Hybrid door core and trim module with integrated components

Abstract

This invention relates to an integrated door system, comprising: an outer panel;a trim panel module having a first and a second side, the first side adapted to communicate with an interior of a vehicle and the second side adapted to attach to the outer panel;a window surround disposed between the outer panel and the second side of the trim panel module; andan integrated reinforcement assembly disposed on the second side of the trim panel module and about a lower portion of the window surround.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a conventional door as used in the prior art.

FIG. 2 is a schematic illustration of a conventional door having a pre-assembled mounting panel as used in the prior art.

FIG. 3 is a schematic view of one illustrative embodiment of an integrated door system according to one or more embodiments described.

FIG. 4 is a schematic illustration of the outer panel shown in FIG. 3.

FIG. 5 is a partial plan view of the window surround shown in FIG. 3.

FIG. 6 is an enlarged, partial cross-section of the window surround 320 along lines A-A of FIG. 5.

FIG. 7 is a schematic illustration of an illustrative reinforcement assembly according to one or more embodiments described.

FIG. 8 is a schematic illustration of another illustrative reinforcement assembly according to one or more embodiments described.

FIG. 9 is a schematic illustration of yet another illustrative reinforcement assembly according to one or more embodiments described.

FIG. 10 is a schematic view of the exterior side of the outer panel according to one or more embodiments described.

FIG. 11A is a schematic view of the exterior side of the trim module according to one or more embodiments described.

FIG. 11B is a schematic view of the interior side of the trim module according to one or more embodiments described.

FIG. 12 is a schematic view of another illustrative trim module according to one or more embodiments described.

FIGS. 13A, 13B, and 13C show an illustrative window lift system that can be used with the integrated system according to one or more embodiments described.

FIGS. 14A, 14B, and 14C show another illustrative window lift system that can be used with the integrated system according to one or more embodiments described.

FIG. 15 is a schematic view of certain sealing systems that can be integrated into the door system according to one or more embodiments described.

FIG. 16 is another schematic view of certain sealing systems that can be integrated into the door system according to one or more embodiments described.

Claims

1. An integrated door system, comprising: an outer panel;a trim panel module having a first and a second side, the first side adapted to communicate with an interior of a vehicle and the second side adapted to attached to the outer panel;a window surround disposed between the outer panel and the second side of the trim panel module; andan integrated reinforcement assembly disposed on the second side of the trim panel module and about a lower portion of the window surround.

2. The door system of claim 1, wherein the trim panel module comprises one or more door lock controls, window controls, and side mirror controls disposed on the first side thereof.

3. The door system of claim 1, wherein the lower portion of the window surround comprises one or more profiles for guiding a window glass thereon.

4. The door system of claim 1, wherein the window surround includes a low friction coating at least partially injection molded thereon.

5. The door system of claim 1, wherein the reinforcement assembly is a separate component assembled onto the second side of the trim panel module.

6. The door system of claim 1, wherein the reinforcement assembly is integrated with the trim panel module by being insert molded on the second side of the trim panel module.

7. The door system of claim 1, wherein the reinforcement assembly is disposed about the one or more window tracks defining a space for a window glass to move therebetween.

8. The door system of claim 1, wherein the reinforcement assembly comprises at least two side bars vertically spaced apart with at least two support bars.

9. The door system of claim 8, wherein the at least two side bars each include a hinge member disposed at one end thereof.

10. The door system of claim 8, wherein at least one of the two side bars includes a latch assembly disposed at one end thereof.

11. The door system of claim 1, wherein the trim panel module is injection molded with at least one of a speaker box, map pocket, air channel, motor support, and arm rest.

12. The door system of claim 1, wherein the window support is injection molded.

13. The door system of claim 1, wherein the trim panel module is injection molded with polypropylene.

14. The door system of claim 1, wherein the trim panel module is injection molded with reinforced polypropylene.

15. The door system of claim 1, wherein the window surround is injection molded with polypropylene.

16. The door system of claim 1, wherein the window surround is injection molded with reinforced polypropylene.

17. An integrated door system, comprising:

18. The door system of claim 17, wherein the trim panel module is directly coupled to the outer panel.

19. The door system of claim 17, wherein the trim panel module comprises one or more door lock controls, window controls, and side mirror controls disposed on the first side thereof.

20. The door system of claim 17, wherein the reinforcement assembly is a separate component assembled onto the second side of the trim panel module.

21. The door system of claim 17, wherein the reinforcement assembly is integrated with the trim panel module by being insert molded on the second side of the trim panel module.

22. The door system of claim 17, wherein the reinforcement assembly comprises at least two side bars vertically spaced apart with at least two support bars.

23. The door system of claim 22, wherein the at least two side bars each include a hinge member disposed at one end thereof.

24. The door system of claim 22, wherein at least one of the two side bars includes a latch assembly disposed at one end thereof.

25. The door system of claim 17, wherein the trim panel module is injection molded with at least one of a speaker box, map pocket, air channel, motor support, and arm rest.

26. The door system of claim 17, wherein the trim panel module is injection molded with one or more components having a living hinge attached thereto.

27. The door system of claim 17, wherein the trim panel module is injection molded with polypropylene.

28. The door system of claim 17, wherein the trim panel module is injection molded with reinforced polypropylene.

29. The door system of claim 17, wherein the trim panel module comprises one or more integrated sealing systems injected molded therewith.

30. The door system of claim 17, wherein the trim panel module further comprises one or more integrated side bolsters injected molded therewith.

31. The door system of claim 17, wherein the reinforcement assembly is assembled on the outer panel.

32. A method for assembling an integrated door system, comprising:

33. The method of claim 32, wherein the outer panel is stamped from steel.

34. The method of claim 32, wherein the outer panel is injection molded from one or more materials comprising polypropylene, one or more engineering resins, or a combination thereof.

35. The method of claim 32, wherein the trim panel module is injection molded.

36. The method of claim 32, wherein the trim panel module is injection molded with polypropylene.

37. The method of claim 32, wherein the trim panel module is injection molded with reinforced polypropylene.

38. The method of claim 32, wherein the trim panel module is directly coupled to the outer panel.

39. The method of claim 32, wherein the trim panel module comprises one or more door lock controls, window controls, and side mirror controls disposed on the first side thereof.

40. The method of claim 32, wherein the reinforcement assembly is a separate component assembled onto the second side of the trim panel module.

41. The method of claim 32, wherein the reinforcement assembly is integrated with the trim panel module by being insert molded on the second side of the trim panel module.

42. The method of claim 32, wherein the reinforcement assembly comprises at least two side bars vertically spaced apart with at least two support bars.

43. The method of claim 42, wherein the at least two side bars each include a hinge member disposed at one end thereof.

44. The method of claim 42, wherein at least one of the two side bars includes a latch assembly disposed at one end thereof.

45. The method of claim 32, wherein the trim panel module is injection molded with at least one of a speaker box, map pocket, air channel, motor support, and arm rest.

46. The method of claim 32, wherein the trim panel module is injection molded with one or more components having a living hinge attached thereto.

47. The method of claim 32, wherein the trim panel module comprises one or more integrated sealing systems injected molded therewith.

48. The method of claim 32, wherein the trim panel module further comprises one or more integrated side bolsters injected molded therewith.

49. The method of claim 32, wherein the reinforcement assembly is assembled on the outer panel.

50. The method of claim 32, further comprising assembling a window surround between the outer panel and the trim panel module.

51. The method of claim 50, wherein the reinforcement section is assembled about a lower portion of the window surround.

52. The method of claim 51, wherein the reinforcement section is assembled about a lower portion of the window surround defining a space for a window glass to pass there through.

53. The method of claim 52, wherein the lower portion of the window surround comprises one or more profiles for guiding a window glass thereon.

54. The method of claim 51, wherein the window surround includes a low friction coating at least partially injection molded thereon.