Patent Abstract:
A door module includes a bracket having a hinge portion which permits alignment of the handle support of the door module with a door shell attachment portion. The hinge portion of the bracket comprises a flexible strip that allows the bracket to flex between a first and installed position. To install the door module, the hinge portion of the bracket is flexed to the first position such that additional clearance is provided between the door module and the door shell. The door module is located in the door shell and aligned with the door shell attachment portion. The hinge portion is released to the installed position and the handle support is secured to an outside handle.

Full Description:
RELATED APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 10/816,261, filed Apr. 1, 2004. Now U.S. Pat. No. 7,111,893 issued on Sep. 26, 2006. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to vehicle door assemblies and, more particularly, to a vehicle door module with an attachment portion to secure and align an external handle during installation of the door module. 
     A vehicle door typically includes an outer shell that houses various door components. The door components include a door panel that is received into the outer shell. The door panel operates as an attachment for various door components such as window guides, a safety system, a sound system, and a door locking mechanism. The door panel, attached components, and accompanying system of cables and wires to operate the various components are typically preassembled and then installed into the outer shell as a module. 
     In particular, the door module includes a handle support that attaches to an external handle through a door shell attachment portion. To attach the external handle to the handle support, the handle support must be aligned with the attachment portion. 
     Clearance between the width of the door module and the inner width of the door shell is generally small, which may increase the difficulty for an assembler to insert the door module into the door shell and visually align the handle support with the door shell attachment portion. Also, the door module is generally rigid and may be difficult to adjust relative to the attachment portion once the door module is inside the door shell. Presently, insertion of the door module into the door shell, alignment of the handle support with the attachment portion, and attachment of the external handle may be a laborious task. 
     Accordingly, it is desirable to provide a door module that permits relatively uncomplicated installation and alignment of a handle support. 
     SUMMARY OF THE INVENTION 
     The door module according to the present invention includes a latch bracket attached to a door panel. The latch bracket is attached to a door latch which is attached to a handle bracket. The handle bracket includes a hinge portion that flexes during installation of the door module into the door shell. The handle bracket attaches to a handle support that connects to an external door handle through the door shell. 
     Another door module includes a handle bracket having an annular body portion, a latch attachment portion, and a handle support arm. Arcuate hooks couple the door latch to the handle bracket in a “snap-fit” type of design. A flexible strip allows the handle bracket to flex between positions. 
     In another door module, a method for aligning the door module with the door shell attachment portion includes flexing a biased hinge portions of the handle bracket to a first position that allows the door module greater clearance with the door shell and facilitates installation of the door module. The greater clearance also allows an assembler to visually align the handle support with the door shell attachment portion. 
     Another door module includes a handle bracket having a sheathed portion that blocks a seam located on the door latch to prevent debris, water and the like from directly impinging upon the door latch. 
     In another door module, the handle bracket includes an annular body portion with a latch support attachment portion that engages a latch attachment portion. The annular body portion includes a flexible strip hinge portion that allows the handle bracket to flex between positions. The latch attachment portion of the handle bracket is secured to the door latch and the latch support attachment portion. Arcuate hooks mate with the door latch in a “snap-fit” type of design. A sheathed portion extends from the engagement portion and covers a seam located on the door latch to prevent debris, water and the like from directly impinging upon the door latch. 
     The door module according to the present invention provides a bracket having a hinge portion that allows uncomplicated alignment of the handle support. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows. 
         FIG. 1A  shows general perspective view of a vehicle having a door and a door module; 
         FIG. 1B  shows a cross sectional view of a door module received in a door shell; 
         FIG. 2  shows an angled perspective view of a door module; 
         FIG. 3  shows an angled perspective view of a handle bracket; and 
         FIG. 4  shows an angled perspective view of another handle bracket. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1A  illustrates a vehicle  10  having a door  12 . The door  12  includes a door module  14 . As shown in  FIG. 1B , a door shell  18  of the door  12  receives the door module  14  therein with a clearance  16  between the door module  14  and the door shell  18 . The door module  14  is coupled to an external handle  20  through a door shell attachment portion  22 . 
     Referring to  FIG. 2 , the door module  14  includes a door panel  30  that accommodates window guides  32   a  and  32   b , each of which define parallel axes  34  along which a window (not shown) moves. A latch bracket  36  is attached to the door panel  30  and extends generally perpendicular to the axis  32   a ,  32   b . The latch bracket  36  includes attachment bosses  38  for attachment to the door panel  30  through fasteners or the like. An extended support arm  40  attaches to a door latch  42 . The door latch  42  is attached to a handle bracket  44  with a latch attachment portion  46  that extends generally in the X-Z plane  48  which is generally perpendicular to the door panel  30 . The handle bracket  44  further includes a hinge portion  50  that can pivot from an open to a closed position during installation of the door module  14  into the door shell  18 . A handle support arm  52  of the handle bracket  44  extends generally in the Z-Y plane  54  and attaches to a handle support  56 . The handle support  56  connects to the external handle  20  through the door shell  18  as referred to in  FIG. 1B . 
     The door module  14  also includes a personal identification code (“PIC”) cable  58  that operates an entry keypad (not shown) on the exterior of the door. The PIC cable  58  routes through the handle support  56 , the handle bracket  44 , and the latch bracket  36  to a controller unit  60  in the vehicle  10 . The latch bracket  36  and the handle bracket  44  include a latch bracket cable holder  62  and handle bracket cable holder  64 , respectively, for routing and retaining the PIC cable  58 . 
     Referring to  FIG. 3 , the handle bracket  44  includes an annular body portion  74  defining a Z-Y plane  76 . A latch attachment portion  78  extends generally in the X-Z plane  77  and secures the door latch  42  ( FIG. 2 ) using arcuate hooks  79 . The arcuate hooks  79  preferably mate with the door latch  42  in a “snap-fit” type of design. The handle support arm  52  extends in the Z-Y plane  76  for securing the handle support  56  ( FIG. 2 ). 
     The annular body portion  74  includes a hinge portion  50 . The hinge portion  50  comprises a flexible strip  80  that allows the handle support arm  52  to flex relative to the door panel  30 . Flexing the hinge portion  50  in a direction  82  achieves a first position  84 . 
     The hinge portion  50  provides a method for aligning the handle support  56  of the door module  14  with the door shell attachment portion  22 . The method includes flexing the hinge portion  50  to a first position  84  and inserting the door module  14  into the door shell  18 . The first position  84  is relatively closer to the door panel  30  than before flexing. The handle support  56  is aligned with the door shell attachment portion  22 , and the hinge portion  50  is unflexed to an installed position  85 . The installed position  85  is relatively farther from the door panel  30  than the first position. The external handle  20  is attached through the door shell attachment portion  22 . The hinge portion  50  is biased to the installed position  85 . When flexing the hinge portion  50  to the first position  84 , the hinge portion  50  must be held at the first position while inserting the door module  14  into the door shell  18 . When the hinge portion  50  is released from the first position  84 , the bias moves the hinge portion to the installed position  85 . In other examples, the hinge portion  50  has no bias or is biased toward the first position  84 . 
     The hinge portion  50  provides for alignment of the handle support  44  with the door shell attachment portion  22 . During assembly, flexing the hinge portion  50  to the first position  84  creates increased clearance  16  between the door shell  18  and the door module  14  than if the hinge portion was rigid. The increased clearance facilitates insertion of the door module  14  into the door shell  18 . Also, the greater clearance  16  allows an assembler to visually align the handle support  56  with the door shell attachment portion  22 . The hinge portion  50  has no function once the door module has been installed. 
     The handle bracket  44  also includes a sheathed portion  86  that extends generally perpendicular from the latch attachment portion  78 . The sheathed portion  86  includes a generally arcuate surface  88  that extends into two planar walls  90 . The planar walls  90  further include a center wall  92  interposed between the planar walls  90 . The center wall  92  preferably blocks a seam located on the door latch  42  (not shown) to prevent debris, water and the like from directly impinging upon the door latch  42 . 
     Referring to  FIG. 4 , the handle bracket  102  includes an annular body portion  104  defining a Z-Y plane  106 , which is approximately parallel to the door panel  30 . A latch support attachment portion  108  extends generally in the X-Z plane  108  and engages a latch attachment portion  110 . The handle support arm  112  extends in the Z-Y plane  106  for securing the handle support  56  ( FIG. 2 ). 
     The annular body portion  104  includes a hinge portion  114 . The hinge portion  114  comprises a flexible strip  116  that allows the handle support arm  112  to flex relative to the door panel  30 . Flexing the hinge portion  114  in a direction  118  achieves a first position  120 . Unflexing the hinge portion  114  achieves an installed position  121 . The hinge portion  114  is biased to the installed position  121 , although in other examples the hinge portion  50  is biased to the first position or has no bias. 
     The latch attachment portion  110  of the handle bracket  102  includes an engagement portion  122  for securing to the door latch  42  ( FIG. 2 ). The engagement portion  122  includes an upper engagement portion  124  and a lower engagement portion  126 . The upper engagement portion  124  secures the latch attachment portion  110  to the latch support attachment portion  108 . The lower engagement portion  126  secures the latch attachment portion  110  to the door latch  42  using arcuate hooks  128 . The arcuate hooks  128  preferably mate with the door latch  42  in a “snap-fit” type of design. 
     The latch attachment portion  110  also includes a sheathed portion  130  that extends generally perpendicular from the engagement portion  122 . The sheathed portion  130  includes a generally arcuate surface  132  that extends into two planar walls  134 . The planar walls  134  further include a center wall  136  interposed between the planar walls  134 . The center wall  136  preferably blocks a seam located on the door latch  42  (not shown) to prevent debris, water and the like from directly impinging upon the door latch  42 . 
     Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.

Technology Classification (CPC): 8