Door module for motor vehicles with plastic functional components

Abstract

The invention relates to a one-piece door module for motor vehicles, encompassing a self-supporting metal carrier panel, which also encompasses, as integral constituents, a multiplicity of plastic functional components which are connected securely and permanently to the metal carrier panel in one operation by the outsert technique.

1 . A one-piece door module for motor vehicles comprising a one-piece self-supporting metal carrier panel and thereon, as integral constituents, plastic funcational components which are connected securely and permanently to the metal carrier panel in one operation.  
     
     
         2 . The door module as claimed in    claim 1   , wherein said self-supporting carrier panel has a three-dimensional shape which is essentially matched to the shape of the motor vehicle door into which it is to be incorporated.  
     
     
         3 . The door module as claimed in    claim 1   , wherien said self-supporting carrier panel has a thickness in the range of from 0.1 to 5 cm.  
     
     
         4 . The door module as claimed in    claim 3   , wherein said self-supporting carrier panel has a thickness in the range of from 0.2 to 2 cm.  
     
     
         5 . The door moedule as claimed in    claim 1   , wherein said plastic functional components are made from thermoplastic material.  
     
     
         6 . The door module as claimed in    claim 5   , wherein said thermoplastic material is selected from plastics based on polypropylene, polyamide, polyester, polyphenylene oxide, polyoxymethylene, polyphenylene sulfide, polyurethane, polycarbonate or blends made from polyester with acrylonitrile-butadiene-styrene copolymers or with acrylonitrile-styrene-acrylate graft polymers.  
     
     
         7 . The door module as claimed in    claim 5    or    6    wherein said thermoplastic material is reinforced with glass fibers or carbon fibers.  
     
     
         8 . The door module as claimed in    claim 1   , wherein said plastic functional components encompass window lifter profiles for a movable side window and at least one retaining element for an electric motor for moving said side window.  
     
     
         9 . The door module as claimed in    claim 8   , wherein said window lifter profiles are made of a thermoplastic material having high wear resistance.  
     
     
         10 . The door module as claimed in    claim 8   , wherein said window lifter profiles further comprise at least one movable retaining element each for connecting said side window.  
     
     
         11 . The door module as claimed in    claim 10   , wherein said window lifter profiles are made of a thermoplastic material having high wear resistance with respect to said movable retaining element.  
     
     
         12 . The door module as claimed in    claim 1   , comprising an electrically insulating film made of polyester, polyethylene, polypropylene, cycloolefin copolymer, polyphenylene sulfide, polyimide or polyether imide, and wherein electrical conductor tracks which serve for the electrical connection of electrically operated functional components in the area of the door module have been applied to the electrically insulating film.  
     
     
         13 . The door module as claimed in    claim 12   , wherein said electrically insulating film simultaneously functions as a moisture barrier.  
     
     
         14 . A process for producing a door module as claimed in any of the preceding claims, comprising injection-molding plastic onto a prefabricated metal carrier panel in precisely defined, limited areas to form said plastic functional components.  
     
     
         15 . The process as claimed in    claim 14   , comprising molding-on plastic functional components in the form of window lifter profiles in the folded-out state and, after solidification, swinging said window lifter profiles from the folded-out state around into proximity with the carrier panel, and fixing them there.  
     
     
         16 . The process as claimed in    claim 14   , further comprising inserting or clipping electrically conductive power cables or ribbon cables into respectively onto molded-on plastic functional components shaped as retaining elements.  
     
     
         17 . The process as claimed in    claim 14   , wherein, in addition, a sealing composition for sealing the joints with adjacent or superimposed surfaces is applied to or injection-molded onto the door module in areas close to its edges or, when the door module encompasses an electrically insulating film, also to or onto the film.  
     
     
         18 . The process as claimed in    claim 14   , wherein, in addition, conductor tracks in the form of electrically conductive compounds are applied to the carrier panel, or when the door module encompasses an electrically insulating film, to said film by hot-stamping of aluminum foil or copper foil.  
     
     
         19 . The process as claimed in    claim 15   , wherein said window lifter profiles are post-treated by plasma treatment or corona treatment to improve their wear resistance.