CZ260699A3 - Door module for motor vehicles with functional elements of plastic - Google Patents

Abstract

The solution relates to a single door module promoter a vehicle comprising a self-supporting support plate (1) made of This the carrier plate (1) additionally has a larger integral part a plurality of plastic elements made of plastic work step firmly and unreleasably connected with metal carrier plate (1).

Description

DOOR MODULE FOR MOTOR VEHICLES WITH PLASTIC FUNCTIONAL ELEMENTS

Technical field

The invention relates to a one-piece door module for motor vehicles, comprising a self-supporting metal support plate (e.g., pressed bent sheet metal) and a plurality of retaining elements in the form of elevations, recesses and recesses to facilitate assembly of the motor vehicle.

BACKGROUND OF THE INVENTION

With advanced automation in the assembly of motor vehicles, it is necessary or at least very desirable that the associated assembly units of fixed and movable parts can be assembled together as far as possible before their final installation into the emerging motor vehicle and be tested for functionality according to purpose .

Typically, conventional door modules consist of a metal plate onto which additional functional elements such as holding and guiding elements are additionally screwed or welded. The metal door modules preferably have a relatively high intrinsic stability. However, not all of the functional elements can be made directly from metal, but additionally contain additional elements

78013 (78013a.doc) «9 9 • materials, mostly plastic, which requires additional treatment of the prefabricated metal body in order to allow the functional elements of different materials to be movably or immovably fixed at the intended places of use.

SUMMARY OF THE INVENTION

SUMMARY OF THE INVENTION It is therefore an object of the invention to provide a door module with a metal carrier plate which is technically simple to manufacture but which already contains all the necessary holding, guiding and operating elements and therefore further simplifies machine assembly.

This object is solved by a door module of the kind mentioned at the outset, the feature of which is that it additionally comprises, as integral parts, functional plastic elements which are fixedly and releasably connected to the carrier plate in one working step.

The term door module according to the invention means a one-piece self-supporting support plate which, by its three-dimensional geometry, is substantially adapted to the geometry of the motor vehicle door into which it is to be incorporated. The layer thickness of the support plate may be between 0.1 and 5 cm. A door module is a semi-finished product, in which components, such as window openers, door openers, loudspeakers and the like, are usually incorporated into the vehicle door and then form a functional unit.

The door module according to the invention comprises a support plate of

78013 (78013a.doc) • 9 • Metal • metal • • • • • • • • • • • • • • • • All bendable and stampable metals, such as sheet metal, are suitable as metals, but metals that have a high corrosion resistance, such as galvanized sheet metal, are preferred. Light metals of aluminum or magnesium alloys are particularly advantageous if they have sufficient mechanical strength.

As an integral part, the door module according to the invention comprises a number of functional plastic elements. The integral feature of the invention means that the functional elements form a unit with the metal support plate and cannot be disengaged from the metal body. This feature is realized by the so-called outsert technique. Outsert technique is known and is described, for example, in Plast magazine, October 1994, pages 21-23. It represents a combination of bending and injection molding techniques, whereby in one step, the plastic is sprayed onto a precast metal plate in precisely defined, locally delimited areas. Fixation of the functional elements of plastic is not effected by adhesive means, but is due to mechanical anchoring, in which the plastic, for example in the molten state, flows around the edge and then solidifies. Outsert technology is usually used for small components for electrical appliances such as car radios or video recorders, but has not yet been used for door modules.

Thermoplastic plastics are suitable as plastics for the functional elements of the door module of the invention. In addition to standard polymers such as polyolefins, plastics based on polypropylene, polyamide, polyester, polyphenylene oxide, polyoxymethylene, polyphenylene sulfide,

78013.doc or. also reinforced with fiberglass or carbon fiber. In particular, polyethylene terephthalate or polybutylene terephthalate may be used as the polyester. The glass fiber reinforcement can optionally be performed with long and / or short fibers. According to the invention it is also possible for the individual functional elements to consist of different plastics or for a single functional element to consist of a plurality of different plastics. In this case, only the injection molding steps must be carried out sequentially or simultaneously on multiple injection molding units.

The door module according to the invention has a plurality of functional elements, i. protruding retaining and guiding elements from the surface of the support plate as integral parts, in which, for example, other functional elements may also be permanently incorporated to be fixed or geometrically designed such that movable functional elements such as gears or levers can be determined direction of their controlled guided movement. The term functional elements also includes electrical components which are directly electrically conductive connected. In particular, the starter rails for the glass side window, movably provided in the door of the motor vehicle, as well as the holding elements for the electric motor causing the side window movement are integrated or sprayed into the door module according to the invention. Advantageously, the guide rails for the side window can also be integrated in the regions of the door module according to the invention close to the side edges.

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In addition, it may be particularly advantageous if the door module or the parts of the functional elements, preferably at least in the region of the starter rails for the side window, are subjected to special additional treatment in order to guarantee particularly high wear resistance against the retaining elements for the side window windows. The side window retainers, which are movably provided on the window trigger rails, are usually made of polyacetal, in particular polyoxymethylene. For finishing, the door module of the invention may be subjected to corona discharge or plasma treatment or flame treatment, which are used at least in the region of the starter rails for the side window.

In a further embodiment of the invention, the wear resistance to the polyoxymethylene retaining elements can also be realized by pressing or spraying the door module at the critical points of the starter rails of the side window with a plastic which already has a high wear resistance compared to polyoxymethylene.

In a further embodiment of the invention, the door module can be additionally combined with an electrically insulating film of polyethylene, polypropylene, cycloolefinincopolymer, polyester, polyphenylene sulfide, polyimide or polyetherimide. In particular, electrical conductive tracks may be placed on such an electrically insulating film, which serve to cabling electrically driven functional elements in the region of the door module, such as window-trigger motors or loudspeakers. At the same time, the electrically conductive foil can provide an important additional insulation function

78013 (78013a.doc) • · ·····

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BRIEF DESCRIPTION OF THE DRAWINGS

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the door module of the present invention from the side facing the interior passenger compartment; and FIG. 2 is a perspective view of the door module of the present invention from the side facing away. interior passenger compartment.

DETAILED DESCRIPTION OF THE INVENTION

In Figure 1, reference numeral 1 denotes a carrier plate which, by its three-dimensional geometry, is substantially adapted to lightly bulge a motor vehicle door. The vertically extending starter rails 2/2 ¹ for side windows not shown here are an integral part of the door module and replace the metal window rails, which are usually retrofitted in this area. The window actuator rails are shown in FIG. 1 in the folded-out state 8/8 ¹ and dashed in the folded-out state 2/2 '. In the manufacture of the door module according to the invention, they are sprayed in the folded-out state and are later snapped in during assembly, wherein

78013 (78013a.doc)

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Conveniently, suitable retaining elements such as snap hooks or similar fasteners are secured against unintentional folding back. In addition, it can be seen in FIG. 1 that the window lifter rails 8/8 ¹ are provided with grooves 2 for better and more accurate lowering of the windows, which can be subjected to a subsequent plasma or Quran treatment, which is not visible, to improve their wear resistance.

The metal support plate 1 in the embodiment shown for better weight reduction is not formed over the entire surface, but has various trapezoid shaped recesses 4 and, in particular, also a mounting 4 for the electric motor (not shown) and (here circular) recesses 2 for the loudspeaker. Various fasteners of different plastics are sprayed in these areas. In addition, Figure 4 shows a current supply 4 in the form of conductive paths, which can be supplied with electric current by a central supply 6 (e.g. a socket contact). Also fasteners with an outsert technique are sprayed onto the support plate 1.

In Figure 2 the same reference numerals have the same meaning as in Figure 1. In particular there is also shown the supporting plate 1, and the dashed lines vertically extending rail 2.2 ¹ starters for the side windows not shown. The support plate 1 has trapezoidal recesses 6, an electric motor mounting 6 and a circular recess 7 for the loudspeaker. Laterally, a central power supply 6 is shown which leads to conductive paths not visible in this illustration. In addition, the picture shows that the rails of the 2/2 ¹ window launcher are tilted (8/8 ') at the factory and then into the area

78013f78013a.doc) The support plates 1 snap into place.

metal, as indicated by dashed lines, oscillates and

Represented by:

Dr. Miloš Všetečka v.r.

78013 (78013a.doc)

JUDr. Milos Všetečka advocate

120 00 Prague 2, Halkova 2

Claims (12)

A one-piece door module for motor vehicles, comprising a self-supporting metal support plate, characterized in that it additionally has integral functional components made of plastic, which are fixedly and releasably connected to the metal support plate in one working step. Door module according to claim 1, characterized in that it comprises a one-piece self-supporting support plate which, by its three-dimensional geometry, is substantially adapted to the geometry of the motor vehicle door into which it is to be incorporated and has a layer thickness ranging from 0.1 to 5 cm, preferably from 0.2 to 2 cm. Door module according to claim 1 or 2, characterized in that the functional elements are of thermoplastic plastic, preferably of a plastic based on polypropylene, polyamide, polyester, polyphenylene oxide, polyoxymethylene, polyphenylene sulphide, polyurethane, polycarbonates or a mixture of polyester with acrylonitrile butadiene. styrene copolymers or with acrylonitrile-styrene acrylic ester cleavable polymers, which can also be reinforced with glass or carbon fibers. Door module according to one of Claims 1 to 3, characterized in that the starter rails for the movable side window as well as the holding elements for the electric motor causing the motor are integrated into the door module. 16 78013 (78013a.doc) tt · ···· ··· · tt tttttt · tt tt t tt · tt ··· tttt · tt tt ► · • tttt tt side window movement. Door module according to one of Claims 1 to 4, characterized in that it has an extremely high wear resistance to the side window holders in the region of the starter rails for the side window. Door module according to one of Claims 1 to 5, characterized in that it additionally comprises an electrically insulating film of polyethylene, polypropylene, cycloolefinincopolymer, polyester, polyphenylene sulphide, polyimide or polyetherimide and that electrical conductive tracks are applied to the electrically insulating film. for the wiring of electrically powered functional elements in the region of the door module. Door module according to claim 6, characterized in that the electrically insulating foil also has a moisture insulation function. A method for manufacturing a door module according to any one of claims 1 to 7, wherein the prefabricated metal support plate is sprayed with plastic in precisely defined, locally delimited areas, characterized in that the plastic window guide rails are sprayed in the tilted state and that after the plastic has solidified, the raised window lifter rails swing into the area of the carrier plate and fix there. Method according to claim 8, characterized in that the electrically conductive power cable is additionally or flat 16 78013 (78013a.doc) 0000 0 · 0 00 00 • 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00000000 00 00 00 0 0 0 0 0 0 0 0 • 0,000,000 0 0 0 0 0 0 0 0 2 (OI - 77 plugs or clicks on the injected retaining elements. Method according to claim 8 or 9, characterized in that, in addition to the door module in the region close to the lateral edges or in the case of an electrically insulating film, a sealant is also applied or sprayed onto the film to seal the joints to adjacent or abutting surfaces. Method according to one of Claims 8 to 10, characterized in that additionally conductive tracks, such as electrically conductive connections, are applied by hot stamping on an aluminum or copper foil to the support plate or, in the case of an electrically insulating foil, on the foil. Method according to any one of claims 8 to 11, characterized in that the window trigger rails are subsequently treated by plasma or corona treatment to improve their wear resistance.