Door panel assembly

Abstract

A door panel assembly includes a panel with a window lifting mechanism mounted on one side and a power mechanism mounted on an opposite side. The panel has a first alignment feature for aligning the window lifting mechanism relative to the panel and a second alignment feature for aligning the power mechanism relative to the panel. The first and second alignment features facilitate alignment of the window regulator and the power mechanism to each other. Further, the first and second alignment features allow initial assembly of one of the window regulator or power mechanism components to the panel with a subsequent assembly of the remaining component to the, panel without having to hold the first component in place.

1 . A door panel assembly including a door panel, a window regulator housing mounted on a first side of the door panel and a power mechanism mounted on a second side of the door panel, in which the panel includes at least one first alignment feature for aligning the window regulator housing relative to the door panel and at least one second alignment feature for aligning the power mechanism relative to the door panel.  
     
     
         2 . A door panel assembly as defined in  claim 1  in which the door panel forms part of a door inner skin.  
     
     
         3 . A door panel assembly as defined in  claim 1  in which the door panel forms part of a door module panel.  
     
     
         4 . A door panel assembly as defined in any preceding claim in which the at least one first and/or second alignment features are pressed features of the door panel.  
     
     
         5 . A door panel assembly as defined in  claim 4  in which the at least one first and second alignment features are formed on opposing sides of the same pressed feature.  
     
     
         6 . A door panel assembly as defined in  claim 5  in which one of said at least one first and second alignment features includes a projection received in a recess of the window regulator housing or power mechanism and the other of said at least one first and second alignment features includes a recess for receiving a projection of the window regulator housing or power mechanism.  
     
     
         7 . A door panel assembly as defined in  claims 1  to  3  in which the least one first and/or second alignment features are tabs bent from the door panel.  
     
     
         8 . A door panel assembly as defined in any preceding claim in which the least one first and/or second alignment features includes a fixing hole for securing the window regulator housing or power mechanism to the door panel.  
     
     
         9 . A door panel assembly as defined in  claim 8  when dependent upon  claims 4  to  6  in which the fixing hole is contiguous with the pressed feature.  
     
     
         10 . A door panel assembly as defined in  claim 8  when dependent upon  claim 7  in which the fixing hole is contiguous with the tab.  
     
     
         11 . A door panel assembly as defined in  claims 1  to  3  in which the at least one first and/or second alignment features is a dowel secured to, and projecting from the door panel.  
     
     
         12 . A door panel assembly as defined in  claim 11  in which a single dowel provides both the at least one first and second alignment features.  
     
     
         13 . A door panel assembly as defined in claims  11  or  12  in which the dowel is riveted or swaged to the door panel.  
     
     
         14 . A door panel assembly as defined in claims  11  or  12  in which the dowel has a first threaded portion which engages a corresponding threaded portion of the door panel to secure the dowel to the door panel  
     
     
         15 . A door panel assembly as defined in  claims 11  to  14  in which the dowel includes a second threaded portion for engagement with a threaded fastener to secure the window regulator housing or power mechanism relative to the door panel  
     
     
         16 . A door panel assembly as defined in any preceding claim in which the assembly includes separate fixing features which secure at least one of the window regulator housing and power mechanism relative to the door panel.  
     
     
         17 . A door panel assembly as defined in  claim 16  in which the fixing feature is a projection on one of the window regulator housing, door panel or power mechanism having a tang for engagement with another of the window regulator housing door panel and power mechanism to secure the components together.  
     
     
         18 . A door panel assembly as defined in any preceding claim in which the power mechanism is a motor.  
     
     
         19 . A door panel assembly as defined in  claims 1  to  18  in which the power mechanism is a manual window winder.  
     
     
         20 . A door panel assembly as hereinbefore described with reference to or as shown in FIG. 2 or  3  or  4  or  5  or  6  or  7  when applied to FIG. 1 of the accompanying drawings.