Door assembly with integrated window sealing system

DOOR ASSEMBLY WITH INTEGRATED WINDOW SEALING SYSTEM

The present invention relates to a door system. More particularly, embodiments of the present invention relate to door systems for automobiles, particularly vehicles such as cars and trucks.

BACKGROUND ART A conventional automotive door includes several individual pieces that are assembled to a frame or shell. A car door can have 50 to 100 or more individual parts, depending on the vehicle and optional package. These components may include a variety of hardware and electrical components and seals. Exemplary hardware components may include handles, mirrors, window adjusters, window tracks, windows, door locks, and impact bolsters. Certain electrical components may include wire harnesses, speakers, window motors, and exterior mirror motors. Exemplary sealing components include glass run channels, beltline seals, lower sash seals, plugs, grommets, and body to door seals.

Each part is usually supplied by a different vendor or supplier, some of which are known in the industry as Tier 1, Tier 2, and Tier 3 suppliers. In most cases, original equipment manufacturers (OEMs) produce door frames and exterior skins that are each stamped from cold rolled steel, welded together, and painted to provide a door shell. The frame and skin can be stamped from one blank to form the door shell. Numerous individual parts from Tier 1, Tier 2 and Tier 3 suppliers are typically assembled on OEM door shells on an OEM assembly line.

The process of attaching parts to a door shell is time intensive and requires expensive logistical requirements and/or systems to ensure that the right parts are present in the right place at the right time. The assembly process may also require a large amount of expensive floor space. Each part is attached to the door shell using at least one of several different means including clips, screws, fittings, adhesives, to name a few. In most cases, 20 to 45 different assembly steps are required to complete the entire assembly process of the door.

1 shows a schematic illustration of a conventional door 100 . Typically, door 100 has an interior trim panel 110 , an interior panel 120 , an intrusion beam 130 , a reinforcement section 140 , and an exterior panel 150 . Typically, inner panel 120, piercing beam 130, reinforcing section 140, and outer panel 150 are each formed from steel, stamped, welded together, and painted at an OEM. Numerous hardware, electrical and sealing components such as those described above (not shown in FIG. 1 for simplicity) are typically assembled to steel inner panel 120 at an OEM. Likewise, various parts (not shown for simplicity) for interior trim panel 110 including lights, switches, armrests, map pockets, handles, etc. are assembled at a Tier 1 supplier and shipped to the OEM. The OEM attaches the assembled trim panel 110 to the assembled inner panel 120 and final electrical and hardware connections are made.

Therefore, the door manufacturing process is intensive and time consuming. The assembly process also requires a high degree of logistics planning to ensure that all parts are available and assembled in the correct manner and order. Other ancillary related costs include ordering, storage, maintenance, transportation, functional testing, and quality control, in addition to floor space for assembling the various parts. All of these factors end up making the final product very expensive.

According to the initial cost reduction and component integration idea, it was attempted to use a pre-assembled mounting panel in which all or part of the hardware and electrical components are assembled as shown in FIG. 2 . 2 schematically shows a conventional door 200 having a pre-assembled mounting panel 210 . Inner door handle (215), handle link cable (220), window motor (225), window adjuster (230), speaker (235), window guide rail (240), drum pulley (245), cable (250), and a number of parts including the door lock unit 260 are assembled to the mounting panel 210 .

All or part of the hardware and electrical components may be installed on the mounting panel 210 from an external supplier, such as a Tier 1 supplier. Mounting panel 210 is typically made of stamped steel, thermoformed glass mat reinforced thermoplastic (GMT) or injection molded long glass fiber reinforced polypropylene. After the applicable parts are assembled to the mounting panel 210 at an external supplier, the assembled mounting panel 210 is shipped to the OEM for installation in a door panel sub-assembly or exterior panel 270 . Thereafter, the inner trim panel 280 is attached to the outer panel 270 . US Pat. No. 6,857,688; 6,640,500; 6,546,674; 6,449,907; 5,820,191; 5,355,629; 5,040,335; 4,882,842; 4,648,208; and WO 01/25055 Al discloses other partial integration ideas.

Some examples of pre-assembled mounting panels are believed to be productive. However, the number of parts and the required assembly time remain largely unchanged. The cost benefits for OEMs are primarily due to the logistical cost savings that are absorbed by the tiered suppliers.

Accordingly, there is a need for a door assembly having fewer individual parts. There is also a need for a door assembly that minimizes the number of individual parts that require assembly.

The present invention provides a door system,

a) door structures;

b) a body on which one or more parts are disposed;

c) a first module having an upper cavity configured to at least partially surround a first side of the window glass and a lower cavity configured to at least partially engage the body;

d) a second module configured to at least partially surround a second side of the window glass and configured to at least partially contact the upper cavity of the first module, and

e) a door system comprising a trim module configured to at least partially cover the core module.

1 is a schematic view of a conventional door used in the prior art;

2 is a schematic view of a prior art door with pre-assembled mounting panels used in the prior art;

3 is a schematic diagram of one exemplary embodiment of an integrated door system in accordance with one or more embodiments described;

4 is a schematic diagram of one exemplary embodiment of a door structure in accordance with one or more embodiments described;

5A is a schematic diagram of one exemplary embodiment of an outer core module in accordance with one or more embodiments described;

5B is an enlarged cross-sectional view of the glass run channel 350 on line AA of FIG. 5A ;

6 is a schematic diagram of a first side of an exemplary core module in accordance with one or more embodiments described;

7 is a schematic diagram of a second side of the core module shown in FIG. 6 , which is an exemplary core module in accordance with one or more embodiments described;

8A is a schematic diagram of one exemplary embodiment of a window trim module in accordance with one or more embodiments described;

Fig. 8b is an enlarged cross-sectional view of the window trim module on line BB of Fig. 8a;

Fig. 8c is an enlarged cross-sectional view of the window trim module taken along line CC of Fig. 8a;

9 is a schematic view of an exemplary reinforcing member in accordance with one or more embodiments described;

10 is a schematic plan view of an exemplary reinforcing member to which a cover plate is attached;

11 is a cross-sectional view of an exemplary reinforcing member having one or more clips to secure a cover plate thereon;

12 is a partial cross-sectional view of an exemplary reinforcing member having a profiled edge of a protrusion;

13 is a schematic view of an exemplary reinforcing member having one or more reinforcing structures disposed thereon;

14 is a schematic view of an exemplary reinforcing member having one or more reinforcing structures disposed therein having a diamond-like pattern;

15 is a schematic view of an exemplary reinforcing member having one or more reinforcing structures disposed therein having a honeycomb pattern;

16 is a schematic view of a reinforcing member having one or more recesses for attachment to an insert in accordance with one or more embodiments described;

17 is a schematic view of a reinforcing member having one or more openings for attachment to an insert in accordance with one or more embodiments described;

18 is an enlarged schematic view of a reinforcing member having one or more slits for attachment to an insert in accordance with one or more embodiments described;

19 is an enlarged fragmentary cross-sectional view of a reinforcing member disposed with one or more clips for engaging and retaining a cover plate in accordance with one or more embodiments described;

20 is a schematic view of an exemplary cover plate having one or more clips formed thereon for securing to a reinforcing member in accordance with one or more embodiments described;

21 is a schematic diagram of one embodiment of a window lift system in accordance with one or more embodiments described;

22 is an enlarged partial cross-sectional view of the motor housing shown in FIG. 21;

Fig. 23 is an enlarged partial cross-sectional view of the window track shown in Fig. 21;

24 is a schematic diagram of another embodiment of a window lift system in accordance with one or more embodiments described;

25 is an enlarged partial cross-sectional view of the motor housing shown in FIG. 24;

Fig. 26 is an enlarged partial cross-sectional view of the window track shown in Fig. 24;

27 is a schematic side view of one embodiment of an exemplary lock assembly having a sliding mechanism for assembly, with the sliding mechanism in a pre-assembled position;

Fig. 28 is a schematic side view of the sliding mechanism shown in Fig. 27, with the sliding mechanism in an assembled position;

Fig. 29 is an enlarged partial cross-sectional view taken along line AA of the sliding mechanism shown in Fig. 28;

30 is a schematic side view of another embodiment of an exemplary lock assembly having a sliding mechanism for assembly, with the sliding mechanism in a pre-assembled position;

Fig. 31 is a schematic side view of the sliding mechanism shown in Fig. 30, with the sliding mechanism in an assembled position;

Fig. 32 is an enlarged partial cross-sectional view taken along line AA of the sliding mechanism shown in Fig. 31;

A detailed description will now be provided. Each of the claims defines a separate invention, which, for infringement purposes, is intended to cover equivalents of the various elements or limitations specified in the claims. Depending on the context, all hereinafter references to "invention" may in some cases refer only to specific embodiments. In other instances, a reference to the "invention" will be deemed to refer to the subject matter recited in one or more claims rather than the entirety of the claims. While each of the inventions will now be described in more detail, including specific embodiments, modifications and examples, the invention is included to enable any person skilled in the art to make and use the invention when combined with the available information and techniques. It is not limited to these examples, modifications or examples that are used.

3 is a schematic diagram of an example door system in accordance with one or more embodiments herein. In at least one particular embodiment, the door system includes a door structure 300 , an outer core module 325 , a core module 400 , a window trim module 525 , and a trim panel 700 . The outer core module 325 is a frame structure resembling the door structure 300 . The window trim module 525 resembles a conventional upper window perimeter shape, and is assembled to the outer core module 325 and the upper portion of the core module 400 . That is, the core module 400 resembles the outer core module 325 under the window trim module 525 . The trim panel 700 covers the core module 400 and completes the assembly of the door system.

Preferably, the door system utilizes multi-material injection molding techniques or robotic extrusion to integrate the various parts. Multi-material injection molding techniques can injection mold two or more materials into a single or multiple cavity mold. A two-part or material process is commonly known as "2K" and a three-material process is commonly known as "3K". Any suitable multi-material injection molding machine may be used, such as the Engel Victory Combi machine available from Engel Corp. Additional in-mold processing techniques may also be used to enhance and/or facilitate integration. Exemplary in-mold processing techniques include, but are not limited to, multi-cavity tools, insert molding, movable core sections, and gas/water assist. Robotic extrusion may also be used alone or in combination with any of these processing techniques. Robotic extrusion is particularly useful for applying sealing members or other functional parts to structures that have already been injection molded. With this system it is also possible to create a hollow seal cross section if required.

The term "door" as used herein is intended to encompass any door. For example, the term "door" is intended to be used as a hinged, sliding, lifting, or any other vehicle for any vehicle, including a vehicle, truck, SUV, train, boat, airplane, etc., whether personal, recreational or commercial. It may refer to one or more passenger doors, lift gates, tailgates and hatchbacks with alternative opening and closing motions.

Each of substrates 300 , 350 , 400 , 525 , 700 may have one or more seals, plugs, and/or grommets. Preferably, the one or more seals, plugs, and grommets are injection molded onto the substrate. Any one or more of the seals, plugs, and grommets may be molded directly into the substrate using two or three shot injection molding or robotic extrusion techniques. Integrated seals, plugs and grommets help prevent or eliminate immersion, rocking and vibration. These parts also increase the acoustic performance of the part (ie, provide sound insulation and "closing sound" of the door), while allowing some movement while compensating for differences in part tolerances and expansion.

As shown in FIG. 3 , the trim panel 700 includes one or more of a speaker cover 710 , an armrest 720 , a door handle 730 , a window switch 740 , a door lock switch 750 , and a side mirror control 760 . ), a map pocket 770 and an internal light 780 may be additionally provided. The trim panel 700 may provide a housing or substrate to which other electrical, mechanical and sealing components will be attached, integrally molded or insert molded. Exemplary components include airbags, air vents, switches; door handle; door lock; elbow rest; map pocket; speaker cover or grille; speaker; beltline seal; plug; grommet; and core to frame seals. Exemplary switches include window glass controls, window locks, exterior mirror positioning controls, door locks, seat positioning controls, and stereo controls.

Preferably, the trim panel 700 is injection molded from one or more materials such as polyethylene, polypropylene and/or one or more other suitable materials described herein. In one or more embodiments, armrest 720 , speaker cover 710 , and map pocket 770 are injection molded into trim panel 700 using multi-material or multi-shot injection molding techniques. Each of trim panel 700 , armrest 720 , speaker cover 710 , and map pocket 770 may each comprise one or more of the same or different materials comprising polyethylene, polypropylene, and/or one or more other suitable materials described herein. It can be injection molded into the material.

Looking at the door structure 300 in more detail, FIG. 4 is a schematic plan view of one embodiment. The door structure 300 may be fabricated from one or more individual panels. For example, the door structure 300 may have an outer skin 320 and an inner support 330 that are attached to each other. Each of the outer skin 320 and the inner support 330 may be injection-molded with polyethylene or polypropylene, and more preferably, may be injection-molded with reinforced polypropylene. In certain embodiments, each of the outer skin 320 and inner support 330 may be injection molded, cast, extruded, molded, or formed in any other manner from one or more other suitable materials, such as those described herein. . In one or more embodiments, each of the outer skin 320 and inner support 330 may be stamped, assembled, and painted from aluminum or cold rolled steel to meet OEM specifications. In one or more embodiments, each of the outer skin 320 and inner support 330 is fabricated from a different type of steel (ie, a "tailored blank"), welded together, stamped, and welded together as desired. can be painted. Further, the door structure 300 may be a single piece or a single panel.

The door structure 300 has a first side or interior side 310 facing the passenger compartment of the vehicle. The inner side 310 of the door structure 300 may have a concave cavity 315 , which upon assembly at least a portion of the core module 400 may have a concave cavity 315 of the door structure 300 . It has a size and shape similar to that of the core module 400 to fit into the 315 . In one or more embodiments, the core module 400 has a peripheral seal (not shown in this figure) that can be integrally formed together or attached separately. This seal creates a wet/dry barrier between the door structure 300 and the core module 400 , aids in the formation of a wobble-free assembly, assists in reducing noise transmission, and assists in compensating for thermal expansion. The door structure 300 also has a second or outer side (not shown in this figure) to which side mirrors and an outer door handle (not shown in this figure) can be attached. As used herein, the term "interior" refers to an orientation or orientation toward the interior or passenger compartment of a vehicle, and the term "exterior" refers to an orientation or direction facing away from the interior or passenger compartment of a vehicle. refers to

In one or more embodiments above or elsewhere herein, the door structure 300 does not have a reinforcing structure or member disposed at or near the beltline 353 . The absence of reinforcing structures or members allows better access to window glass and other parts that require assembly or repair. In particular, the absence of such obstructions in the beltline 353 facilitates window glass assembly and disassembly, as will be discussed in greater detail below. The absence of reinforcing structures or members also reduces the total weight of the door assembly, which reduces the weight of the vehicle and increases gas fuel economy.

5A is a schematic diagram of one exemplary embodiment of an outer core module 325 in accordance with one or more embodiments described herein. The outer core module 325 is a frame structure having an upper cavity 326 and a lower cavity 327 . The two cavities 326 and 327 are separated by a support member approximately at the beltline. One or more seals that provide increased noise reduction and improved leak resistance may be readily integrated with the external core module 325 .

The outer core module 325 has a glass run channel 350 . As shown in FIG. 5A , at least a portion of the glass run channel 350 is disposed within the upper cavity 326 , and at least a portion of the glass run channel 350 is disposed within the lower cavity 327 of the outer core module 325 . do. In one or more embodiments, the glass run channel 350 includes an upper portion 351 disposed within the upper cavity 326 of the outer core module 325 , and one or more lower portions 352 disposed within the lower cavity 327 . has For example, the first portion 352A of the glass run channel 350 is attached to the outer core module 325 below the beltline support 328 along the A post side of the outer core module 325 and the glass run The second portion 352B of the channel 350 is attached below the beltline support 328 along the B post side of the outer core module 325 . Preferably, at least one of the first and second portions 352A, 352B of the glass run channel 350 has a length sufficient to contact the window glass when the window glass is in its lower position. More preferably, the first and second portions 352A, 352B of the glass run channel 350 are both of sufficient length to contact the window glass when the window glass is in the lower position.

Glass run channels 350 may be fabricated from one or more separate sections or members that are fitted, welded, or otherwise attached together or held in a fixed orientation relative to each other. Preferably, the glass run channel 350 is made of a single piece. Alternatively, portions or sections 351 , 352A, 352B may each be a separate piece or constitute two or more pieces. In one or more embodiments, the glass run channel 350 has one or more cross-sections (ie, profiles) configured to contact the window glass. Exemplary profiles include "U" shapes, "L" shapes, and combinations thereof, alone or in combination with one or more ribs, bulbs, or other sealing elements.

FIG. 5B is an enlarged cross-sectional view of the glass run channel 350 on line AA of FIG. 5A . In one or more embodiments, the upper portion 351 of the glass run channel 350 has an open or "L" shaped profile 355 that may contact the outer edge of a window glass (not shown). As will be discussed in more detail below, window trim module 525 may have a matching profile (eg, an open or "L" shaped profile) that contacts the outer edge of the window glass such that the window glass is pressed and sealed therebetween. .

Still referring to FIG. 5B , the A pillar side of the lower portion 352A preferably has an "L" shaped profile like the B pillar side of the lower profile 35B. The "L" shaped profile 355 contacts the outer (ie, outer) perimeter of the window glass. As will be described in more detail later, the core module 400 is configured with a complementary shaped profile (i.e., open or "L") such that the matching profile is in contact with the inner (i.e., interior) perimeter of the window glass to guide the window glass during assembly. "type profile). This sealing system comprises a method in which opposing profiles (ie, seals) on the upper portion 351 of the window trim module 325 and the glass run channel 350 each work together to form a seal on the upper portion of the window glass; similar.

Considering the core module 400 in more detail, FIG. 6 is a schematic diagram of a core module 400 in accordance with one or more embodiments herein. As noted above, the core module 400 includes one or more hardware components, electrical components, and a sealing member (ie, a "seal"). Exemplary components assembled to core module 400 include window adjusters, motors, tracks, impact bolsters, wire harnesses, speaker boxes or receptacles, speakers, window motors, exterior mirror motors, beltline seals, plugs, grommets, and Core to frame seals include, but are not limited to. However, for simplicity and ease of illustration, the core module 400 in FIG. 6 includes one or more bolsters or crash pads 410 , a speaker box 425 , a window track 440 , a motor support 445 , and a window. It is shown having a glass 460 , a beltline seal 465 , and a glass run channel 470 . It should be noted that the core module 400 may include any other components conventional for a car door. For example, the core module 400 may include one or more speakers 420 , a door control unit 430 , a door lock 435 , and a cable lock 447 . The core module 400 may also include one or more air distribution channels (not shown) for heating or cooling.

Preferably, the individual parts are injection molded into the core module 400 . For example, one or more bolsters 410 , speaker box 425 , window track 440 , motor support 445 , reinforcement section 450 , beltline seal 465 , and air distribution channels (not shown). ) may be integrally formed with the core module 400 using multi-material or multi-shot injection molding techniques. Accordingly, since the parts are integral parts of the core module 400 rather than individual parts requiring expensive assembly, the assembly time is greatly reduced.

The side bolster 410 may be a foam member such as a foam block. The side bolsters 410 may also be hollow structures. Preferably, the bolster 410 is injection molded using a rigid material. The bolster 410 may be injection molded from the same material as the core module 400 , or may be double shot molded into the core module 400 using multi-injection molding techniques.

In one or more embodiments, the core module 400 further includes a reinforcing member 450 . The reinforcing member 450 adds strength and rigidity to the core module 400 and the entire door system when assembled. As mentioned above, conventional doors have reinforcing bars that are attached to the door frame. In the embodiment shown in Figure 6, the core module 400 and the reinforcing member 450 are integrally formed, thereby reducing the number of parts in the door and/or simplifying the installation and functional testing of the door assembly, particularly the window lift system. It may be assembled to the core module 400 to facilitate. The reinforcing member 450 may be disposed on the inner side ("first side") of the core module 400 or disposed on the outer side ("second side") of the core module 400 . The reinforcing member 450 is shown on the inner side of the core module 400 in FIG. 6 .

Considering reinforcing member 450 in more detail, reinforcing member 450 may be a rod or plate or any other structure that adds strength to the door system. Preferably, the reinforcing member 450 is longer than its width and thickness, such as a rod or plate, and is disposed near the belt line of the door. The reinforcing member 450 may be manufactured as a separate part and assembled to the core module, or the reinforcing member may be insert-molded together with the core module 400 . In one or more embodiments, the reinforcing member 450 and the core module 400 are made of the same material or are made of the same combination of different materials. In one or more embodiments, the reinforcing member and the core module are made of different materials or different combinations of different materials. Moreover, the reinforcing member 450 may be stamped from steel or aluminum, or made from one or more non-metallic materials, such as polyethylene, polypropylene, or one or more other materials discussed herein. Preferably, the reinforcing member 450 is injection molded together with the core module 400 in a two-part process ("2K process"). More preferably, the reinforcing member 450 is stamped with aluminum, steel or other suitable metal or alloy, inserted into an injection molding tool, and at least partially over-molded with the core module 400 material.

7 is a schematic diagram of one or more components of a core module 400 disposed on a second or outer side thereof. The glass run channel 470 is preferably 2K molded on the second side of the core module 400 using a multi-material injection molding machine. The second material is preferably slip coated to reduce friction with the window glass, or the surface friction of the second material may be low enough so that the glass can slide along it with an acceptable force. Alternatively, the glass run channel 470 may be a separate member attached or otherwise assembled to the core module 400 .

Glass run channel 470 may have one or more profiles, such as "U"-shaped, "L"-shaped, or any combination thereof, alone or in combination with one or more ribs, bulbs, or other sealing elements. As described above, the glass run channel 470 is configured to match at least one "L"-shaped profile of the lower portion 350A of the glass run channel 350 on the door structure 300 , as shown in FIGS. 5A and 5B . It is preferred to have a rib or shape profile. Thus, when the core module 400 is attached to the outer door module 325 , the engagement profile of the glass run channels 470 , 352 provides a forming guide for the window glass 460 to proceed.

Still referring to FIG. 7 , the one or more window tracks 440 are preferably disposed on the second side of the core module 400 . As noted above, one or more window tracks 440 may be integrated with the core module 400 . Preferably, the window track 440 is injection molded into the core module 400 . A slip coating may be inserted into the mold whose window tracks 440 are formed to reduce friction with the window glass. This can be done using 2K or multi-material injection techniques or robotic extrusion. Alternatively, a slip coating may be inserted into the tool before the track 440 is formed. This can be done, for example, as a coating on a thin polymer film. Alternatively, a thin polymer film with a down coating can be inserted into the tool and overmolded. The slip coating is preferably made of a material that can reduce friction between the window track 440 and the window glass. The slip coating may be made of polyethylene, polypropylene, or other suitable material, including the materials discussed herein. If the friction coefficient of the raw material, which is the raw material for the seal, is sufficiently low, it is not necessary to add a low friction surface to the seal.

The integration of the glass run channel 470 to the core module 400 and the beltline reinforcement integration (ie, the reinforcement member 450 ), as shown in FIG. Pre-installation may be allowed. The use of inner and outer core modules allows the complete glass run channel to be fully integrated into the door module and pre-tested. A small number of parts have to be fed into the assembly line and need to be assembled on the assembly line. Thus, the window mechanism and controls can be tested by the first-tier supplier among the assemblers of the core module 400, thereby reducing the time and cost of OEM assembly. To test the correct functioning of the glass run channel, the glass run channel consists of several extruded profiles of different shapes interconnected by corner moldings and/or connected to end moldings by welding or bonding. Deviations from the extrusion two-dimensional shape of the profile may be created in the post-processing step.

If a (multi-material) injection molded seal is used, the geometry of the seal can be designed much more freely. Injection molding allows the number or angle of individual sealing lips to be varied over the length of the seal. In this way, the improvement of sealing properties (with respect to moisture, sound or airflow) can be improved without the additional cost of local overmolding of the seal.

Corner moldings and end moldings also serve an aesthetic function. Injection molded seals provide design freedom and allow for an aesthetically pleasing profile. The surface of the extruded seal may be smooth. The surface of the extruded seal may also be covered or granulated with a downed material or a low friction coating. Thermoplastic materials (eg polypropylene) may also allow for different colors for the profile. These colors can be changed quickly in the injection molding process and can have different colors on one seal when multiple machines are used.

Looking at window trim module 525 in more detail, FIG. 8A is a schematic diagram of one exemplary embodiment. FIG. 8B is an enlarged cross-sectional view of the window trim module 525 taken along line BB of FIG. 8A . 8A and 8B , the window trim module 525 is also a frame structure having an opening cavity 525A formed therein. The window trim module 525 has a glass run channel 572 disposed on its second or outer side. The glass run channel 572 may have one or more profiles, such as "U"-shaped, "L"-shaped, and combinations thereof, alone or in combination with one or more ribs, bulbs, or other sealing elements. Preferably, the glass run channel 572 matches the open or "L" shaped profile of the upper portion 351 of the glass run channel 350 of the outer core module 325 shown in FIGS. 5A and 5B . It has a shaped profile or at least one lip, such as profile 355 shown in FIG. Thus, when the window trim module 525 is attached to the outer core module 325 , the engagement profile of the glass run channels 572 , 351 provides a sealed guide for the window glass to proceed.

In one or more embodiments above or elsewhere herein, window trim module 525 further includes an inner beltline seal 573 integrally formed therewith. FIG. 8C shows an enlarged cross-sectional view of inner beltline seal 573 on line CC of FIG. 8A . The inner beltline seal 573 is preferably 2K molded to the second side of the outer core module 525 using a multi-material injection molding machine. The second material is preferably downed or slip coated to reduce friction on the window glass, or the surface friction of the second material may be low enough to allow the glass to slide along it with an acceptable force. Alternatively, the inner beltline seal 573 may be a separate member attached to or otherwise assembled to the outer core module 525 . The inner beltline seal 573 may also be incorporated into the inner core module 525 depending on the required application.

9 is a schematic diagram of an exemplary reinforcing member 450 that may be used. The reinforcing member 450 may have an upper flange 451 and a lower flange 452 for assembly to the core module 400 (not shown in this figure). Although not shown in this figure, each flange 451 , 452 may have one or more openings for receiving one or more fastening members, such as clips, screws, bolts, rivets, and the like. In one or more embodiments, the reinforcing member 450 may include a concave section 453 disposed between the flanges 451 , 452 , as shown in FIG. 9 . The concave section 453 can have any depth that is constant or variable. The main purpose of its depth is to provide stiffness (ie resistance to deformation). The depth varies depending on the vehicle being made, for example, from 0.05 inches (1.27 mm) to 8 inches (20.32 cm), from 1 inch (2.54 cm) to 6 inches (15.24 cm), or from 0.5 inches (1.27 cm) to 3 inches ( 7.62 cm).

In one or more embodiments above or elsewhere herein, the reinforcing member 450 may include a cover plate 455 disposed thereon to provide additional strength and stiffness, as shown in FIG. 10 . . 10 is a schematic plan view of a reinforcing member 450 to which a cover plate 455 is attached. The cover plate 455 is preferably fixed to the reinforcing member 450 at the upper and lower flanges 451 and 452 . The cover plate 455 may be attached to the reinforcing member 450 using any mechanical fastener or adhesive including, for example, screws, bolts, rivets, clips, and the like. The cover plate 455 may also be spot welded to the reinforcing member 450 .

In one or more embodiments above or elsewhere herein, the cover plate 455 may be attached to the reinforcing member 450 using one or more clips 456 as shown in FIG. 11 . 11 is a schematic cross-sectional view of a reinforcing member 450 having one or more clips 456 to retain the cover plate 455 thereon. Preferably, the one or more clips 456 are integrally formed with the reinforcing member 450 or are injection molded, although they may be easily attached during assembly.

In one or more embodiments above or elsewhere herein, the cover plate 455 may slide onto the reinforcing member 450 . For example, the cover plate 455 may have a profile edge configured to slide across the engagement profile edge of the reinforcing member 450 , as shown in FIG. 12 . 12 shows a partial cross-section of a reinforcing member 450 and a cover plate 455 having a profile edge configured to slide thereon. The profiled protrusion 457 of the reinforcing member 450 engages the profiled edge 455A of the cover plate 455 which acts as a rail or guide against which the cover plate 455 can slide. The gap between the profile protrusion 455A of the cover plate 455 and the profile protrusion 457 of the reinforcing member 450 is such that the cover plate 455 slides into place and remains in place without vibration or wobble during subsequent use. It is desirable that it is just enough for

In one or more embodiments above or elsewhere herein, the reinforcing member 450 may include an insert or reinforcing structure 458 disposed in the recessed section 453 as shown in FIG. 13 . 13 is a schematic view of an exemplary reinforcing member 450 having one or more inserts 458 . Preferably, the insert 458 has one or more fingers or ribs 458A, which may be formed by overmolding a plastic structure into the recessed section 453 of the reinforcing member 450 . Insert 458 increases resistance to deformation. Insert 458 can provide significantly higher energy absorption and buckling resistance. After overmolding the insert 458, a cover plate 455 may be placed thereon to provide additional strength as described above with reference to FIGS.

In one or more embodiments above or elsewhere herein, the ribs 458A of the insert 458 may be disposed in a variety of patterns, as shown in FIGS. 13 , 14 and 15 . For example, the ribs 458A may have a rectangular pattern to resemble a checkerboard, as shown in FIG. 13 . In one or more embodiments, the ribs 458A may have a diamond-shaped pattern as shown in FIG. 14 . In one or more embodiments, the ribs 458A may have a honeycomb or polygonal pattern as shown in FIG. 15 . Other patterns include tubular or circular, and may depend on the stiffness and strength required for the application and design requirements.

In one or more embodiments above or elsewhere herein, the insert 458 is disposed within the recessed section 453 of the reinforcing member 450 using various techniques such as those shown in FIGS. 16-18 . or otherwise attached to this concave section. 16 , 17 , and 18 each show a schematic view of a reinforcing member 450 having various manners for retaining or retaining an insert 458 . For example, the reinforcing member 450 may have one or more recesses or depressions 450A to provide location or fixation for at least a portion of the insert 458 as shown in FIG. 16 . can be provided Accordingly, the insert 458 may be fitted into the recess 450A of the reinforcing member 450 and include an engaging protrusion (not shown) for contacting the body of the core module 400 . Accordingly, the insert 458 can be held in place during assembly. If an optional cover plate 455 is used, the insert 458 may be held in place with the recess 450A until the cover plate 455 is secured in place.

In one or more embodiments above or elsewhere herein, one or more openings 450B may be formed in the recessed section 453 of the reinforcing member 450 , as shown in FIG. 17 . During the overmolding injection process, the opening 450B allows the material of the insert 458 to flow through the reinforcing member 450 . Accordingly, the material of the insert 458 remains within the reinforcing member 450 and is secured in place.

In one or more embodiments above or elsewhere herein, the reinforcing member 450 is one or more slits or openings for receiving the protruding features 458B of the insert 458 , as shown in FIG. 18 . (450C) may be provided. The protruding features 458B of the insert 458 may only be extensions of one or more ribs 458A. One or more slits 450C of reinforcement member 450 may be biased or otherwise designed to provide a friction fit to hold insert 458 in place.

In any of the embodiments described above with reference to FIGS. 16 , 17 and 18 , the insert 458 can be held in place on the stiffening section 450 and ready to be used. Alternatively, the insert 458 may be held in place on the reinforcing section 450 for a period of time sufficient for the adhesive of the cover plate 455 to reach sufficient strength, thus holding the insert 458 in place during use. It relies on the cover plate 455 to hold it. Additionally, the described embodiment may retain the insert 458 in place on the stiffening section 450 for a period of time during which the cover plate 455 may be mechanically fastened to the stiffening member 450 or the core module 400 . let there be Some examples of suitable mechanical fasteners include clip screws, heat stakes, rivets, blind rivets, and bolts. Spot welding may also be used.

Preferably, the cover plate 455 and the reinforcing member 450 are clipped to each other. For example, FIG. 19 shows an enlarged fragmentary cross-sectional view of the reinforcing member 450 with one or more clips 456 disposed to engage and retain the cover plate 455 in place. Clip 456 may be designed to simply hold cover plate 455 in contact with the backside of cover plate 455 . In one or more embodiments above or elsewhere herein, an adhesive layer 459 may be used to hold the cover plate 455 in place. Accordingly, the clip 456 may be designed to have sufficient structural strength to hold the cover plate 455 until the adhesive (ie, glue) layer 459 is dry. The adhesive layer 459 is desirable to prevent noise due to fluctuations and vibrations.

20 is a schematic diagram of an exemplary cover plate 455 having one or more clips 456A formed thereon. One or more clips 456A may be injection molded onto or otherwise attached to cover plate 455 . Other methods for fastening the cover plate 455 to the reinforcing member 450 can readily be devised, including the use of "Christmas tree" type fasteners commonly used to attach the trim panel to the door structure. These fasteners may also be injection molded into the cover plate 455 to provide a high degree of part integration and reduce assembly time.

21 , 22 and 23 show an example window lift system 500 that may be used with the integrated core module 400 . In at least one embodiment, the window lift system 500 includes a motor housing or receptacle 507 , a cross arm lifter 520 , an adjuster 530 , and window tracks 545 , 550 . The cross arm lifter 520 includes a gear or toothed member 522 , a first extending member 524 , and a second extending member 526 .

As shown in FIG. 22 , a lift motor 505 may be attached to the core module 400 . The motor 505 may be attached to the inner or outer side of the core module 400 . The motor housing or receptacle 507 may be injection molded on either side of the core module 400, and the motor 505 may use snap connections, rivets, adhesives, screws, or any other fasteners (shown) for connecting parts. not), can be easily mounted or assembled to the integrally formed motor housing 507 .

21 and 22 , the motor 505 drives the toothed member 522 in a clockwise or counterclockwise direction about a pivot point 515 . The toothed member 522 is attached to or integral with the first elongate member 524 . The first elongate member 524 has a first end 524A attached to the adjuster 530 . The adjuster 530 is attached to the bottom of the window glass 535 . At least a portion of the adjuster 530 is configured to fit within the integrally formed track 550 . Track 550 is integrally formed with core module 400 through injection molding using one or more of mono material molding, 2K molding, in-mold labeling, and insert molding techniques, as described above. The adjuster 530 and the window track 550 each have engagement profiles 532 and 552 in which the adjuster 530 is guided along the profile 552 of the track 550 when engaged, as shown in FIG. 23 . It can be formed to have.

The first extension member 524 is pivotally connected to the second extension member 526 at a pivot point 515 . A first end 526A of the second elongate member 526 communicates with a track 545 . The second end 526B of the second elongate member 526 is attached to the adjuster 530 . The track 545 may be integrally formed with the core module 400 through injection molding, or the track 545 may be a separate part such as a rail-like member attached to the core module 400 or inserted molded into the core. have. As motor 505 drives toothed member 522 , elongated members 524 , 526 work together via pivot point 515 to raise and lower adjuster 530 and window glass 535 . The window glass 535 is supported by an adjustment device 530 and a glass run channel.

24 , 25 and 26 schematically illustrate another embodiment of a window lift system 600 . 24 is a simplified schematic diagram of a core module 400 having a window lift system 600 . The window lift system 600 includes a motor housing 620 and two or more adjusters 610A, 610B, each configured on a track member 615A, 615B. As shown in FIG. 25 , a motor 605 is attached to the motor housing 620 on the core module 400 . The motor housing 620 may be formed on the inner side or the outer side of the core module 400 . Preferably, the motor housing or receptacle 620 is injection molded onto the core module 400 . Motor 605 may be easily mounted or assembled to integrally formed motor housing 620 using clip snap connections, rivets, screws, adhesives, or any other fasteners (not shown).

Window 625 is secured to adjuster 610A, 610B by one or more fasteners and/or adhesive-like material (not shown). Adjusters 610A, 610B and window tracks 615A, 615B, respectively, may be formed to have an engagement profile in which, when engaged, the adjusters are guided along the profile of their respective tracks, as shown in FIG. 26 .

Window lift system 600 further includes one or more Bowden cables (two 640 and 645 are shown in FIG. 24). Cables 640 and 645 are connected to adjusters 610A and 610B. As motor 620 alternately tows cables 640 and 645 , adjusters 610A and 610B move window 625 up or down. Window 625 is supported by adjusters 610A, 610B in communication with tracks 615A, 615B. These tracks may be integrally formed, insert molded, or assembled to the core module 400 .

<u>ingredient</u>

The aforementioned components, including the door structure 300 , the outer core module 325 , the core module 400 , the window trim module 525 and the trim panel 700 , provide essential properties such as stiffness and strength, for example. It can be made of any material having Suitable materials include, but are not limited to, propylene homopolymers, propylene copolymers, ethylene homopolymers, ethylene copolymers, and any one or more of the following polymeric resins:

a) Nylon 6 (N6), Nylon 66 (N66), Nylon 46 (N46), Nylon 11 (N11), Nylon 12 (N12), Nylon 610 (N610), Nylon 612 (N612), Nylon 6/66 Copolymer (N6/66), Nylon 6/66/610 (N6/66/610), Nylon MXD6 (MXD6), Nylon 6T (N6T), Nylon 6/6T Copolymer, Nylon 66/PP Copolymer, Nylon 66/PPS polyamide resins such as copolymers;

b) polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET/PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal polyester polyester resins such as polyoxalkyene diimide diacid/polybutyrate terephthalate copolymers, and other aromatic polyesters;

c) polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), methacrylonitrile-styrene copolymer, methacrylonitrile-styrene-butadiene copolymer, and acrylonitrile polynitrile resins such as nitrile-butadiene-styrene (ABS);

d) polymethacrylate resins such as polymethyl methacrylate and polyethylacrylate;

e) cellulosic resins such as cellulose acetate and cellulose acetate butyrate;

f) fluororesins such as polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), polychlorofluoroethylene (PCTFE), and tetrafluoroethylene/ethylene/copolymer (ETFE);

g) polyimide resins such as aromatic polyimides;

h) polysulfones;

i) polyacetals;

j) polyactones;

k) polyphenylene oxide and polyphenylene sulfide;

l) styrene-maleic anhydride;

m) aromatic polyketones;

n) polycarbonate (PC);

o) elastomers such as ethylene-propylene rubber (EPR), ethylene propylene-diene monomer rubber (EPDM), styrene block copolymer (SBC), polyisobutylene (PIB), butyl rubber, neoprene rubber, halobutyl rubber, and the like; and

p) A mixture of any and all of a) to o) above.

In one or more embodiments above or elsewhere herein, the material may include one or more fillers for additional strength. The filler may be present in an amount of 0.001 wt % to 50 wt % in one embodiment, 0.01 wt % to 25 wt % in another embodiment, and 0.2 wt % in another embodiment based on the weight of the composition. It may be present in an amount from wt % to 10 wt %. Preferred fillers include titanium dioxide, silicon carbide, silica [and other oxides of silica (precipitated or not)], antimony oxide, lead carbonate, zinc white, lidofon, zircon, corundum, spinel, apatite, barite ( Barytes) powder, barium sulfate, magnesite, carbon black, dolomite, calcium carbonate, sand, glass beads, mineral mass, talc, and Mg, Ca, or Zn ions with Al, Cr, or Fe and CO, hydrated or not<sb>3</sb> and/or HPO<sb>4</sb>of hydrotalcite compounds; Quartz powder, hydrogen chloride magnesium carbonate, short glass fiber, long glass fiber, glass fiber, polyethylene terephthalate fiber, wollastonite, mica, carbon fiber, nanoclay, nanocomposite, magnesium hydroxide sulfate trihydrate, clay, alumina, and other metals oxides and carbonates, metal hydroxides, chromium, phosphorous and brominated flame retardants, antimony trioxide, silicon, and any combinations and mixtures thereof. Other exemplary fillers include one or more of polypropylene fibers, polyamide fibers, para-aramid fibers (eg Kevlar or Twaron), meta-aramid fibers (eg Nomex), polyethylene fibers (eg Dyneema). ), and combinations thereof.

The material may also include a nanocomposite that is a mixture of a polymer and one or more organo-clays. Exemplary organo-clays are ammonium, primary alkylammonium, secondary alkylammonium, tertiary alkylammonium, quaternary alkylammonium, aliphatic, aromatic or arylaliphatic amines, phosphonium derivatives of phosphines or sulfides or aliphatic, aromatic or aryl aliphatic amines, phosphines or sulfonium derivatives of sulfides. In addition, organo-clays are montmorillonite, sodium montmorillonite, calcium montmorillonite, magnesium montmorillonite, nontronite, weidellite, volconite, laponite, hectorite, saponite. , soconite, magadite, kenyite, sovocaite, svindordite, stevensite, vermiculite, halloysite, aluminum oxide, hydrotalcite, illite, lectorite, tarosovite, redicite and/or It may be selected from one or more of Florin mica.

When present, the organo-clay is preferably comprised in an amount of 0.1 to 50 wt % in the nanocomposite based on the total weight of the nanocomposite. The stabilizing function may be selected from one or more of phenols, ketones, hindered amines, substituted phenols, substituted ketones, substituted hindered amines, and combinations thereof. The nanocomposite may further comprise at least one elastomeric ethylene-propylene copolymer, typically present in the nanocomposite in an amount of from 1 to 70 wt %, based on the total weight of the nanocomposite.

For areas, sections or parts of the door system 300 required to provide the structure, reinforced polypropylene (PP) is preferred. Most preferred is PP reinforced with PET fiber or any other material that is light yet provides a good balance of stiffness, impact strength and has a low coefficient of linear thermal expansion (CLTE).

In one or more embodiments above or elsewhere herein, the polymer may be impact modified to provide improved impact resistance. Impact modifiers include, but are not limited to, plastomers, ethylene propylene rubber (EPR), ethylene propylene diene monomer rubber (EPDM), polypropylene maleate, polyethylene maleate, and other maleic polymers, hydroxylated It can be used in combination with compatibilizers such as polypropylene and other hydroxylated polymers, derivatives thereof, and any combination thereof.

In another embodiment, the material may comprise a plastomer, preferably a mixture of propylene plastomers. As used herein, the term "plastomer" has a density of 0.85 g/cm 3 to 0.915 g/cm 3 according to ASTM D-4703 Method B or ASTM D-1505 and is ASTM D at 190° C., 2.1 kg. -1238 to one or more polyolefin polymers and/or copolymers having a melt index (MI) between 0.10 dg/min and 30 dg/min. Preferred plastomers are 0.10 dg/min to 20 dg/min in one embodiment, 0.2 dg/min to 10 dg/min in another embodiment, 0.3 dg/min in another embodiment, as measured by ASTM D-1238 It has a melt index (MI) of min to 8 dg/min. Preferred plastomers may have an average molecular weight of 10,000 to 800,000 in one embodiment and 20,000 to 700,000 in another embodiment. The molecular weight distribution (Mw/Mn) of the preferred plastomer is in the range of 1.5 to 5 in one embodiment, and in the range of 2.0 to 4 in another embodiment. The 1% secant flexural modulus (ASTM D-790) of the preferred plastomer is in the range of 10 MPa to 150 MPa in one embodiment, and in the range of 20 MPa to 100 MPa in another embodiment. Additionally, preferred plastomers have melting points (Tm) of 30°C to 80°C (first melting peak) and 50°C to 125°C (second melting peak) in one embodiment, and 40°C to 70°C in another embodiment °C (first melting peak) and a melting point (Tm) of 50°C to 100°C (second melting peak).

In one or more embodiments above or elsewhere herein, the plastomer may be a copolymer of an ethylene derived unit and at least one of C3 to C10 α-olefin derived units. Preferably, the copolymer has a density of less than 0.915 g/cm 3 . The amount of comonomer (C3 to C10 α-olefin derived units) present in the plastomer is from 2 wt % to 35 wt % in one embodiment, from 5 wt % to 30 wt % in another embodiment, and from 15 wt % to about 15 wt % in another embodiment. 25 wt %, in another embodiment from 20 wt % to 30 wt %.

In one or more embodiments above or elsewhere herein, the plastomer comprises one or more metallocenes of ethylene derived units and high α-olefin derived units such as propylene, 1-butene, 1-hexene and 1-octene. It may be a catalyzed copolymer. Preferably, the plastomer sufficiently comprises one or more of these comonomer units to yield a density between 0.860 g/cm 3 and 0.900 g/cm 3 . Examples of commercially available plastomers include: 1-hexane derived units composed of 18 wt % to 22 wt % of the plastomer and having a density of 0.895 g/cm 3 and an MI of 3.5 dg/min; , EXACT 4150, a copolymer of ethylene and 1-hexane (available from ExxonMobil Chemical Company); and EXACT 8201 (ExxonMobil Chemical Company), a copolymer of ethylene and 1-octene, with a 1-octene derived unit composed of 26 to 30 wt% of a plastomer and having a density of 0.882 g/cm 3 and an MI of 1.0 dg/min. available from).

Preferred mixtures for use as molding materials herein typically comprise from about 15 wt %, 20 wt % or 25 wt % to about 80 wt %, 90 wt % or 100 wt % polymer, optionally about 0 wt %, 5 wt % or 10 wt % to about 35 wt %, 40 wt %, or 50 wt % filler, and optionally from about 0 wt %, 5 wt %, or 10 wt % to about 35 wt %, 40 wt % or 50 wt % plastomer. In one or more embodiments, preferred mixtures comprise one or more of the polymers described in an amount from about 15 wt %, 20 wt % or 25 wt % to about 80 wt %, 90 wt % or 100 wt %. In one or more embodiments, a preferred mixture comprises at least about 1 wt %, 5 wt %, 10 wt %, 15 wt % or 20 wt % of the plastomer. In one or more embodiments, preferred blends include at least about 1 wt %, 5 wt %, 10 wt %, 15 wt %, or 20 wt % filler.

Preferably, a mixture for use herein will have a tensile strength of at least 6,500 MPa, at least 7,500 MPa, or at least 9,000 MPa. Additionally, preferred mixtures will have a flexural modulus of at least 1,750 MPa, such as at least 1,800 MPa or at least about 2,000 MPa.

In addition to the materials and polymers described above, areas or parts that need to have sealing properties include one or more of a thermoplastic vulcanizate (TPV), a thermoplastic elastomer (TPE), a thermoplastic olefin (TPO), a polyurethane (PU), or an EPR or EPDM. Elastomers such as can be used. These materials can be used in a dense (non-foaming) state or in a foamed state. Most preferably, TPVs are selected because of their inherent mechanical properties that provide excellent sealing performance and injection molding capability. Another aspect of these materials would be the compatibilization of the structural and sealing materials or their ability to adhere to each other. The material of the structural and/or sealing system may be functionalized or may have secondary additives or components added to the material to provide good adhesion.

<u>assembly order</u>

Referring again to FIG. 3 , the door system can be easily assembled. In at least one particular embodiment, the door system may be assembled in the following order. First, parts are inserted into an injection mold to manufacture the core module 400 . The core module 400 and the inserted parts are injection molded with the first material. A second material such as polypropylene, polyethylene and/or thermoplastic vulcanizate (TPV) is injection molded to create a flexible part (seal, plug, grommet, or soft touch portion of the skin) on the core module 400 . . Gas or water can also be used to create a hollow profile if needed for additional structural strength. A blowing agent may be used to create a foam structure to minimize sink marks or to create a foam structure for increased stiffness. The core module 400 on which the integrated part is formed is ejected from the tool. Afterwards, parts that have not yet been integrated into the core module are assembled. A window glass 535 is assembled to the core module 400 . The window trim module 525 and the outer core module 325 are now assembled to the core module 400 . Then, if necessary, the window glass 535 is adjusted accordingly. The finished core sub-assembly can now be functionally tested and ready to be sent to the assembly line.

In the assembly line, the finished core sub-assembly is attached to the door structure 300 , the trim panel 700 is attached to the assembly, and then all connections (mechanical and electrical) between the core 400 and the door structure 300 . or other) is done. Alternatively, the trim panel 700 can be attached to the finished core sub-assembly, which is then attached to the door structure 300 . The door assembly is then ready for assembly into the vehicle.

27, 28 and 29 show exemplary partial cross-sectional views of one embodiment of a door assembly using a sliding lock assembly 900 to facilitate assembly. The sliding lock assembly 900 may place the lock in a first ("retracted") position while transporting the core module 400 and mounting it to the door structure 300 . The lock assembly 900 may then be actuated or moved to a second ("assembled") position.

27 is an exemplary side view of the sliding lock assembly 900 in a pre-assembled or retracted position. 28 is an exemplary side view of sliding lock assembly 900 in an assembled position. 29 is a partial cross-sectional view taken along line AA of FIG. 28 .

Referring to FIG. 27 , the lock mechanism 800 includes a sliding mechanism 920 (ie, a sled or slider) capable of moving the lock mechanism 800 during assembly of the core module 400 to the door structure 300 . ) is connected or otherwise fixed. Preferably, the sliding mechanism 920 is configured to move laterally within a single plane, although it is assumed that the sliding mechanism 920 may be configured to move laterally in two horizontal planes, for example along the X and Y axes. is composed At least a portion of the lock mechanism 800 may be attached to the sliding mechanism 920 by attaching, welding, screwing, bolting, riveting, clipping, or otherwise attached using any known technique. The sliding mechanism 920 may also be an integral part of the locking mechanism 800 if desired.

As shown in FIG. 29 , the core module 400 may include a rail or track system 930 attached to or integrally formed with at least a portion of its outer surface. The sliding mechanism 920 may also include a track or rail system 935 having an engagement profile for engaging the profile of the track system 930 of the core module 400 . The sliding mechanism 920 may be moved from the first position or retracted position shown in FIG. 27 to the second position or the assembled position shown in FIG. 28 after the core module 400 is attached to the door structure 300 . .

In one or more embodiments, a tool (not shown) may be used to move the lock mechanism 800 from the first position to the second position. For example, a simple tool can be inserted through the hole where the lock mechanism 800 will come into contact with the door structure 300 . The tool may be configured to engage the lock mechanism 800 and manipulate (ie, pull) the lock mechanism 800 to a second or assembled position in which the lock mechanism 800 may be mounted to the door structure 300 . ) can be used to

30, 31, and 32 are side views of a door assembly using another embodiment of a sliding lock assembly 100 to facilitate assembly. In particular, FIG. 30 is a schematic side view of the sliding lock assembly 1000 in a first or pre-assembled position. 31 is a schematic side view of the sliding lock assembly 1000 in an assembled or second position. FIG. 32 is a partial cross-sectional view taken along line AA of FIG. 31 .

30 to 32 , the sliding lock assembly 1000 includes a sliding mechanism 1010 in communication with a handle or lever 1020 for operating the lock mechanism 800 . The sliding mechanism 1010 and the handle 1020 may be injection molded into a portion of the core module 400 . Preferably, the handle 1020 is formed in a recess 1022 formed in the upper surface of the core module 400 as shown in FIGS. 30 and 31 . The handle 1020 may be injection molded as a single body with the sliding mechanism 1010, as shown in cross-section in FIG. Preferably, the sliding mechanism 1010 is connected to the lock mechanism 800 using one or more legs or anchors 1010A (three shown) disposed at least partially within the lock mechanism 800 as shown in FIG. 32 . do.

Operation of the lock assembly 1000 is similar to that described above with reference to FIGS. 27-29 except that the handle 1020 can be used to operate the sliding mechanism 1010 and the lock mechanism 800 . Of course, a tool (not shown) may be used if necessary to assist in moving the sliding mechanism 1010 from the first position shown in FIG. 30 to the second position shown in FIG. 31 .

As mentioned above, the degree of integration described can significantly reduce the cost and assembly complexity of the finished door. Assembly errors are also reduced, if not eliminated. The cost of functional testing after final assembly is also reduced or eliminated because the majority of functions can be tested prior to final assembly (ie pre-test). In addition, the use of plastic materials in door assembly can provide lower overall weight, better part integration, improved noise isolation, greater design freedom, and are inexpensive (i.e., by using interchangeable inserts in injection molding tools). It will allow design variations.

Additionally, the described arrangement of the reinforcing section and seal system allows for easy installation and assembly of the door system. In particular, the placement of the reinforcement section and the seal system provides easy access to the various parts of the door, including the window and the window lift system. This arrangement also allows the working parts of the door, in particular the window lift system, to be functionally tested prior to the final installation of the door to the vehicle. Thus, valuable time and logistical problems are significantly reduced.

In addition, the provided door system reduces the number of assembly steps and individual components (ie parts) required to manufacture the finished door. The incorporation of the reinforcing section alone makes component assembly easier, reduces the weight of the door, and enables functional testing of various assembled components and components. In addition, the integrated parts can be precisely positioned, and thus less subject to human error or omission.

In another embodiment, the present invention relates to:

One. In the door system,

door structure,

a body on which one or more parts are disposed;

a first module having an upper cavity configured to at least partially surround a first side of the window glass and a lower cavity configured to at least partially engage the body;

a second module configured to at least partially surround a second side of the window glass and configured to at least partially contact the upper cavity of the first module; and

a trim module configured to at least partially cover the core module;

door system.

2. The method of claim 1,

wherein the body comprises at least one reinforcing member disposed on its first side

door system.

3. 3. The method according to claim 1 or 2,

wherein the body further comprises a glass run channel disposed at least on a second side thereof.

door system.

4. 4. The method of claim 3,

A glass run channel disposed at least on the second side of the body has an open profile.

door system.

5. 5. The method of any one of claims 1, 2, 3 or 4,

wherein the one or more parts are injection molded onto the body.

door system.

6. 6. The method according to any one of claims 1 to 5,

wherein one or more seals are disposed on the body

door system.

7. 7. The method of claim 6,

wherein the one or more seals are injection molded onto the body.

door system.

8. 8. The method of any one of claims 2, 3, 4, 5, 6 or 7,

wherein the reinforcing member includes a first flange and a second flange, each flange configured to contact a first side of the body

door system.

9. 9. The method of any one of claims 2, 3, 4, 5, 6, 7 or 8,

wherein the reinforcing member comprises a first flange, a second flange and a recess between the flanges.

door system.

10. 10. The method according to any one of claims 2 to 9,

wherein the reinforcing member further comprises an insert disposed therein, wherein the insert comprises at least one reinforcing member.

door system.

11. 11. The method according to any one of claims 2 to 10,

wherein the reinforcing member further comprises a cover plate disposed thereon to form a hollow cavity therebetween.

door system.

12. 12. The method according to any one of claims 1 to 11,

The one or more parts may include a window adjuster, a window track, a window glass, a window switch, a door lock, a door handle, a door lock switch, an armrest, a map pocket, an impact bolster, a wire harness, a speaker, a window motor, an exterior mirror motor, a plug, grommet, or a combination thereof

door system.

13. 13. The method according to any one of claims 6 to 12,

wherein the at least one seal comprises a glass run channel seal, a beltline seal, a lower sash seal, a core to frame seal, or a combination thereof.

door system.

14. 14. The method according to any one of claims 1 to 13,

wherein the one or more parts are integrally formed on the body.

door system.

15. 15. The method according to any one of claims 1 to 14,

wherein the at least one component comprises a window adjuster, a window track, an impact bolster, an air channel, a window motor housing, a map pocket, a speaker box, a plug, a grommet, or a combination thereof.

door system.

16. 16. The method according to any one of claims 1 to 15,

The body is characterized in that it comprises polypropylene

door system.

17. 17. The method according to any one of claims 1 to 16,

The body is injection molded with polypropylene, characterized in that

door system.

18. 18. The method according to any one of claims 1 to 17,

wherein the body comprises one or more engineering resins

door system.

19. 19. The method according to any one of claims 1 to 18,

wherein the body is injection molded with one or more engineering resins

door system.

20. 20. The method according to any one of claims 1 to 19,

The main body is polyamide resin, polyester resin, polynitrile resin, polymethacrylate resin, cellulose resin, fluororesin, polyimide resin, polysulfone, polyacetal, polyactone, polyphenylene oxide, polyphenylene sulfide, styrene-maleic anhydride, aromatic polyketone, and polycarbonate comprising at least one engineering resin selected from the group consisting of

door system.

21. 21. The method according to any one of claims 1 to 20,

The main body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET/PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal poly Esters, polyoxalkyene diimide diacid/polybutyrate terephthalate copolymer, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), methacrylonitrile-styrene copolymer , methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene-styrene (ABS), derivatives thereof, and mixtures or mixtures thereof, characterized in that injection molding with one or more engineering resins selected from the group consisting of

door system.

22. 22. The method according to any one of claims 1 to 21,

wherein the first module is configured to be assembled on a door structure

door system.

23. 23. The method according to any one of claims 1 to 22,

wherein the second module is assembled to an upper portion of the core module and configured to be in contact with at least a portion of the first module.

door system.

24. 24. The method according to any one of claims 1 to 23,

wherein the body is configured to cover the lower cavity of the first module.

door system.

25. 25. The method according to any one of claims 1 to 24,

and a wet/dry barrier disposed on the second module and the body.

door system.

26. In the door system,

door structure,

at least one window glass,

A glass run, comprising: a first module on which one or more components are disposed, a body having a first side and a second side, a reinforcing member disposed on the first side of the body, and an open profile disposed on the second side of the body a first module comprising a channel;

a second module having an upper cavity configured to at least partially surround a first side of the window glass and a lower cavity configured to at least partially engage the first module;

a third module configured to at least partially surround a second side of the window glass and configured to at least partially contact an upper cavity of the second module, and

and a trim panel configured to cover the first module.

door system.

27. 27. The method of claim 26,

The first side of the body is characterized in that facing the interior compartment of the vehicle.

door system.

28. 28. The method of claim 26 or 27,

wherein the glass run channel extends beyond at least the belt line of the body.

door system.

29. 29. The method of any one of claims 26, 27 or 28,

A glass run channel disposed at least on the second side of the body has an open profile.

door system.

30. 30. The method according to any one of claims 26 to 29,

wherein the one or more parts are injection molded onto the body.

door system.

31. 31. The method of claim 26 or 30,

wherein one or more seals are disposed on the body

door system.

32. 32. The method of claim 31,

wherein the one or more seals are injection molded onto the body.

door system.

33. 33. The method according to any one of claims 26 to 32,

wherein the reinforcing member includes a first flange and a second flange, each flange configured to contact a first side of the body

door system.

34. 34. The method according to any one of claims 26 to 33,

wherein the reinforcing member comprises a first flange, a second flange and a recess between the flanges.

door system.

35. 35. The method of claim 34,

wherein the reinforcing member further comprises an insert disposed therein, wherein the insert comprises at least one reinforcing member.

door system.

36. 36. The method of claim 35,

wherein the reinforcing member further comprises a cover plate disposed thereon to form a hollow cavity therebetween.

door system.

37. 37. The method according to any one of claims 26 to 36,

The one or more parts may include a window adjuster, a window track, a window glass, a window switch, a door lock, a door handle, a door lock switch, an armrest, a map pocket, an impact bolster, a wire harness, a speaker, a window motor, an exterior mirror motor, a plug, grommet, or a combination thereof

door system.

38. 32. The method of claim 31,

wherein the at least one seal comprises a glass run channel seal, a beltline seal, a lower sash seal, a core to frame seal, or a combination thereof.

door system.

39. 39. The method according to any one of claims 26 to 38,

wherein at least one of the one or more parts is injection molded onto the body.

door system.

40. 40. The method according to any one of claims 26 to 39,

wherein the at least one component comprises a window adjuster, a window track, an impact bolster, an air channel, a window motor housing, a map pocket, a speaker box, a plug, a grommet, or a combination thereof.

door system.

41. 41. The method according to any one of claims 26 to 40,

The body is characterized in that it comprises polypropylene

door system.

42. 42. The method according to any one of claims 26 to 41,

The body is injection molded with polypropylene, characterized in that

door system.

43. 43. The method according to any one of claims 26 to 42,

wherein the body comprises one or more engineering resins

door system.

44. 44. The method according to any one of claims 26 to 43,

wherein the body is injection molded with one or more engineering resins

door system.

45. 45. The method according to any one of claims 26 to 44,

The main body is polyamide resin, polyester resin, polynitrile resin, polymethacrylate resin, cellulose resin, fluororesin, polyimide resin, polysulfone, polyacetal, polyactone, polyphenylene oxide, polyphenylene sulfide, styrene-maleic anhydride, aromatic polyketone, and polycarbonate comprising at least one engineering resin selected from the group consisting of

door system.

46. 46. The method according to any one of claims 26 to 45,

The main body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET/PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal poly Esters, polyoxalkyene diimide diacid/polybutyrate terephthalate copolymer, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), methacrylonitrile-styrene copolymer , methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene-styrene (ABS), derivatives thereof, and mixtures or mixtures thereof, characterized in that injection molding with one or more engineering resins selected from the group consisting of

door system.

47. 47. The method according to any one of claims 26 to 46,

wherein the second module is configured to be assembled on a door structure

door system.

48. 48. The method according to any one of claims 26 to 47,

wherein the third module is assembled to the upper portion of the first module and configured to be in contact with at least a portion of the second module.

door system.

49. 49. The method according to any one of claims 26 to 48,

wherein the body is configured to cover the lower cavity of the second module.

door system.

50. 50. The method according to any one of claims 26 to 49,

and a wet/dry barrier configured to cover the second and third modules.

door system.

51. 51. The method according to any one of claims 26 to 50,

one or more window tracks are injection molded on the second side of the body

door system.

52. 52. The method according to any one of claims 26 to 51,

One or more impact bolsters are injection molded on the first side of the body

door system.

53. 53. The method according to any one of claims 26 to 52,

wherein the window glass is slid between the first module and the second module.

door system.

54. In the door system,

door structure,

at least one window glass,

A glass run, comprising: a first module on which one or more components are disposed, a body having a first side and a second side, a reinforcing member disposed on the first side of the body, and an open profile disposed on the second side of the body a first module comprising a channel;

a second module configured to surround the inner surface of the door structure, the second module having an annular body through which a support member is disposed to form an upper cavity and a lower cavity;

a third module configured to at least partially surround a second side of the window glass and configured to at least partially contact an upper cavity of the second module, and

and a trim panel configured to cover the first module.

door system.

55. 55. The method of claim 54,

wherein the glass run channel extends beyond the beltline of at least the first module.

door system.

56. 56. The method of claim 54 or 55,

A glass run channel disposed at least on the second side of the first module has an open profile.

door system.

57. 57. The method of any one of claims 54, 55 or 56,

wherein said at least one component is injection molded onto said first module.

door system.

58. 58. The method of any one of claims 54, 55, 56 or 57,

one or more seals disposed on the first module

door system.

59. 59. The method according to any one of claims 54 to 58,

wherein the one or more seals are injection molded onto the first module.

door system.

60. 60. The method according to any one of claims 54 to 59,

wherein the reinforcing member includes a first flange and a second flange, each flange configured to contact a first side of the first module

door system.

61. 61. The method of any one of claims 54 to 60,

wherein the reinforcing member comprises a first flange, a second flange and a recess between the flanges.

door system.

62. 62. The method of claim 61,

wherein the reinforcing member further comprises an insert disposed therein, wherein the insert comprises at least one reinforcing member.

door system.

63. 63. The method of claim 62,

wherein the reinforcing member further comprises a cover plate disposed thereon to form a hollow cavity therebetween.

door system.

64. 64. The method according to any one of claims 54 to 63,

The one or more parts may include a window adjuster, a window track, a window glass, a window switch, a door lock, a door handle, a door lock switch, an armrest, a map pocket, an impact bolster, a wire harness, a speaker, a window motor, an exterior mirror motor, a plug, grommet, or a combination thereof

door system.

65. 65. The method of claim 64,

wherein at least one of the one or more parts is injection molded onto the first module.

door system.

66. 66. The method of any one of claims 54 to 65,

wherein the at least one component comprises a window adjuster, a window track, an impact bolster, an air channel, a window motor housing, a map pocket, a speaker box, a plug, a grommet, or a combination thereof.

door system.

67. 67. The method according to any one of claims 54 to 66,

wherein the second module comprises polypropylene

door system.

68. 68. The method of any one of claims 54 to 67,

wherein the second module is injection molded with polypropylene

door system.

69. 69. The method according to any one of claims 54 to 68,

wherein the second module comprises one or more engineering resins

door system.

70. 70. The method of any one of claims 54 to 69,

wherein the second module is injection molded with one or more engineering resins

door system.

71. 71. The method according to any one of claims 54 to 70,

The second module includes polyamide resin, polyester resin, polynitrile resin, polymethacrylate resin, cellulose resin, fluororesin, polyimide resin, polysulfone, polyacetal, polyactone, polyphenylene oxide, polyphenylene characterized in that it comprises at least one engineering resin selected from the group consisting of sulfides, styrene-maleic anhydride, aromatic polyketones, and polycarbonates.

door system.

72. 72. The method of any one of claims 54 to 71,

The second module is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET/PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), Liquid crystalline polyester, polyoxalkyene diimide diacid/polybutyrate terephthalate copolymer, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), methacrylonitrile-styrene Injection molding of at least one engineering resin selected from the group consisting of copolymer, methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene-styrene (ABS), derivatives thereof, and mixtures or mixtures thereof to do

door system.

73. 73. The method of any one of claims 54 to 72,

wherein the second module is configured to be assembled on a door structure

door system.

74. 74. The method of any one of claims 54 to 73,

wherein the third module is assembled to the upper portion of the first module and configured to be in contact with at least a portion of the second module.

door system.

75. 75. The method of any one of claims 54 to 74,

wherein the first module is configured to cover the lower cavity of the second module.

door system.

76. 76. The method of any one of claims 54 to 75,

One or more window tracks are injection molded on the second side of the first module.

door system.

77. 77. The method of any one of claims 54 to 76,

One or more impact bolsters are injection molded on the first side of the first module

door system.

78. 78. The method of any one of claims 54 to 77,

wherein the window glass is slid between the first module and the second module.

door system.

A person skilled in the art will appreciate that the door system described above can be used as a complete system or its individual parts can each be used as separate mini-systems or modular units to assist in the integration of two or more parts when needed.

Certain embodiments and features have been described using a set of numerical upper and lower bounds. It should be understood that ranges from any lower limit to upper limit are contemplated, unless otherwise stated. Certain lower limits, upper limits and ranges appear in one or more of the claims below. All numerical values are "about" or "approximate" of the indicated values, and are intended to account for experimental errors and deviations as would be expected by those skilled in the art.

Various terms have been defined above. To the extent that a term used in the claims is not defined above, the broadest limitation provided by a person skilled in the art should be given to the term as reflected in at least one published publication or published patent. In addition, all patents, testing procedures, and other documents, including priority, cited herein are incorporated by reference in their entirety to the extent that their disclosure is not inconsistent with this application, with all rights granted by such reference.

Although the foregoing relates to embodiments of the present invention, other and additional embodiments of the present invention are contemplated within the basic scope thereof, the scope of which is determined by the following claims.