Vehicle Door Module

This invention relates to a module for mounting on the inner panel of a door of a motor vehicle.

It is known to mount components, such as a window lift mechanism, door lock handle, loudspeaker, etc. on the inner panel of a door of a motor vehicle. Assembly of such components on the inner panel requires the formation of holes in the inner panel and can be very time consuming.

It is an object of the present invention to provide an improvement to this known arrangement.

A module in accordance with the present invention for mounting in an aperture in the inner panel of a door of a motor vehicle comprises a structural member having a central portion and at least two arms extending away from the central portion in different directions, each arm having a free end securable to the inner panel such that the or at least two of the arms extend across the aperture when mounted on the inner panel; a support panel secured to the structural member; and at least one door component mounted on the support panel and/or the structural member.

With the present invention, the structural member provides rigidity and strength for the inner panel. Door components, such as a door latch and associated components, a loudspeaker, a window lift mechanism, etc. can be pre-assembled on the support panel and/or the structural member before the structural member is secured on the inner panel. This arrangement provides easier assembly of the door components on the door. By suitable selection of materials, the weight can be reduced without reducing the structural strength relative to the known arrangement described above.

The present invention will now be described, by way of example, with reference to the accompanying drawing, in which the sole figure is a side view of a module in accordance with the present invention mounted in an aperture in the inner panel of a door of a motor vehicle.

The FIGURE of the drawing shows a door 10 of a motor vehicle before the inner trim is fitted to the door. The door 10 comprises an inner panel 12 within which an aperture 14 has been formed. The module 16 in accordance with the present invention is mounted directly on the inner panel 12, as shown, or on a reinforcing member associated with the inner panel. The module 16 comprises a structural member 18 which is substantially X-shaped and which has a central portion 20 and four arms 22 extending away from the central portion. The structural member 18 is preferably formed from two members 24 which are joined or cross at their centres, each member being stamped from sheet steel or aluminium to have a substantially C-shaped cross-section. The free end 26 of each arm 22 is secured to the inner panel 12 such that the members 24 extend across the aperture 14, preferably substantially diagonally or diametrically. In an alternative arrangement, the structural member may be substantially T-shaped or Y-shaped and comprise three arms, at least two of which form a member 24 which extends across the aperture 14, preferably substantially diagonally or diametrically. In a further alternative arrangement, the structural member may comprise a single member 24 having two arms which extend away from the central portion in substantially opposed directions, and therefore extend across the aperture 14, preferably substantially diagonally or diametrically. In a still further alternative arrangement, the structural member may be formed from any other suitable metallic material (such as magnesium) or moulded from plastics material.

The module 16 further comprises a support panel 28 which is secured to the structural member 18 and to the inner panel 12. The support panel 28 can be formed in one-piece, or from several pieces which are joined together, and is preferably formed from plastics material. Where the structural member 18 is moulded from plastics material, the support panel 28 and the structural member may be moulded in one-piece. Various door components are mounted on the support panel 28 and the structural member 18. A window lift mechanism 30 is secured to the central portion 20 of the structural member 18 at the pivot point 32 of the window lift mechanism. An electric motor 34 for driving the window lift mechanism 30 is mounted on the support panel 28, or can be mounted on one of the arms 22 of the structural member 18. Control circuitry 36 for the electric motor 34, loudspeakers 38, and a door latch handle 40 are also mounted on the support panel 28. Other door components may be mounted on the support panel 28 and or the structural member 18.

The window lift mechanism 30 can be secured to the structural member 18 prior to the mounting of the structural member on the inner panel 12. The electric motor 34, control circuitry 36, loudspeakers 38, and door latch handle 40 can be pre-assembled on the support panel 28 prior to the mounting of the support panel on the inner panel 12 and the structural member 18. The support panel 28 can be secured to the structural member 18 either prior to, or after, the mounting of the structural member on the inner panel 12.

The module 16 can therefore be pre-assembled before mounting on the inner panel 12. The structural member 18 provides strength and rigidity for the inner panel 12.