Abstract:
A motor vehicle door includes a box door body formed from a door outer skin and a door inner skin, a large surface cut out section in the door inner skin capable of being covered by a wet/dry space partition with a sealing element. The motor vehicle door also includes a frame structure, containing a window frame, and is connected through a fastening part to the door body. An outer seal near the vehicle body is also formed on the vehicle door. The wet/dry space partition covers, at least in part, a fastening region near the vehicle body and a door inside window sill. The sealing element on the wet/dry space partition runs through an area overlap of the partition and another sealing element is mounted between the frame structure and the door body that extends at least from the outer contour of wet/dry space partition sealing element to the outer seal.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application is a National Phase Patent Application of International Application Number PCT/DE01/02074, filed on May 23, 2001, which claims priority of German Patent Application No. 100 26 053.5, filed May 25, 2000. 

   FIELD 
   The invention relates to a motor vehicle door with a box-like door body, a frame structure which can be connected to it as well as with a large surface area cut-out section in the door inner skin which can be covered by a wet/dry space partition. Furthermore the invention provides an assembly process for the relevant vehicle door. 
   BACKGROUND 
   Known motor vehicle doors of this kind, which have a box-like door body and a frame structure connectable therewith, use for a cover the door inner skin whose external contour extends up to the outer seal of the door. The corresponding seal can thereby extend right into the area inside the overlapping door outer skin. 
   This structural design requires the door inner skin to have a very high mechanical stability and comparatively close tolerances to be observed in order to guarantee a permanent highgrade sealing section. Furthermore, relatively high production costs are involved. A further drawback of the concept described is that the overall hollow space of the door can be formed solely as a wet space which then requires the use of damp-proof door components, such as for example motors, electronic control devices, plugs and cables in a so-called wet space design. 
   A generic motor vehicle door is described in DE 197 44 810 A1. It consists basically of a door box with a large-surface area cut-out and a door frame module which has a window frame with a transverse profile on the door window sill side and a module support pre-fitted on the frame. The door frame module can be inserted from above into the door box and then connected to it through fixing means. The prefitted module support thereby seals in water-tight manner the cut-out section in the door inside panel of the door box so that between the module support and the door inside skin there is a dry space for mounting the functional elements such as window lifters, speakers etc. In order to seal the ledge on the inside of the door between the frame module and the door box level with the door window sill there is a v-shaped recess provided in the door inner skin beyond which extends a sealing element which runs along the edges of the window frame and door inner skin facing the inside of the door. 
   This technical solution also makes the door inner skin part of the seal against damp and wet although it is also established that compared to the solution first described lower forces affecting the seal have to be transferred from the fixing elements of the door inner skin. More importantly the fact has to be considered that the door inner skin through its active connection with the circumferential sealing element of the outer seal is restricted in its choice of design. 
   SUMMARY 
   The object of the invention is to develop the motor vehicle door of the generic kind which whilst using a frame module combines the advantages of a door divided into a wet and dry space with a technically simple and functionally reliable wet/dry space partition without having to involve the door inner skin in the problems of providing a seal. 
   In one embodiment, the structural design of the motor vehicle door is designed so that the fastening region of the box-like door body for the fastening parts of the frame structure and the door inner window sill are covered at least in part by the external contour of the sealing element of the wet/dry space partition wherein a sealing element mounted in the fixing region between the frame structure and door body extends at least from the outer contour of the sealing element of the wet/dry space partition up to the outer seal between the vehicle door and door body. 
   According to one embodiment, the sealing planes of the sealing elements mounted between the fastening parts of the frame structure and the fastening regions of the door body on the one hand, and of the sealing element of the wet/space partition on the other run at an angle to each other. The sealing elements can thereby criss cross each other with contact so that the outer sealing line of the wet/dry space partition, the seal between the frame structure and the door body, as well as the outer seal of the vehicle door form a cohesive sealing contour. In the event that the sealing elements criss cross each other only in the projection in the X-Z plane (door plane), thus without contact, then care must be taken so that the intermediate region has a sufficiently high resistance so that it compares quasi with a seal. 
   According to another embodiment, positioning means are provided which are suitable for fixing the clearance between the sealing faces of the frame structure and door body. Such positioning means can be formed integral, for example in the surface of the door body and/or fastening part supporting the sealing element, such as ribs, dished impressions or the like. If necessary the seal is recessed out in the region of the positioning means. The clearance between the facing sealing surfaces of the frame structure and door body is smaller than the height of a non-compressed elastic seal. If the clearance between the sealing surfaces between the interfitted parts (of the frame structure and door body) is greater than the height of the non-compressed seal the sealing action can be reached by operating tensioning or fixing means by means of which the distance between the sealing faces can be sufficiently reduced. 
   The positioning means described are suitable for improving the alignment of the parts which are to be connected as well as the precision in the dimensions of the door and to restrict the mechanical strain on the elastic seal which increases its service life. 
   At this point it should be pointed out that the sealing gap between the sealing surfaces of the frame structure and door body can also be filled out by an inflatable seal. It is conceivable in this connection to connect the inflatable seal to a so-called back pipe which sends the back pressure to the seal during driving. Thus the sealing action would become more intensive the faster the driving speed. 
   The wet/dry space partition can advantageously be formed by a support plate (e.g. of sheet metal or plastics) on which function units such as window lifter, lock, controls or the like, are prefitted. In the edge region of the support plate is a circumferential seal or the external contour of the support plate is itself designed as the seal, e.g. as a constituent part of a plastics plate which is made using 2-component injection moulding technology. 
   The seal which is arranged according to the invention between the frame structure and the door body can be prefitted on the frame or on the door body. Obviously it is also possible to attach parts of this seal to the frame and to the door body. Advantageously the fastening parts of the frame structure lie at least in part inside the surface area enclosed by the seal of the support plate. 
   The use of the invention is not restricted to special constructions of the interfaces between the frame structure and door body. It is only required that the seal running between the frame structure and the door body extends between the outside seal of the door and the sealing element of the support plate of the wet/dry space partition. 
   According to a design variation of the corresponding interface the substantially vertically aligned frame pillars of the window frame have projections which are formed as fastening parts and are associated with fastening regions of the door body. The fastening part is thereby connectable to a fastening region of the door inner skin which is open to the outside (facing the A, B, or C pillar), e.g. in the form of an angled socket. 
   A further variation however proposes that fastening parts are attached to the substantially horizontally aligned frame pillars on the door window sill side and are spaced from the edge regions of the window frame towards the centre of the door. In this case a fastening region of the door inner skin is provided which is open to the inside. 
   In general the frame structure will have two fastening parts which run substantially parallel and in the vertical direction. With a frame structure which has a wet/dry space partition formed as a support plate module and supporting a door lock which projects over the edge of the support plate, at least the fastening part facing away from the door lock and the associated angled socket of the door body have no projections or the like in order to ensure after “threading in” the lock into the door body and positioning the associated fastening part, unrestricted swivelling is allowed (in the Y-direction) of the other fastening part into the ideal assembly position. 
   When fitting the door body and frame structure a so-called reference point system (RPS) can be advantageous. The frame module with the wet/dry space partition prefitted thereon is thereby first brought into connection with the door body through the reference point system (RPS) and aligned. The fixing of the wet/dry space partition on the door body then takes place which enhances the stiffness of the door. The door body and frame structure are then fixedly connected together. During this assembly sequence it can be ensured that the wet/dry space partition does not twist or distort whereby undesired position changes of the accessory parts fixed thereon could occur. Naturally the assembly steps described above could proceed in a different sequence whilst observing the aforesaid tolerance conditions. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will now be explained in further detail with reference to the embodiments and drawings in which: 
       FIG. 1   a  shows a view of a frame structure with two side, inwardly off-set fastening parts in the form of side pieces; 
       FIG. 1   b  shows a view of the frame structure of  FIG. 1   a  with the wet/dry space partition fixed thereon in the form of a metal support plate; 
       FIG. 1   c  shows a view of a box-shaped door body with a large surface area cut-out section in the door inside panel; 
       FIG. 2   a  shows a view of the frame structure and door body assembled without wet/dry space partition; 
       FIG. 2   b  shows a view of the assembled vehicle door with frame structure, door body and wet/dry space partition; 
       FIG. 3   a  shows a perspective view of a fixing region of the frame structure without sealing elements (viewed from the sides of the door outside panel); 
       FIG. 3   b , as  FIG. 3   a , but with a sealing element on the downward facing end surface of the window frame side piece; 
       FIG. 3   c , as  FIG. 3   a , but with sealing elements on the downward facing end surface of the window frame side piece and the screw surface of a fastening part; 
       FIG. 3   ab  shows a perspective view of a fixing region of the door body with sealing elements on the upward facing end surface and screw surface of the fixing beam (viewed towards the door outside panel); 
       FIG. 3   cc  as  FIG. 3   ab , but without sealing elements; 
       FIG. 3   d  shows a perspective view of a door cut-out section in the region of the join between the door body and frame structure, with the door outside seal clearly visible; 
       FIG. 3   e  as  FIG. 3   d  but with a design element to cover the join; 
       FIG. 4   a  shows a perspective view of a fixing region of the frame structure with sealing elements on three sealing faces running at an angle to each other (viewed from the sides of the door outside panel); 
       FIG. 4   b  shows a perspective view of a fixing region of the frame structure with sealing elements on two sealing faces which run at an angle to each other (viewed from the sides of the door outside panel); 
       FIG. 4   c  shows a perspective view of a fixing region of the frame structure without sealing elements; 
       FIG. 4   aa  shows a perspective view of a fixing region of the door body without sealing elements for sealing the interface between the door body and the frame structure, but with clearly visible door outside seal and indicated path of the sealing element of the wet/dry space partition (viewed towards the door outside panel); 
       FIG. 4   bb  as  FIG. 4   aa , but with sealing elements on surfaces adjoining the fixing beam at the side; 
       FIG. 4   cc  as  FIG. 4   bb  but additionally with sealing elements on the screw face and upwardly directed end face of the fixing beam; 
       FIG. 4   d  as  FIG. 4   cc  but without the sealing element fixed on the end face of the fixing beam; 
       FIG. 4   e  as  FIG. 4   d  but with a design element covering the body work edge; 
       FIG. 5   a  shows a perspective view of the part having the fastening region of the door body with an outwardly open angled socket and indications for three possible different paths of the sealing element of the wet/dry space partition; 
       FIG. 5   b  shows a view of the cut out section of a frame structure with a fastening part directly formed on the window frame side piece; 
       FIG. 5   c  shows a view of the assembly of the parts of  FIG. 5   a  and  5   b.   
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The parts illustrated in  FIGS. 1   a  to  1   c  show the principle construction of a motor vehicle door, for which the seal according to the invention can be used. Accordingly the door consists substantially of the following three sub-systems: 
   Frame Structure: 
   The frame structure  3  of the depicted driver door has a window frame  30  with a vertical post-like frame region  300  on the B-pillar side which is connected to the edge of a transverse beam  33  on the window sill side. Two fastening parts  31 ,  32  are spaced apart and extend out from the side edges of the beam  33  functioning as the window sill reinforcement and serve to connect the frame structure  3  to the door body. 
   Wet/dry Space Partition: 
   The wet/dry space partition  2  generally represents a support plate made from metal or plastics or as a so-called Outsert part with a sealing element  20  around the edge and on which a number of function units such as e.g. window lifter drive  21 , speaker  22 , lock  23 , cable harness and others are prefitted. The said sealing element  20  need not necessarily be formed as a separate strip-like part which is to be connected to the support plate  2 . It can also be provided in the form of a large surface sealing mat or sealing foil which is placed as a lining over the support part  2 . When using a wet/dry space partition  2  of plastics it is possible to injection mould the sealing element  20  in the same injection tool as the wet/dry space partition by using socalled multi-component injection moulding technology. 
   The modular parts described above, namely the frame structure  3  and the wet/dry space partition  2 , can advantageously be connected together to form one superposed module. This is best carded out by fixing points which extend along the upper edge of the wet/dry space partition  2  and the window sill reinforcement  33 . Thus during subsequent assembly on the door body only one part then has to be handled. The high degree of integration of the overriding module makes it possible to carry out an extensive prechecking of the parts systems and to meet the highest demands regarding quality. 
   Door Body: 
   The door body  1  consists of a door outer skin  1   a  and a door inner skin  1   b  which are connected together through a surround-like region. A large surface cut out section  10  which opens upwards is incorporated in the door inner skin  1   b  and after completing the door assembly will be closed and sealed by the wet/dry space partition  2 . For this purpose the overlapping edges of the door inner skin  1   b  and the support plate  2  are pressed onto each other with the seal  20  interposed through fixing means (preferably screws or rivets). In the illustrated embodiment in  FIG. 1   c , a window sill reinforcement  1   aa  is additionally provided in the upper edge region of the door outer skin. 
   By leaving out the wet/dry space partition  2   FIG. 2   a  shows the interfaces between the door body  1  and the frame structure  3 , thus the fastening parts  31 ,  32  of the frame structure  3  and the associated fastening regions  11   b ,  12   b  of the door body  1 . The base surfaces  40  thereby also form through the join  123  between the parts  1 , 3  a cohesive support surface for the outside seal  4  of the door. 
     FIG. 2   b  shows the addition of the wet/dry space partition  2  so that the cut out section  10  and the fixing regions  11   a ,  11   b ,  31 ,  32  are likewise covered in part, like the intermediate region of the window sill  33 . Furthermore the door outside seal  4  is indicated diagrammatically in a partial area of the base surface  40 . 
   In order to allow a better description of some of the possible variations of the interfaces between the three partial systems frame structure  3 , wet/dry space partition  2  and door body  1   FIGS. 3   a - 3   cc  show different embodiments of the fastening parts  31  on the frame side and the fastening regions  11   ba  of the door body  1  which can be combined therewith. The differences thereby relate solely to the arrangement of the sealing elements. According to these embodiments the fastening parts  31  are made from light metal casting and have fixing points  3100  provided with internal threads. The window sill  33  and the vertical frame region  300  are fixed or moulded thereon. The edge of the wet/dry space partition  2  supporting the sealing element  20 ,  20   a  engages at the sides (on the outside) over the fastening part  31  and thus also the adjoining fastening region  11   ba  on the door side as well as the interposed gap which is to be sealed. 
   A first combination variation exists between the fixing part  31  of  FIG. 3   a  and the beam-like fastening region  11   ba  of  FIG. 3   ab  whose screw surface  110 ′ and upwardly aligned end surface  111 ′ are covered with sealing elements. The path of the outer seal  20   a  which is illustrated diagrammatically shows that this intersects with contact the seal arranged on the screw face  110 ′. The door inside seal (not shown) which is in contact with the sealing element of the end face  111 ′ extends on the base surface  40  of the door inner skin  1   b . A secure protection of the vehicle interior from the outside dampness is ensured through this combination of sealing elements  20 ,  20   a ,  4 ,  40 ,  110 ′,  111 ′. 
   The sealing variation of the door body according to  FIG. 3   ab  can obviously also be combined with the frame structure variations of  FIGS. 3   a  and  3   c . It is however more advantageous to assign only one sealing element to one sealing gap so that with a combination of the variations of  FIGS. 3   b  and  3   ab  the sealing element of the support surface  111 ′ ought to be omitted. In this case the one side edge of the sealing element arranged on the downward facing end surface  301 ′ would adjoin against the door outside seal  4 . For the embodiment variation of  FIG. 3   c  with the sealing elements on the screw face  310 ′ and end face  301 ′ there is the seal-free variation of  FIG. 3   cc.    
   The corresponding sealing elements can thus be combined in very different ways and are preferably fixed by adhesive on the selected surfaces  110 ′,  111 ′,  301 ′,  310 ′. In each case these sealing elements arranged between the fastening regions  11   b ,  11   ba ,  11   bb ,  11   bc ,  12   b ,  31 ,  32  of the frame structure  3  and door body  1  and having the sealing elements  20 ,  20   a ,  20   b ,  20   c ,  20   d  of the wet/dry space partition  2  and the outer seal  4  of the door body  1  form a composite or cohesive bond without restricting the freedom of design for the door. 
     FIG. 3   d  shows the corresponding door section after assembly in the region of the join  123  between the frame structure  3  and the door body  1  as well as the indicated path of the outer seal  4 . The path of the sealing element  20  extends over a part of the fastening region  11   ba  on the body side, the fastening part  31  of the frame structure  3  as dwell as the shaft reinforcement  33 . In  FIG. 3   e  a design element  1230  is shown which covers the join  123  and which is covered in part by a door inside trim (not shown) whose external contour  5  is indicated by a chain-dotted line. 
   According to a further variation of the invention, see  FIGS. 4   aa - 4   cc , the strut-like fastening region  11   bb  on the body side is adjoined by side support faces  112 ,  112 ′,  113 ,  113 ′ which are associated with faces  302 ,  302 ′,  310 ,  310 ′,  311 ,  311 ′ of the fastening part  31  on the frame structure side. The path of the sealing element  20 ,  20   a  of the support plate  2  is unchanged relative to the variation described above ( FIGS. 3   a - 3   e ). 
   According to this the designs according to  FIGS. 4   a  and  4   aa  are to be combined with each other whereby the fastening part on the frame structure side supports all the sealing elements which are attached to the faces  301 ′,  302 ′,  310 ′,  311 ′ in three planes and correspond with associated faces  110 ,  111 ,  112 ,  113  of the fastening region  11   bb  of the door body  1 . The outer seal  4  running on the side face  40  can thus be formed and arranged so that it contacts both the seal on the surface  301 ′ and the seal on the surface  302 ′. 
   With the embodiment of  FIGS. 4   b  and  4   bb  the sealing elements are spread out over the fastening regions  11   bb ,  31  of the frame structure  3  and the door body  1  whilst according to the variation of  FIGS. 4   c  and  4   cc  all the sealing elements are prefitted on the fastening region  11   bb  on the door body side. 
   The embodiments illustrated in  FIGS. 4   d  and  4   e  differ only through the design element  1130  formed in one piece on the seal which covers the acute angled corner of the door outer skin  1   a . To this end a fastening part  31  can advantageously be combined with a seal arranged on the downward facing surface  301  of the window frame section  300  and supported on the upward facing surface  111  of the fastening region  11   bb.    
   From the perspective view of  FIG. 5   a  a variation of the invention is shown whose fastening region  11   bc  on the door body side has an outward opening angled socket for receiving the fastening part  31 ′ on the frame side (see  FIG. 5   b ). This fastening part  31 ′ is formed as a direct extension of the window frame region  300 ′ and is covered on its screw face  310 ′ and the downward facing support surface  312 ′ with sealing elements. Furthermore the side support face  113   a  can also be provided with a sealing element which is not shown in this illustration and which extends up to the outer seal  4  which extends along the vertically aligned base surface  40 . In the described embodiment the sealing element  20  can extend corresponding to the contour  20   d  indicated over surface  112   a  and up to the interface between the surface  114  and  312 ′. 
   If however the sealing element is to be omitted between the faces  114  and  312  then the path of the seal  20  can correspond to the contour  20   c  which does not intersect the corresponding interface areas  114 ,  312  to prevent penetration of dampness. 
   If in addition the sealing element at the screw surface  310 ′ is to be omitted then as a replacement a sealing element can be provided between the faces  111   a ,  111   a ′ and  313 . The permissible region of the sealing element  20  would then be restricted to the path of the contour  20   b  wherein the interface between the surfaces  110   a  and  310 ′ is no longer crossed.  FIG. 5   c  shows only the assembly of the door body and frame module in the region of the binding areas  11   bc ,  31 ′.