter assembly  33 , as well as the unitization of presenter assembly  33  with the carrier module  20 . In accordance with an aspect of the disclosure, the presenter assembly  33  provides an ability to easily position the carrier  21  of carrier module  20  in its proper location for reliable, sealed fixation to the inner panel  18 , while at the same time providing an ability to move the outside handle assembly  31  along multiple axes relative to the carrier  21 , though being coupled thereto, thereby allowing the outside handle assembly  31  to be easily and properly positioned for fixation in an opening  35  in the outer panel  16 , while at the same time allowing the latch assembly  30  to be properly located in an opening  39  in a shut face  37  ( FIG. 2 ) of the closure panel  11 . It will be appreciated by the skilled artisan that the carrier module  20  and carrier  21  thereof, along with presenter assembly  33 , can be incorporated into a rear passenger door  13  or any other closure panel desired. 
     The outer panel  16  forms at least part of the exterior surface of the door assembly  10 . The inner panel  18  provides a structural member for the mounting of one or more trim pieces that form an inner surface of the door assembly  10 . Some of the inner panel  18  may itself also form part of the inner surface of the door assembly  10 , if desired. The outer and inner panels  16 ,  18  are connected together to provide a door panel structure  22  that forms the internal door cavity  24  that contains various components of the door assembly  10 , including components of the carrier module  20  and the presenter assembly  33 . To facilitate assembly of the components into the cavity  24 , the inner panel  18  includes opening  26 . The opening  26  is sized to allow access to the internal door cavity  24  as necessary and desired for assembly and service of components therein, as is known. 
     The outer and inner panels  16 ,  18  may be made from any suitable material or combination of materials. For example, the outer and inner panels  16 ,  18  may both be made from a suitable metal (e.g. a suitable steel). In another example, the outer panel  16  may be made from a suitable polymeric or composite material (e.g. fiberglass) and the inner panel may be made from a suitable metal, by way of example and without limitation. 
     A pair of hinges  28  are connected to door panel structure  22  and pivotally mount a front end of door panel structure  22  to the vehicle body  12 . Door latch  30  is mounted in the opening  39  of shut face  37  of door panel structure  22  to permit the releasable closure of passenger door  11  against vehicle body  12 , as is known. Hinges  28  and door latch  30  act as force transfer members through which forces in passenger door  11  are transmitted to vehicle body  12 . Such forces include, for example, side-impact forces from another vehicle or object colliding with the vehicle  14 . 
     Carrier  21  is shown as being configured for sealed mounting to inner panel  18  and to support a plurality of door hardware components, in addition to presenter assembly  33 , such as window and door latch components, including a power-operated window regulator having an electric motor-driven cable, pulleys, and lifter plates for moving a window  34  within glass run channels, by way of example and without limitation, as will be understood by one possessing ordinary skill in the vehicle door assembly art. 
     In accordance with a non-limiting embodiment, carrier  21  can be formed to function both as a fluid (water and moisture) barrier and as a sound barrier, and can be provided as a single-piece panel configured to receive a plurality of the aforementioned powered actuators and door hardware components in integrally formed contoured pockets. The carrier  21  can be adapted to be installed in fixed attachment to a surface of the inner panel  18  facing the passenger compartment of the vehicle  14  upon fixing the various components, such as those discussed above, in the internal door cavity  22 . Further, in order to facilitate assembly, including ensuring the carrier  21  is properly located and fixed in sealed relation relative to the inner panel  18 , the carrier  21  can be formed including a peripherally extending seal bead  36 . The seal bead  36  can be provided as any suitable continuous bead of adhesive material capable of maintaining a fluid-tight seal between the carrier  21  and an outer surface of the inner panel  18 , such as butyl, by way of example and without limitation. A selectively removable protective layer  38 , sometimes referred to as release paper or release film, and referred to hereafter as release member  38 , can be disposed over the seal bead  36  until it is desired to expose the seal bead  36  for bonding with the inner panel  18 , thereby protecting the seal bead  36  against unwanted contamination. 
     Carrier  21  can be formed having a plurality of fastener through openings  74  adjacent an outer periphery  48  and can further include a metal or plastic grommet  76  fixed in each of the plurality of fastener through openings  74 . Grommets  76  provide compressive structural support for receipt of fasteners  78  used to fix carrier  21  to inner panel  18 , wherein grommets  76  prevent over-compression and tearing of the natural fibrous material. 
     Presenter assembly  33  includes a main body  40  configured for attachment to carrier  21  of door module  10 . Main body  40  is shown as having a generally planar, C-shaped portion, with legs  44  of the C-shaped portion extending to free ends  46  configured to attachment to carrier  21 . Free ends  46  are shown as having hook-shaped claws or fingers  47  configured for fixed receipt of the outer periphery  48  of carrier  21 . It is to be recognized that any suitable fastening mechanism can be used to fix main body  40  to carrier  21 , including mechanical fasteners and/or adhesives, by way of example and without limitation. With main body  40  being generally c-shaped, weight reduction is attained by having a region void of material between legs  44 . Main body  40  has a mount extension  49  configured for fixed attachment to latch assembly  30 . 
     An extension member, also referred to as arm  50 , extends outwardly in spaced relation from the main body  40 . Arm  50  can be formed as a monolithic piece of material with main body  40 , such as via a molding process, by way of example and without limitation. As such, in a non-limiting embodiment, it is contemplated that main body  40  and arm  50  are molded via any suitable polymeric material, though other materials, including metal, are contemplated herein. Arm  50  is cantilevered from the main body  40 , with arm  50  being flexible to allow the handle chassis  31  to move toward the main body  40  along a first axis A 1  and away from the main body  40  along the first axis A 1 . Arm  50  has a first portion  52  extending outwardly from the main body  40 , and shown, by way of example and without limitation, as extending generally transversely from an outer edge of the main body  40 , and a second portion  54  extending in inclined relation from, and shown, by way of example and without limitation, as extending generally transversely from the first portion  52  to a free end  56 . As best identified in  FIG. 7 , second portion  54  extends along a plane P in overlying relation with main body  40  and is generally planar and L-shaped or obliquely shaped as viewed along an axis extending generally transversely to the plane P. The L-shape or oblique shape is defined by a first portion  54   a  extending from first portion  52  and by a second portion  54   b  extending from the first portion  54   a  to the free end  56 . Free end  56  is an example of a second section of the door module  10 , where arm  50  is configured to act as a living hinge between the first section and the second section of the door module  10 . A living hinge may be formed between other first and second sections of door module  10  without limitation. First portion  54   a  and second portion  54   b  are inclined within plane P relative to one another having an included angle (a;  FIG. 6A ) between 90 to 179 degrees, and shown as being between about 90 to 135 degrees, by way of example and without limitation. Although the L-shape or oblique shape enhances flexibility of arm  50  in a compact space, it is contemplated that the second portion  54  could be straight, if desired. Accordingly, being cantilevered and generally L or oblique-shaped enhances the flexibility of arm  50  along the first axis A 1  to facilitate assembly, as discussed further below. 
     Handle chassis  31  is operably coupled to the free end  56  of arm  50 , such that the handle chassis  31  is moveable relative to the main body  40 . Handle chassis  31  is moveable along the first axis A 1  in fixed relation with arm  50  and is moveable along a second axis A 2  extending in inclined relation to the first axis A 1 , and in accordance with one aspect of the disclosure, second axis A 2  extends generally transversely to the first axis A 1 . Accordingly, handle chassis  31  is moveable along multiple axes during assembly, thereby facilitating assembly of presenter assembly  33 . Handle chassis  31  is able to move toward the main body  40  along the first axis A 1  to facilitate fitting presenter assembly  33  between the outer and inner panels  16 ,  18  during the initial stages of assembly ( FIGS. 9-11 ) and away from the main body  40  along the first axis A 1  during the final stage of assembly ( FIG. 12 ) when handle chassis  31  is properly aligned with and received in the opening  35  in outer panel  16 , such as in a snap-type fit within opening  35  under an internal spring bias in arm  50 . 
     To facilitate operable attachment of handle chassis  31  to arm  50 , a handle mount body  58  is connected to the free end  56  of the arm  50 , while the handle chassis  31  is directly connected to the handle mount body  58 . Handle chassis  31  is fixed against movement relative to the handle mount body  58 , while the handle mount body  58  is configured to move relative to the arm  50  along the second axis A 2 . Accordingly, the handle chassis  31  is able to move along the second axis A 2  relative to arm  50 . 
     To establish a relative movement connection between handle mount body  58  and arm  50 , handle mount body  58  has at least one of a projection and a slot, and shown as a projection  60  and a slot  62 , and the arm  50  has at least one of the other of the projection and the slot, and shown as a projection  64  and a slot  66 , wherein the at least one projection and slot is received for sliding movement in the other of the at least one projection and slot along the second axis A 2 . In the exemplary embodiment illustrated, the projection  60  of handle mount body  58  is received in the slot  66  of arm  50  for sliding movement therein, while the projection  64  of arm  50  is received in the slot  62  of handle mount body  58  for sliding movement therein. As best identified in  FIG. 6B , each of the projections  60 ,  64  are shown as having respective hook-shaped ends  61 ,  65  to facilitate maintaining the handle mount body  58  in slideably connected relation with arm  50 , thereby inhibiting the handle mount body  58  from falling off arm  50 . 
     To establish a fixed connection between handle mount body  58  and handle chassis  31 , any suitable fixation mechanism can be used, including mechanical fasteners and/or adhesives, by way of example and without limitation. In the exemplary embodiment illustrated, as best identified in  FIGS. 8 and 8A , handle mount body  58  is shown having a tongue slot  68  and at least one, and shown as a plurality of projections, shown a resilient snap tabs  70 , and handle chassis  31  is shown as having a tongue  71  configured for receipt in tongue slot  68  and at least one, and shown as a plurality of openings  72  configured for snapping receipt of snap tabs  70  therein. As such, tongue  71  can be inserted into tongue slot  68  and then snap tabs  70  can be snapped resiliently into openings  72 , thereby fixing handle chassis  31  to handle mount body  58 . 
     In accordance with another aspect of the disclosure, as diagrammed in  FIG. 14 , a method  1000  of installing a door module  10  within a cavity  24  of a vehicle door  11 ,  13 , wherein the door module  10  has an expanded state ( FIGS. 9 and 12 ) and a collapsed state ( FIGS. 10 and 11 ) is provided. The method  1000  includes a step  1100  of inserting the door module  10  into the cavity  24  of the vehicle door  11 ,  13 , and during the inserting step  1100 , causing  1200  the door module  10  to transition from the expanded state to the collapsed state through abutting contact of the door module  10  with at least one of the outer and inner panels  16 ,  18  of the door panel structure  22  the vehicle door  11 ,  13 . When transitioning to the collapsed state, the handle chassis  31  is caused to move in fixed relation with the arm  50  toward the main body  40  along the first axis A 1  via flexing of the arm  50 . As shown in  FIG. 7A , the majority of flexing can occur at an elbow region where the first portion  54   a  transitions to the second portion  54   a  of arm second portion  54 , 50 , though it is to be understood that flexing can occur throughout the entirety of arm. The flexing of the door module  10  can be provided as a result of a living hinge  53  formed in the door module  10 . Such a living hinge or integral hinge is formed from the same continuous material as the two sections of the door module  10  the living hinge  53  connects. The living hinge  53  may be configured as a flexure hinge or as a compliant joint which approximately acts due to flexural bending of a part of the door module  10 , as would be compared to a hinge connecting two distinct discontinuous pieces of material which do not flex, but rather may pivot relative to each other about a fixed axis of rotation. Thus, the form of relative motion can only be idealized as a rotation. Because of their monolithic arrangement, compliant joints provide numerous approaches for the design of a flexure hinge. The ability of the arm  50  to flex along the first axis A 1  allows the presenter assembly  33  of door module  10  to fit between outer and inner panels  16 ,  18  without causing damage to any components. Further, a step  1300  of aligning the door module  10  into a final assembled position relative to the vehicle door  11 ,  13 , whereat the door module  10  automatically expands from the collapsed state to the expanded state. The aligning can include slidably adjusting the position of the handle chassis  31  along the axis A 2  by sliding handle mount body  58  and handle chassis  31  fixed thereto relative to arm  50 , as best illustrated in  FIGS. 13B and 13C . 
     In accordance with another aspect, the method  1000  further includes recognizing  1400  that the door module  10  is not in the intended final assembly position until the door module  10  transitions from the expanded state to the collapsed state. 
     In accordance with another aspect, the method  1000  further includes recognizing  1500  that the door module  10  is in the intended final assembly position when the door module  10  transitions from the expanded state to the collapsed state. 
     In accordance with another aspect, the method  1000  further includes automatically causing  1600  a handle chassis  31  of the door module  10  to snap into an opening  35  of an outer panel  16  of the vehicle door  11 ,  13  as the door module  10  expands from the collapsed state to the expanded state. It is to be understood that expansion of the door module  10  to the expanded, fully assembled stated requires the handle chassis  31  to be properly positioned in opening  35 , whereat a spring bias within arm  50  causes automatic return of the presenter assembly  33  from the collapses state to the expanded state. 
     It is to be understood that the presenter assembly  33  can be assembled as discussed above without having the carrier module  20  fixed thereto, if desired, whereupon the carrier module  20  can be fixedly attached to presenter assembly  33  after assembling presenter assembly  33  in the internal cavity  24  of door panel structure  22 . 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, assemblies/subassemblies, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.