Abstract:
A door module for a motor vehicle door includes: a cantilever arm for a railless window lifter, wherein the cantilever arm is formed in one piece with the door module, where the cantilever arm projects beyond an outer edge of the door module, and the cantilever arm has, at at least the end which projects beyond the edge of the door module, a receptacle for a deflection means of a window lifter cable.

Description:
BACKGROUND 
     The invention relates to a door module for a motor vehicle door as well as a method for the production of a door module for a motor vehicle door. 
     Various door modules for motor vehicle doors are known in prior art. For example, DE 199 44 965 A1 discloses a door module for a window regulator with guide rail. However, window regulators of this type have the disadvantage that the maximum so-called glass drop, i.e. the maximum hub of the window between the closed and open position is smaller than the distance of the deflection rolls of the window regulator. This problem was solved by the introduction of the window regulator without guide rail. For example, WO 2007/014822 A1 reveals such a window regulator without guide rail. 
     SUMMARY OF THE INVENTION 
     In contrast, the invention is based on the problem of providing an improved door module for a motor vehicle door and an improved method for the production of a door module for a motor vehicle door, whereby the door module is provided with a cantilever arm for a window regulator without guide rail. 
     The problems on which the invention is based are respectively solved by the characteristics of one or more embodiments disclosed and described herein. Preferred embodiments of the invention are also disclosed and described herein. 
     In accordance with the invention, a door model for a motor vehicle door is provided, whereby the door module has a cantilever arm for a window regulator without guide rail, whereby the cantilever arm is formed in one piece with the door module, and whereby the cantilever arm projects beyond an outer edge of the door module. Thereby, the cantilever arm has an attachment for a deflection tool of a window regulator rope at least at that end at which the edge of the door module overhangs. 
     The door module in accordance with the invention has the advantage that in one individual production step, for example, in an extrusion process, the door module as well as the cantilever arm can be produced jointly, consisting of the same material. Thus, during installation, additional installation steps as they would, for example, be necessary for screwing a separately produced cantilever arm onto the door module, are eliminated. 
     According to the present invention, the cantilever is designed in one piece with the door module, this means, that the cantilever arm and the door module form a design unit consisting of the same material, so that corresponding installation steps for the fixation of the cantilever arm at the door module are no longer necessary. Preferably, the material of the cantilever arm and door module is a material that has low creeping properties, so that an unwanted deformation due to higher temperatures and the continual load due to the window regulator rope can be avoided reliably. Such a selection of material may, however, not provide sufficiently good gliding properties under certain circumstances that are required so that a window regulator rope can be guided by the cantilever arm without generating extreme frictional forces. To make an optimal gliding property of a window regulator rope possible by means of corresponding deflection tools mounted at the cantilever arm in spite of that, these deflection tools are separately inserted into a complementary attachment of the cantilever arm. Therefore, the demand made on the deflection tool consists primarily thereof, that here, materials are used that have low frictional properties relative to the window regulator rope. This ensures that the force of the window regulator motor, which is required in order to move the window regulator rope over the deflection tools, can be kept as low as possible. 
     According to one embodiment of the invention, the deflection tools are a static deflection piece or a deflection roll. Static deflection pieces thereby have the advantage of cost-effective production, whereas deflection rolls require more technical effort in production, which means higher production costs, whereby, however, for a deflection roll, the advantage of a still low friction coefficient is given. 
     According to a further embodiment of the invention, the attachment for the formation of a form-fit and/or force-fit connection is formed with the deflection tool. This ensures, that the optimal transmission of force from the window regulator rope to the deflection tool and from the deflection tool to the cantilever arms is guaranteed. As a result, injections of force into certain cantilever arm sections are avoided, which further increases the stability of the cantilever arm. 
     According to a further embodiment of the invention, the cantilever arm has an additional attachment for a deflection tool of the window regulator rope, whereby this additional attachment is located in the direction of extension of the cantilever arm with respect to the end of the cantilever arm that projects beyond the door module. To achieve as large of a glass drop as possible, the additional attachment is preferably in the proximity of the edge of the door module, which is opposite to that edge of the door module, which is covered by the cantilever arm. 
     According to a further embodiment of the invention, the door module further comprises an additional cantilever arm with an additional deflection piece, whereby at least one of the deflection pieces of the cantilever arms is a deflection roll. Preferably, a total of four deflection tools are used hereby, namely three static deflection pieces and a deflection roll. This is an optimal combination, as by using three static deflection pieces, cost-effective production is possible, whereas due to the additional use of a single deflection roll, the effort due to frictional forces, which must be exerted by a window regulator motor onto the window regulator ropes to move a window pane, is kept within limits. Thereby, the window regulator motor can also be configured in such a way that it can move the window regulator ropes in an optimal way under the given conditions. A cost-intensive oversizing of the window regulator motor is thus unnecessary. 
     According to a further embodiment of the invention, the receptacle is provided with a stop tool. With it, it is possible to insert the deflection tool into the attachment in a single step by means of a simple motion in the direction of extension of the cantilever arm. No further labor-intensive screwing or riveting processes are required, as a result of which the cost effectiveness of the production or installation of the door module according to the invention is further optimized. 
     According to a further embodiment of the invention, the receptacle for the static deflection piece is designed arched, whereby the stop tool is located in the center with respect to the arch. Preferably, the stop tool is a recess of the cantilever arm, whereby the recess is designed for housing a snap tab mounted on the static deflection piece. The use of an arched static deflection piece has the advantage that here, an optimal transmission of force from the window regulator rope to the deflection piece and from the deflection piece to the cantilever arm is guaranteed. Here too, in turn, injections of force at the cantilever arm are reliably avoided, as a result of which the overall stability of the door module is significantly increased. Here too, the central location of the stop tool relative to the arch facilitates optimal force transmission. 
     According to one embodiment of the invention, the cantilever arm has a honeycomb structure. The use of a honeycomb structure has the advantage that material can be saved in the production of the cantilever arm without, however, having to make do without high mechanical stability of the cantilever arm. The material savings represent a reduction of production costs of the door module and in addition, they make an acceleration of the production process of the door module in accordance with the invention possible, for example, in an extrusion process, as due to the honeycomb structure and the thereby present low mass of plastic, the hardening times of the plastic are reduced. 
     According to a further embodiment of the invention, the attachment is located centrally with respect to the cross section of the cantilever arm. This in turn facilitates the optimal transmission of the force of the deflection tools to the cantilever arm. 
     According to a further embodiment of the invention, the cantilever arm consists of fiber glass-containing polypropylene. This has the advantage that the creeping properties of the cantilever arm can also be minimized at higher temperatures without, however, sacrificing any mechanical elasticity, breaking resistance, as well as having to accept a decrease in machining properties. 
     In a further aspect, the invention relates to a method for the production of a door module for a motor vehicle door, whereby the production process comprises the step of providing the door module, whereby the door module is provided with a cantilever arm for a window regulator without guide rail, whereby the cantilever arm is formed in one piece with the door module, whereby the cantilever arm projects beyond an outer edge of the door module and whereby the cantilever arm, at least at the end that projects beyond the edge of the door module, has an attachment for a deflection tool of a window regulator rope. In a further step, the deflection tool is inserted into the attachment. 
     According to a further embodiment of the invention, the production of the door module takes place jointly with the cantilever arm in an extrusion process. 
     According to a further embodiment of the invention, the method for the production of the door module further includes a step for attaching a gasket on the revolving edge of the door module, whereby the gasket is applied to the door model by means of inclined extrusion. The gasket is necessary in order to separate the wet space from the dry space in a motor vehicle door, i.e. separate that side water-tight that is facing the vehicle interior. In this process there is, however, the difficulty, that conventionally used extrusion processes prevent an application of the gasket on the revolving edge of the door module to the extent, that at various positions the cantilever arm projects beyond the edge of the door module. This problem is solved by using inclined extrusion, in which the extrusion head is guided in such a way, that it can also apply the sealing mass onto the edge of the door module even located under the cantilever arm, which projects beyond the edge of the door module. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the following, preferred embodiments of the invention are explained in more detail in conjunction with the drawings. Shown are: 
         FIG. 1 : a view of a door module in accordance with the invention in a motor vehicle door, 
         FIG. 2 : an additional view of the door module in accordance with the invention in a motor vehicle door, 
         FIG. 3 : a view of various attachments of the cantilever arm, 
         FIG. 4 : a further view of the cantilever arm in accordance with the invention, 
         FIG. 5 : an additional view of the door module in accordance with the invention, and 
         FIG. 6 : a flow diagram of a method for the production of a door module. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following, similar elements are identified with the same reference numbers. 
       FIG. 1  shows a view of the door module  102  in accordance with the invention in a motor vehicle door  100 . The vehicle door has a recess  104 , onto which the door module  102  is placed. The side facing the viewer in  FIG. 1  thereby corresponds to the wet side of the door module, on which a window pane is mounted which is not shown here. This window pane is moved in the direction or against direction  122  by means of a window regulator without guide rail. 
     The window regulator without guide rail consists of cantilever arms  106  and  118 . The ends of these cantilever arms respectively contain deflection tools  112 , which guide a window regulator rope to the individual deflection tools as well as to a window regulator motor  124 . Carriers  120  are thereby fastened to the window regulator ropes  114 , whereby the carriers  120  are designed to therein house the window pane in order to thereby, by a motion of the window regulator ropes  114  and thus a movement of the carriers  120 , move the window pane into and counter to direction  122 . 
     It is now important in  FIG. 1 , that the cantilever arms  106  are designed for one, in one piece with the door module  102 . Further, it is critical that these cantilever arms  106  project beyond an outer edge  108  of the door module. The cantilever arms  106  have attachments at their ends  110 , into which deflection tools  112  for the window regulator rope  114  can be inserted. 
     Further, door module  102  has a gasket  126 , which extends inside of the outer edge  108  of door module  102 . The gasket  126  thereby seals off the wet space of the motor vehicle door from the dry space. 
       FIG. 2  shows a further schematic view of the door module  102  in accordance with the invention in a motor vehicle door  100 . The difference between  FIG. 1  now lies therein, that at the upper right cantilever arm a deflection tool  200  was inserted, whereby the deflection tool  200  is a deflection roll. Thus, in  FIG. 2 , four cantilever arms  106  or  112  are present, whereby three of the cantilever arms carry a static deflection piece  112  and a fourth cantilever arm  106  has a deflection tool in the form of a deflection roll  200 . This combination of all three deflection pieces and a deflection roll has the advantage that cost-effective products such as static deflection tools  112  can be used, whereby in addition, cost-effective window regulator motors  124  can be used, as because of the use of the deflection roll  200 , the force exerted by the motor for moving the window regulator ropes  114 , can be kept within limits. An alternative to that would be the exclusive use of deflection pieces which, however, would require a stronger and more powerful window regulator motor  124 , which would in turn have higher production costs as a consequence, 
     Concerning cantilever arms  106  and  118  that are opposite to each other let it also be noted, that these can be connected to be continuous with each other by means of a bar  116 . Such a bar  116  has the advantage that the overall ability to bear mechanical load is increased, as the window regulator rope  114  extends—in sections—parallel to the bar from the deflection tool  112  of the cantilever arm  106  to the deflection tool  112  of the cantilever arm  118 . 
       FIG. 3  shows a view of different cantilever arms. Thereby, in  FIG. 3   a  a conventional deflection roll  200  is shown, which is fastened by means of a rivet  302  at the cantilever arm of the door module  102 . This means that for the production of the door module sketched in  FIG. 3   a , a riveting process is required for fastening the deflection roll  200  at the corresponding cantilever arm. This has two disadvantages, namely for one, complicated handling, which is time-intensive and requires corresponding machinery. For another, the disadvantage results that the mechanical load capacity is severely limited due to the rivet connection to the cantilever arm. 
     A remedy for that is created with the door module in accordance with the invention as sketched in  FIGS. 3   b  and  3   c . In  FIG. 3   b , the deflection roll  200  is shown, the axis of which is inserted into a corresponding attachment  306  of the cantilever arm  106 . Thereby, the attachment  306  has snap elements  300 , so that after installation of the deflection roll  200 , the deflection roll is prevented from falling out of attachment  306 . Here, it is also still important that the deflection roll  200  is centered with respect to the cross section of the cantilever arm  106 , preferably in the Y direction of the motor vehicle as well as also in the X direction of the motor vehicle. With that, an optimal transmission of force from the window regulator rope to the deflection roll  200  and thus onto the cantilever arm  106  is ensured. 
     Instead of a deflection roll  200 ,  FIG. 3   c  shows a static deflection piece  112 . The static deflection piece  112  is in turn housed in the attachment  306  of the cantilever arm  106 . On the side facing the cantilever arm, the deflection piece  112  has a snap tab  304 , which is locked into a corresponding counter attachment after insertion into the opening  306 . With that, a form-fit and/or force-fit connection of the static deflection piece  112  with cantilever arm  106  is ensured. 
       FIG. 4  shows a further schematic view of the cantilever arm in accordance with the invention. The cantilever arm  106  is formed in one piece with the door module  102 . At the end of the cantilever arm  106  that projects beyond the door module it has an attachment  306 , into which the static deflection piece  112  can be inserted. The static deflection piece  112 , as well as the counter attachment  306  are formed in arches, so that an optimal transmission of force onto the cantilever arm  106  can take place. Further, the arched static deflection piece has a snap tab  304 , which can be inserted into a corresponding counter attachment  404  at cantilever arm  106 . By means of it, the deflection piece  112  is secured against falling out of attachment  306 . By means of a simple compression of the snap tab elements of snap tab  304 , however, removing deflection piece  112  from attachment  306  can be realized subsequently which, for example, may be necessary for purposes of repair caused by wear and tear of the deflection piece. 
     The deflection piece has a V-shaped slot  402 , in which the window regulator rope is guided in a semi-circular progression of the slot. 
     Further, the honeycomb structure of the cantilever arm  106  can be seen in  FIG. 4 . This honeycomb structure  400  ensures for one, that the cantilever arm has high mechanical stability. For another, the honeycomb structure ensures a weight reduction of the cantilever arm, as solid material is no longer required here. 
       FIG. 5  shows an additional view of the door module in accordance with the invention. Thereby, the view of  FIG. 5  essentially corresponds to the significantly schematically simplified view of  FIG. 2 . The continuous design of cantilever arms  106  and  118  is clearly visible in  FIG. 5 . However, here too, these continuous cantilever arms are connected with the door module  102  in one piece. The cantilever arm  106  thereby has the honeycomb structure described in  FIG. 4 . Further,  FIG. 5  shows that here too, three of the deflection tools are formed by static deflection pieces  112 , whereas the fourth deflection tool is a deflection roll  200 . 
       FIG. 6  shows a flow diagram of a method for the production of a door module. The method starts in step  600 , the joint production of door module and cantilever arm, whereby the door module is produced together with the cantilever arm in one piece in an extrusion process. Subsequently, a gasket is extruded onto the produced door module in step  602 , whereby the extrusion is performed inclined, i.e. not perpendicular with respect to the door module. In the process; those positions of the door module projecting beyond the cantilever arm can be made accessible for extrusion. Finally, in step  604 , the insertion of the deflection tools into the cantilever arms takes place. Thereby, steps  604  and  602  can be interchanged. 
     REFERENCE NUMBERS 
     
         
           100  motor vehicle door 
           102  door module 
           104  opening 
           106  cantilever arm 
           108  edge 
           110  end of cantilever arm 
           112  static deflection piece 
           114  window regulator rope 
           116  bar 
           118  cantilever arm 
           120  carrier 
           122  direction 
           124  motor 
           126  gasket 
           200  deflection roll 
           300  stop tool 
           302  rivet 
           304  snap tab 
           306  attachment 
           400  honeycomb structure 
           402  V-shaped slot 
           404  opening