Motor vehicle door module

Abstract

A door assembly is disclosed for a motor vehicle. The door assembly comprises a molded door panel having a first side and a second side. The first side of the door panel is adapted to face into a passenger compartment of the motor vehicle. The second side of the door panel supports a belt line reinforcement, a lock and catch assembly, and a window lift assembly. The door assembly of the present invention is adapted for joining with a door exterior.

What is claimed is:  
     
         1 . A door assembly for a motor vehicle, the door assembly comprising: 
 a door panel having an inner side and an outer side, the inner side being adapted to face into a passenger compartment of the motor vehicle;    a catch mounted on the outer side of the door panel and operable to detachably secure the door assembly in a closed position; and    a lock mounted on the outer side of the door panel and engaged with the catch to permit selective operation of the catch.    
     
     
         2 . The door assembly of  claim 1  further comprising an exterior handle mounted on the outer side of the door panel and adapted to operate the catch.  
     
     
         3 . The door assembly of  claim 1  wherein the lock is formed as part of a lock assembly, and the lock assembly comprises a glass edge guide.  
     
     
         4 . The door assembly of  claim 1  further comprising an inner handle mounted on the door panel and adapted to operate the catch.  
     
     
         5 . The door assembly of  claim 4  wherein the inner handle is mounted in a door handle housing formed in the door panel.  
     
     
         6 . The door assembly of  claim 4  wherein the inner handle is connected to the catch by a cable.  
     
     
         7 . The door assembly of  claim 1  further comprising a belt line reinforcement connected to the outer side of the door panel.  
     
     
         8 . The door assembly of  claim 7  wherein the belt line reinforcement comprises metal.  
     
     
         9 . The door assembly of  claim 7  wherein the belt line reinforcement comprises plastic.  
     
     
         10 . The door assembly of  claim 1  further comprising a window regulator connected to the outer side of the door panel.  
     
     
         11 . The door assembly of  claim 10  further comprising a window engaged with the window regulator.  
     
     
         12 . The door assembly of  claim 10  further comprising a motor operably connected to the window regulator.  
     
     
         13 . The door assembly of  claim 10  wherein the window regulator is adapted for movement along a generally vertically oriented member connected to the outer side of the door panel.  
     
     
         14 . The door assembly of  claim 1  further comprising means for dissipating a side impact to the door assembly.  
     
     
         15 . The door assembly of  claim 14  wherein the means for dissipating a side impact comprises foam disposed adjacent the outer side of the door panel.  
     
     
         16 . The door assembly of  claim 1  further comprising a map pocket attached to the door panel.  
     
     
         17 . The door assembly of  claim 1  wherein the door panel includes a speaker impression.  
     
     
         18 . The door assembly of  claim 1  further comprising a wiring harness connected to the outer side of the door panel.  
     
     
         19 . The door assembly of  claim 1  wherein the door panel is injection molded.  
     
     
         20 . The door assembly of  claim 1  wherein the door panel is compression molded.  
     
     
         21 . The door assembly of  claim 1  wherein the door panel comprises olephenic thermoplastic.  
     
     
         22 . The door assembly of  claim 1  wherein the door panel comprises polypropylene.  
     
     
         23 . The door assembly of  claim 1  wherein the door panel comprises acrylonitrile-butadience-styrene.  
     
     
         24 . The door assembly of  claim 1  wherein the door panel comprises a glass-reinforced composite.  
     
     
         25 . The door assembly of  claim 1  further comprising a header attached to the door panel.  
     
     
         26 . A door assembly for a motor vehicle, the door assembly comprising: 
 a trim panel having an inner side and an outer side, the inner side being adapted to face into a passenger compartment of the motor vehicle;    a catch mounted on the outer side of the trim panel and operable to detachably secure the door assembly in a closed position; and    an exterior handle mounted on the outer side of the trim panel and adapted to operate the catch.    
     
     
         27 . The door assembly of  claim 26  further comprising a lock mounted on the outer side of the trim panel and engaged with the catch to permit selective operation of the catch.  
     
     
         28 . The door assembly of  claim 26  wherein the lock is formed as part of a lock assembly, and the lock assembly comprises a glass edge guide.  
     
     
         29 . The door assembly of  claim 26  further comprising an inner handle mounted on the trim panel and adapted to operate the catch.  
     
     
         30 . The door assembly of  claim 29  wherein the inner handle is mounted in a door handle housing formed in the trim panel.  
     
     
         31 . The door assembly of  claim 29  wherein the inner handle is connected to the catch by a cable.  
     
     
         32 . The door assembly of  claim 26  further comprising a belt line reinforcement connected to the outer side of the trim panel.  
     
     
         33 . The door assembly of  claim 32  wherein the belt line reinforcement comprises metal.  
     
     
         34 . The door assembly of  claim 32  wherein the belt line reinforcement comprises plastic.  
     
     
         35 . The door assembly of  claim 26  further comprising a window regulator connected to the outer side of the trim panel.  
     
     
         36 . The door assembly of  claim 35  further comprising a window engaged with the window regulator.  
     
     
         37 . The door assembly of  claim 35  further comprising a motor operably connected to the window regulator.  
     
     
         38 . The door assembly of  claim 35  wherein the window regulator is adapted for movement along a generally vertically oriented member connected to the outer side of the trim panel.  
     
     
         39 . The door assembly of  claim 26  further comprising means for dissipating a side impact to the door assembly.  
     
     
         40 . The door assembly of  claim 39  wherein the means for dissipating a side impact comprises foam disposed adjacent the outer side of the trim panel.  
     
     
         41 . The door assembly of  claim 26  further comprising a map pocket attached to the trim panel.  
     
     
         42 . The door assembly of  claim 26  wherein the trim panel includes a speaker impression.  
     
     
         43 . The door assembly of  claim 26  further comprising a wiring harness connected to the outer side of the trim panel.  
     
     
         44 . The door assembly of  claim 26  wherein the trim panel is injection molded.  
     
     
         45 . The door assembly of  claim 26  wherein the trim panel is compression molded.  
     
     
         46 . The door assembly of  claim 26  wherein the trim panel comprises olephenic thermoplastic.  
     
     
         47 . The door assembly of  claim 26  wherein the trim panel comprises polypropylene.  
     
     
         48 . The door assembly of  claim 26  wherein the trim panel comprises acrylonitrile-butadience-styrene.  
     
     
         49 . The door assembly of  claim 26  wherein the trim panel comprises a glass-reinforced composite.  
     
     
         50 . The door assembly of  claim 26  further comprising a header attached to the trim panel.  
     
     
         51 . A structural door trim module for combining with and reinforcing an outer door panel of a motor vehicle to make a vehicle door assembly, the door trim module comprising: 
 an inner door panel having an inner appearance side and an outer side having a structural characteristic, the inner appearance side being adapted to face into a passenger compartment of the motor vehicle and the outer side being adapted to face the outer door panel; and    an inner door panel reinforcement mounted on the outer side of the inner door panel to provide the structural characteristic and having spaced portions adapted to interface with the outer door panel in respective spaced locations with each spaced portion being readily accessible and operable to detachably and structurally secure the inner door panel in an easy-on, easy-off combination with the outer door panel.    
     
     
         52 . The structural door trim module of  claim 51  wherein said spaced location s are on opposite sides of said inner door panel so that said spaced portions of said inner door reinforcement are more readily accessible when securing the inner door panel in combination with the outer door panel.  
     
     
         53 . The structural door trim module of  claim 51  including a lock mounted on the outer side of the inner door panel for selectively locking and unlocking the outer door panel with respect to the motor vehicle when the inner door panel is secured in combination with the outer door panel, said lock being sufficiently adjacent to one of said spaced portion of said inner door panel reinforcement that said lock is readily accessible and operable to detachably and structurally secure said lock in combination with the outer door panel in one of said spaced locations when the inner door panel is secured in combination with the outer door panel.  
     
     
         54 . The structural door trim module of  claim 53  wherein one of said spaced portions of said inner door panel reinforcement is configured substantially normal to said inner door panel adjacent said lock to cause said one of said spaced portions in one of said spaced locations to interface with a peripheral portion of the outer door panel when both the inner door panel and the lock are secured in combination with the outer door panel.  
     
     
         55 . The structural door trim module of  claim 51  including a window pane frame and a window pane regulator affixed to said inner door panel reinforcement and operable to move said window pane in and out of said window pane frame.  
     
     
         56 . The structural door trim module of  claim 51  wherein said inner door panel reinforcement is configured to resist crash loads impacting the motor vehicle.  
     
     
         57 . The structural door trim module of  claim 51  wherein said inner door panel reinforcement is configured to form a door pull support when the inner door panel is secured in combination with the outer door panel.  
     
     
         58 . The structural door trim module of  claim 51  including a lock mounted on said inner door panel reinforcement and having a handle for operating said lock, said handle adapted to extend into an exterior hand grab position through the outer door panel when said inner door panel is secured in combination with the outer door panel.  
     
     
         59 . The structural door trim module of  claim 53  including a door handle connected to said lock and an interior door handle recess on said inner door panel reinforcement between said spaced portions for receiving said door handle on said inner appearance said of said inner door panel to provide reinforcement for said door handle when said inner door panel is secured in combination with the outer door panel.  
     
     
         60 . The structural door trim module of  claim 51  including a water management system covering the outer side of said inner door panel between said inner and outer door panels when securing the inner door panel in combination with the outer door panel to inhibit the introduction of water, noise and dust into the passenger compartment.  
     
     
         61 . The structural door trim module of  claim 60  including a flange on the inner door panel reinforcement and a belt line glass seal attached to said flange as part of said water management system.  
     
     
         62 . The structural door trim module of  claim 60  including electrical devices on said outer side of said inner door panel, and wherein said water management system is a sheet configured to conformingly seal said electrical devices.  
     
     
         63 . A vehicle door assembly for a motor vehicle comprising an outer door panel having a peripheral flange defining an opening, and a structural door trim module insertable into said opening and having a plurality of electrical components testable and adjustable before said door trim module is inserted into said opening, said door trim module having: 
 an inner door panel having an inner appearance side and an outer side having a structural characteristic for the vehicle door assembly, the inner appearance side being adapted to face into a passenger compartment of the motor vehicle and the outer side facing the outer door panel; and    an inner door panel reinforcement mounted on the outer side of the inner door panel to provide the structural characteristic and having spaced portions at least one of which interfaces with the peripheral flange of the outer door panel and with the peripheral flange of the outer door panel and with each spaced portion being readily accessible and operable to detachably and structurally secure the inner door panel in an easy-on, easy-off combination with the outer door panel.    
     
     
         64 . The vehicle door assembly of  claim 63  wherein said peripheral flange extends between said inner door panel and said outer door panel.  
     
     
         65 . A method of assembling a vehicle door for a motor vehicle comprising: 
 providing an outer door panel with a peripheral flange having a first flange portion substantially normal to said outer door panel and a second flange portion spaced from said first portion and substantially parallel to said outer door panel,    forming a structural door trim module comprising an inner door panel having an inner appearance side and an outer side having a structural characteristic, said inner appearance side being adapted to face into a passenger compartment of the motor vehicle and said outer side being adapted to face the outer door panel;    mounting an inner door panel reinforcement on the outer side of the inner door panel to provide the structural characteristic of said inner door panel, and    forming spaced reinforcement flange portions on said inner door panel reinforcement adapted interface respectively with the first and second flange portions on the outer door panel,    positioning said structural door trim module adjacent said outer door panel so that said first reinforcement flange portion is readily accessible and interfaces with said first outer door panel flange portion and said second reinforcement flange portion is readily accessible and interfaces with said second outer door panel flange portion and,    detachably securing said structural door trim module to said outer door panel by fastening each of said reinforcement flange portions to a respective outer door panel flange portion whereby to reinforce said outer door panel with said structural door trim module.    
     
     
         66 . The method of assembling a vehicle door of  claim 65  including: 
 installing as a part of said structural door trim module an electrical component on the outer side of said inner door panel and sealing said outer side and said electrical component with a watershield before said structural door trim module is positioned adjacent said outer door panel whereby to shield said electrical component and the passenger compartment of the vehicle from the deleterious effects of water, noise and dust.  
 
     
     
         67 . A door assembly for a motor vehicle, the door assembly comprising: 
 a door panel having an inner side and an outer side, the inner side being adapted to face into a passenger compartment of the motor vehicle;    a catch mounted on the outer side of the door panel and operable to detachably secure the door assembly in a closed position; and    a lock mounted on the outer side of the door panel and engaged with the catch to permit selective operation of the catch;    the door assembly being an integral removable unit.