JP2009531230A - Door assembly with integrated window sealing system - Google Patents

Abstract

【Task】
Automobile doors include many parts that are assembled into a frame or shell, and depending on the vehicle / option, can include over 100 parts.
The attachment of parts to a frame or the like is a time-consuming process, and in most cases 20 to 45 different processes are required to complete the assembly process.
Thus, there is a need for a door assembly that requires fewer components.
[Solution]
The present invention relates to a door system and a door structure;
A body comprising one or more components disposed thereon;
A first module having an upper cavity, a lower cavity, the upper cavity at least partially surrounding the first side of the glazing, and the lower cavity at least engaging the body;
The second module includes a decorative panel that at least partially surrounds the second side of the glazing and at least partially contacts the upper cavity of the first module; and at least partially covers the core module.
[Selection] Figure 1

Description

The present invention relates to door systems, and more specifically, embodiments of the present invention relate to door systems for vehicles such as, for example, automobiles, particularly passenger cars and trucks.

The conventional door of an automobile includes many individual parts that are assembled into a frame or shell. Automobile doors may contain over 50 and over 100 individual components or parts depending on the vehicle and optional package. Such components may include various hardware, electrical components and seals. Examples of hardware may include handles, mirrors, window conditioners, window tracks, windows, door locks, and impact bolsters. Some electrical products may include wire harnesses, speakers, window motors, and external mirror motors. Examples of seal components include glass moving grooves, belt lines, lower window frame seals, plugs, grommets, and door and body seals.

Each component is usually supplied by a different seller or supplier, some of which are known in the industry as first, second and third stage suppliers. In most cases, the original equipment manufacturer (OEM) usually punches separately from cold-rolled steel sheets to produce door frames and skins, welds and paints to produce door shells. The frame and skin can be stamped from a single unprocessed board to produce a door shell. Numerous individual components of the first, second and third stage suppliers are typically assembled to the OEM door shell in an OEM assembly line.

The process of attaching the components to the door shell is a time consuming process and requires costly logistics considerations and / or systems to ensure that the right parts are placed in the right place at the right time. I need. The assembly process may also require a large floor area that is expensive. Each component is attached to the door shell using at least one of many different means including clips, screws, fittings, adhesives, to name a few. In order to complete the entire door assembly process, in most cases 20 to 45 different assembly processes are required.

FIG. 1 is a schematic explanatory view of a conventional door 100. Typically, the door 100 has an internal decorative panel 110, an internal panel 120, an intrusion beam 130, a reinforced portion 140, and an external panel 150. Typically, the inner panel 120, the intrusion beam 130, the reinforced portion 140, and the outer panel 150 are each made from steel plate, pressed, welded, and painted at an OEM factory. Many of the hardware, electrical and seal components described above (not shown in FIG. 1 for the sake of brevity) are typically assembled to the steel inner panel 120 at an OEM factory. Similarly, the various components on the interior decoration panel 110, including lighting lights, switches, armrests, map pockets, handles, etc. (also not shown for brevity) are assembled at the supplier's equipment at that stage, Transported to OEM destination. At the OEM site, the assembled decorative panel 110 is attached to the assembled inner panel 120, and the final electrical wiring and each hardware are connected.

Therefore, the door manufacturing process is a process that requires work and time. This assembly process also requires a sophisticated procurement plan because all parts must be prepared and assembled in the correct way and in sequence. Other incidental and related costs include ordering, storage, management, transportation, functional testing, quality control costs as well as floor space for assembling various components. All these elements are stacked up, resulting in a very expensive end product cost.

In accordance with the idea of reducing initial costs and partial integration, attempts have been made to use mounting panels that are pre-assembled with all or part of the hardware and electrical components as shown in FIG. FIG. 2 is a schematic explanatory view of a conventional door 200 including a mounting panel 210 assembled in advance. Many components including an internal door handle 215, a handle connecting cable 220, a window motor 225, a window adjuster 230, a speaker 235, a window guide rail 240, a drum pulley 245, a cable 250 and a door lock unit 260 are attached to the mounting panel. Assembled.

All or some of the hardware and electrical components can be installed on the mounting panel 210 at an external supplier, for example, a first stage supplier. The mounting panel 210 is typically made from stamped steel sheet, thermoformed glass mat reinforced thermoplastic (GMT) or injection molded long glass fiber reinforced polypropylene. Once the necessary components are assembled to the mounting panel 210 by an external supplier, the assembled mounting panel 210 is transported to an OEM destination for installation on a door panel subassembly or external panel 270. The inner decorative panel 280 is attached to the outer panel 270. Other partially integrated ideas are US Pat. Nos. 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 It is described in WO 01/25055 Al.

Some examples of pre-assembled mounting panels are believed to be manufactured.

However, the number of components and the time required to assemble the door are almost unchanged. The cost benefits for OEMs are mainly due to reduced logistics costs by the suppliers that make up the stage hierarchy.

Therefore, there is a need for a door assembly that requires fewer individual components. There is also a need for a door assembly that minimizes the number of individual components required for assembly.

Summary of the Invention

The present invention relates to door systems, including:
a) door structure;
b) a body including one or more components disposed thereon;
c) a first module having an upper cavity, a lower cavity, the upper cavity being adapted to at least partially surround the first side of the glazing and the lower cavity being adapted to at least engage the body ;
d) The second module is adapted to at least partially surround the second side of the glazing and is adapted to at least partially contact the upper cavity of the first module: and
e) A decorative panel adapted to at least partially cover the core module.

Detailed Description of the Invention

The following provides a detailed description of the present invention.

Each claim in the claims defines a separate invention. In the context of infringement, the various features and limitations recited in the claims should be construed to include equivalents thereof. For textual purposes, references to “invention” below, in some cases, relate to certain specific embodiments, and in other cases, references to “invention” refer to one or more claims. But not necessarily all claims, and relates to the invention as defined in the claims. Each invention is described in detail below, including specific embodiments, variations thereof, or examples, but each invention may be used by one of ordinary skill in the art when combined with available information and techniques. It is not limited to the embodiments that can be used, variations thereof, or examples.

FIG. 3 is a schematic illustration of an example of a door system according to one or more embodiments of the present invention. In at least one specific embodiment, the door system includes a door structure 300, an outer core module 325, a core module 400, a window decoration module 525, and a decoration panel 700. The outer core module 325 is a framework structure that is assembled to the door structure 300. The window decoration module 525 is similar to the shape of a conventional upper window enclosure and is assembled to the upper portion of the outer core module 325 and the core module 400. In other words, the core module 400 is assembled below the outer core module 325 and the window decoration module 525. The decorative panel 700 covers the core module 400, and the assembly of the door system is completed.

Preferably, the door system may use multi-material injection molding techniques or robotic extrusion to integrate the various components. Multi-material injection molding techniques can inject two or more materials into a single or multiple cavity mold. Two component or material processes are usually known as “2K”, and three material processes are usually known as “3K”.

Any suitable multi-material injection molding machine can be used, such as the Engel Victory Combi machine from Engel Corp.

In-mold process technology can additionally be used to expand and / or facilitate integration. Examples of in-mold process techniques include, but are not limited to, multi-cavity tools, insert molding, movable core sites, 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 when applying sealing parts or other functional parts to already injection molded structures. By using this system, it is also possible to create a hollow seal cross section if necessary.

As used herein, “door” includes any door. For example, a “door” is one or more passenger car doors that may be hinged, sliding, lifted, or any alternative opening / closing operation, whether a lift gate, tailgate, and hatchback, It may be any means of transportation, including trucks, SUVs, trains, boats, airplanes, etc. and for personal, recreational, military or commercial use.

Each substrate 300, 350, 400, 525, and 700 may each include one or more seals, plugs, and grommets. Preferably one or more seals, plugs and grommets are injection molded onto the substrate. Any of the one or more seals, plugs and grommets can be molded directly onto the substrate using two or three shot injection molding or robotic extrusion techniques. The integrally molded seals, plugs and grommets act to prevent or eliminate water penetration, rattling and vibration. Such components allow some movement and improve the acoustic effect of the part (ie, sound blocking and “closing sound”), while complementing its partial tolerance and expansion. Reduced).

As shown in FIG. 3, the decorative panel 700 further includes one or more speaker covers 710, an armrest 720, a door handle 730, a window switch 740, a door lock switch 750, a side mirror control 760, a map pocket 770, and an interior light 780. But it ’s okay.

The decorative panel 700 can be attached to or integrally molded, or can provide a housing or substrate for other electrical, mechanical or sealing components that are insert molded. Examples of components include air bags, air vents, switches, door handles, door locks, armrests, map pockets, speaker covers or lattices, speakers, belt-in seals, plugs, grommets, and between core and frame. Including, but not limited to, a seal.

Examples of switches include window glass control, window lock, external mirror position control, door lock, seat position control, and stereo control.

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

Consider the door component 300 in more detail. FIG. 4 is a schematic diagram of an embodiment.

The door structure 300 may be fabricated from one or more separate panels. For example, the door structure 300 may include an outer skin 320 and an inner support 330 that are secured together. The outer skin 320 and the inner support 330 may each be injection-molded from polyethylene or polypropylene, and more preferably from reinforced polypropylene. In some embodiments, each of the outer skin 320 and the inner support 330 is injection molded, cast, extruded, molded, or any other method discussed herein. It can be formed from other suitable materials.

In one or more embodiments, the outer skin 320 and the inner support 330 may each be pressed, assembled and painted from aluminum or cold rolled steel, rolled steel to meet OEM specifications.

In one or more embodiments, the outer skin 320 and inner support 330 are made from different types of steel (ie tailored blanks), welded, pressed and painted to the desired color. Can be done. Further, the door structure 300 may be a single component or a single panel.

The door structure 300 has a first side or internal side 310 that faces the passenger portion of the vehicle. The interior side 310 of the door structure 300 has a size and shape similar to the dimensions of the core module 400 such that when assembled, at least a portion of the core module 400 fits into the recessed cavity 315 of the door structure 300. , May have a recessed cavity 315.

In one or more embodiments, the core module 400 has a peripheral seal (not shown in this view) that is integrally formed with the core module 400 or that can be separately attached. This seal creates a moisture / dry barrier between the door structure 300 and the outer core module 400, which helps to create a rattle-free assembly, among other purposes and effects, and suppresses noise transmission and heat Helps compensate for swelling. The door structure 300 also has a second or external side (not shown in this view) to which a side mirror 311 and an external door handle (not shown in this view) can be attached. As used herein, “interior” refers to the direction or orientation toward the interior of the passenger part or vehicle, and “exterior” refers to the direction away from the interior of the passenger part or vehicle. Or the direction.

In one or more embodiments herein, the door structure 300 does not have a reinforcing structure or portion at or near the belt line 353. The absence of a reinforced structure or portion facilitates access to glazing or other components that require assembly or repair. In particular, since the belt line 353 does not have such an obstruction, as will be described in more detail below, it is very easy to assemble and remove the window glass. The absence of a reinforced structure or portion also reduces the overall weight of the door assembly, thereby reducing the weight of the vehicle and extending the mileage per unit fuel.

FIG. 5A is a schematic illustration of one embodiment of an outer core module 325 in one or more embodiments described herein.

The outer core module 325 is a framework structure having an upper cavity 326 and a lower cavity 327. The two cavities 326 and 327 are separated by an indicating portion 328 around the belt line. One or more seals can be easily integrated with the outer core module 325, thereby further reducing noise and improving resistance to water leakage.

The outer core module 325 includes a glass moving groove 350. As shown in FIG. 5A, at least a part of the glass moving groove 350 is located in the upper cavity 326, and at least a part of the glass moving groove 350 is located in the lower cavity 327 of the outer core module 325. In one or more embodiments, the glass run channel 350 has 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 cavity 327. For example, the first portion 352A of the glass moving groove 350 is attached to the outer core module 325 below the beltline support 328 along the A column side of the outer core module 325, and the second portion of the glass moving groove 350 is attached. The portion 352B is attached below the beltline support 328 along the B-column side of the outer core module 325.

Preferably, at least one of the first portion 352A and the second portion 352B of the glass moving groove 350 is sufficiently long to contact the window glass when the window glass is in the lowered position. It is good to have. More preferably, both the first portion 352A and the second portion 352B of the glass moving groove 350 are sufficiently long to contact the window glass when the window glass is in the lowered position. good.

The glass moving groove 350 may be made from one or more separate members or parts that are welded or otherwise attached to each other or maintained in a fixed relationship relative to each other. Preferably, the glass run channel 350 is made from a single piece. Alternatively, the portions or members 351, 352A and 352B may each be separate or more than one. In one or more embodiments, the glass run channel 350 has one or more cross-sections (ie, shapes) adapted to contact the glazing. Examples of shapes include “U” type, “L” type and combinations thereof, either alone or in combination with one or more lips, valves or other sealing elements.

FIG. 5B shows an enlarged cross-sectional view along the line AA of the moving groove 350 of the glass of FIG. 5A. In one or more embodiments, the upper portion 351 of the glass moving groove 350 has an opening or “L” shaped cross section that can contact the outer edge of the window glass (not shown). As will be described in more detail below, the window decoration module 525 may have a paired cross-section (eg, an opening or “L” -shaped cross section) that can contact the outer edge of the glazing, thereby providing a window. Glass is sandwiched and sealed between them.

Still referring to FIG. 5B, the A column side of the lower portion 352A preferably has an “L” shaped cross section 355, similar to the B column side of the lower portion 352B. The “L” shaped cross section 355 contacts the outside (ie, outside) periphery of the glazing. As will be described in more detail below, the core module 400 complements the interior (ie, the inside) periphery of the glazing so that these paired shapes guide the glazing when assembled. May have a general shaped cross section (ie, an open or “L” shaped cross section). Such a seal system is similar to the opposing shape (ie, seal) on the window decoration module 325 and the upper portion 351 of the glass moving groove 350 each serving to form a seal at the upper portion of the window glass. ing.

Describing in more detail about the core module 400, FIG. 6 is a schematic illustration of the core module 400 in one or more embodiments described herein. As noted above, the core module 400 includes one or more hardware components, electrical components, and a sealing portion (ie, a seal).

Examples of components assembled to the core module 400 include window adjusters, motors, tracks, impact bolsters, wire harnesses, speaker boxes or containers, window motors, external mirror motors, belt line seals, plugs, Including but not limited to grommets and core-frame seals. For simplicity and ease of explanation, in FIG. 6, the core module 400 includes one or more bolsters or safety pads 410, a speaker box 425, a window track 440, a motor support 445, a window glass 460, a belt line seal 465, and glass. Are shown as having a moving groove 470.

It should be understood that the core module 400 may include any other components that are typically included in automobile doors. 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 have one or more air distribution channels for heating or air conditioning.

Preferably, the individual components are injection molded onto the core module 400. For example, one or more bolsters 410, speaker box 425, window track 440, motor support 445, reinforced portion 450, beltline seal 465, and air distribution channel (not shown) can be made from multiple materials or multiple shot injection molding techniques. And can be formed integrally with the core module 400. In doing so, these components are part of an integral part of the core module 400 and are not separate components that are expensive to assemble, thus greatly reducing the assembly time.

The side bolster 410 may be a foam member such as a foam block. The side bolster 410 may also have a hollow structure. 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 the bolster 410 may be second shot molded to the core module 400 using a multiple injection molding technique.

In one or more embodiments, the core module 400 further includes a reinforcement portion 450. The reinforced portion 450 increases the strength and rigidity of the core module 400 and the entire door system when assembled.

As discussed above, conventional doors have reinforcing bars attached to the door frame. In the embodiment shown in FIG. 6, the core module 400 and the reinforcing portion 450 are integrally formed, thereby reducing the number of door components and / or components assembled to the core module 400, and the door assembly, in particular the upper and lower windows. Facilitates system installation and functional testing. The reinforcing portion 450 may be disposed on either the inner side surface (“first side surface”) or the outer side surface (“second side surface”) of the core module 400. In FIG. It is shown as being located on the inner side of the.

Considering in more detail about the reinforced portion 450, the reinforced portion 450 may have a round bar, plate, or any other structure that adds strength to the door system.

Preferably, the reinforced portion 450 has a length greater than its width and thickness, similar to a round bar or plate, and may be in close proximity to or adjacent to the belt line of the door.

The reinforcement part may be fabricated from another component and assembled to the core module, or the reinforcement part may be insert molded into the core module 400. In one or more embodiments, the reinforcement portion 450 and the core module 400 are made from the same material or combination of materials. In one or more embodiments, the reinforcing portion 450 and the core module 400 are made from different materials or different combinations of materials.

Further, the reinforced portion 450 may be pressed from steel plate or aluminum, or made from one or more non-metallic materials, such as polyethylene, polypropylene, or one or more other materials described herein. Preferably, the reinforced portion 450 may be injection molded with the core module 400 and two component processes ("2K" process). More preferably, the reinforced portion 450 may be press molded from aluminum, steel plate, or other suitable metal or alloy, inserted into an injection molding tool, and at least partially overmolded with the core module 400 material.

FIG. 7 is a schematic view of one or more components of the core module 400 installed on its second side or external side. The glass moving groove 470 is preferably formed in 2K on the second side of the core module 400 using a multi-material injection molding machine. The second material is preferably coated with a slip coat to reduce friction with the glazing, or the surface friction of the second material slides along it with a force acceptable to the glass It may be as low as possible. Alternatively, the glass moving groove 470 may be a separate part attached to the core module 400 or otherwise a part assembled to the core module 400.

The glass moving groove 470 may be a “U” shaped cross section, an “L” shaped cross section, or any combination thereof alone, or one such as those combined with one or more lips, spheres, or other sealing elements. It can have the above cross section. As noted above, the glass run channel 470 is preferably in the “L” cross section of the lower portion 352A of the glass run channel 350 on the outer core module 325, as shown in FIGS. 5A and 5B. It may have a cross section or at least one lip with a shape that fits. Accordingly, when the core module 400 is attached to the outer core module 325, the cross-section paired with the glass moving grooves 470 and 352 provides a guide having a shape for the window glass 460 to move.

Still referring to FIG. 7, one or more window tracks 440 are preferably provided on the second side of the core module 400. As described above, one or more window tracks 440 may be integral with the core module 400. Preferably, the window track 440 is injection molded into the core module 400. The slip coating may be inserted into a mold in which the window track 440 is formed so as to reduce friction with the window glass. This may be done using 2K or multi-material injection techniques or robotic extrusion. Alternatively, the slip coating can 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 flock coating may be inserted into the tool and overmolded.

The sliding coating is preferably made of a material that can reduce friction between the window track 440 and the window glass. The slip coating includes the materials discussed herein and may be made from polyethylene, polypropylene or other suitable material.

If the coefficient of friction of the base material from which the seal is made is sufficiently low, it is not necessary to add a low friction surface to the seal.

Due to the integration of the beltline reinforcement (ie, the reinforcement portion 450) and the integration of the glass moving groove 470 into the core module 400, the window lifting system including the window glass 460 is completely pre-positioned as shown in FIG. can do. By using the inner and outer core modules, the glass moving groove can be integrated into the core module and its pre-tested. The number of parts supplied to the assembly line can be reduced, and the number of parts assembled on the assembly line can be reduced.

Thus, the window mechanism and controls can be tested at the first stage supplier who is the core module 400 assembler, reducing the time and cost of OEM assembly.

Many glass moving grooves are connected by corner molding and / or joined by end molding or welded to ensure that the glass moving grooves function correctly. Or it consists of several different shaped extruded shapes joined by bonding. Any variation from the extruded two-dimensional shape can be made in a later processing step.

If a (multi-material) injection molded seal is used, the shape of the seal can be designed more freely. Using injection molding, the number or angle of individual seal lips can be varied over the entire length of the seal. In this way, the sealing properties (with respect to humidity, sound or air flow) can be improved without adding the cost of overmolding part of the seal.

Corner and edge shaping also helps improve aesthetic function. Injection molded seals give design freedom and create shapes that give aesthetic effects. The surface of the injection molded seal can be smooth. The surface of the injection molded seal is also particulate or can be covered with a flock material or a low friction coating. Thermoplastic materials (eg, polypropylene) can make the product different colors. These colors can be quickly changed in the injection molding process, and if multiple machines are used, different colors can be applied to a single seal.

Considering the window decoration module 525 in more detail, FIG. 8A is a schematic illustration of an embodiment.

FIG. 8B is an enlarged cross-sectional view taken along line BB of the window decoration panel 525 of FIG. 8A.

Referring to FIGS. 8A and 8B, the window decoration module 525 is also a frame structure with an opening or cavity 525A defined therein. The window decoration module 525 includes a glass moving groove 572 provided on the second or outer side thereof.

Glass moving groove 572 is a “U” shaped cross section, an “L” shaped cross section or any combination thereof alone or in combination with one or more lips, bulbs, or other sealing elements. And can have one or more cross-sections. The glass moving groove 572 is preferably or as shown in FIG. 5B, which is compatible with the opening or “L” shaped cross section of the upper portion 351 of the glass moving groove 350 of the outer core module 325 shown in FIGS. 5A and 5B. It may have a cross-section with a certain shape, or at least one lip such as shape 355. Thus, when the window decoration module 525 is attached to the outer core module 325, the shape paired with the glass moving grooves 572 and 351 provides a sealed guide for the window glass 460 to move.

In one or more embodiments described above or elsewhere herein, the window decoration module 525 further includes an inner beltline seal 573 integrally formed thereon. FIG. 8C is an enlarged cross-sectional view of the inner belt line seal 573 of FIG. 8A along the line CC. The inner beltline seal 573 is preferably 2K molded onto the second side of the outer core module 525 using a multi-material injection molding machine.

The second material is preferably flocked or coated with a slip coat to reduce friction with the glazing, or the surface friction of the second material with a force acceptable to the glass. You may make it low enough to be able to slide along it. Alternatively, the inner beltline seal 573 may be attached to the outer core module 525, or may be another part that is otherwise assembled to the outer core module 525. The inner belt line 573 can also be integrated into the outer core module 525 depending on its desired application.

FIG. 9 is a schematic illustration of a reinforcing portion 450 that can be used. The reinforced portion 450 may include a top flange 451 and a bottom flange 452 for assembly to the core module 400 (not shown in this view). Also, although not shown in this figure, each flange 451, 452 may have one or more holes for receiving one or more fasteners such as clips, screws, bolts, rivets, and the like.

In one or more embodiments, the reinforced portion 450 may have a recessed portion 453 provided between the flanges 451 and 452 as shown in FIG. The recessed portion 453 may have any constant or variable depth. The primary purpose of this depth is to provide rigidity (ie resistance to deformation). The depth may be, for example, 0.05 to 8 inches, 1 to 6 inches, or 0.5 to 3 inches, depending on the type of vehicle.

In one or more embodiments described above or elsewhere herein, the reinforcing portion 450 is further strengthened and rigid by having a cover plate 455 thereon, as shown in FIG. sell. FIG. 10 shows a schematic view of a reinforced portion 450 having a cover plate 455 thereon. The cover plate 455 is preferably fixed to the reinforced portion 450 with a top flange 451 and a bottom flange 452. The cover plate 455 can also be attached to the reinforced portion 450 using an adhesive or a mechanical fixture including, for example, screws, bolts, rivets, clips, and the like. The cover plate 455 can also be spot welded to the strengthened portion 450.

In one or more embodiments described above or elsewhere herein, the cover plate 455 can also be attached to the reinforcement portion 450 using one or more clips 456, as shown in FIG. FIG. 11 shows a schematic cross-sectional view of a reinforced portion 450 having a cover plate 455 mounted thereon by one or more clips. Although one or more clips 456 can be easily attached during assembly, preferably, one or more clips 456 are injection molded or integrally formed with reinforcing portion 450.

In one or more embodiments described above or elsewhere herein, the cover plate 455 can be slid and attached to the reinforcing portion 450. For example, the cover plate 455 can have a shaped end adapted to slide over the shaped end that forms a pair of reinforcing portions 450, as shown in FIG. FIG. 12 shows a partial section of a cover plate 455 having a stiffened portion 450 and a shaped end adapted to engage and slide about it.

The protruding shape 457 of the reinforced portion 450 engages with the shape end 455A of the cover plate 455 and functions as a rail or guide on which the cover plate 455 can slide. The space between the shape end 455A of the cover plate 455 and the protrusion shape 457 of the reinforcing portion 450 is sufficient for the cover plate 455 to be slid and inserted, and so as not to generate vibrations or rattles in later use. It is preferred that it be maintained.

In one or more embodiments described above or elsewhere herein, the reinforcement portion 450 may include an insertion or reinforcement structure 458 provided within the recessed portion 453, shown in FIG. FIG. 13 is a schematic illustration of a reinforced portion 450 having one or more insertion portions 458.

Preferably, the insertion portion 458 may include one or more fingers or collars 458A that can be formed by overmolding a plastic structure within the recessed portion 453 of the reinforcement portion 450. The insertion portion 458 increases resistance to deformation. The insertion portion 458 can provide very high energy absorption and resistance to warping. After overmolding the insert 458, a cover plate 455 may be provided thereon as described above with respect to FIGS. 10-12 to provide additional strength.

In one or more embodiments described above or elsewhere herein, the brace 458A of the insertion portion 458 can be arranged in various patterns as shown in FIGS. For example, as shown in FIG. 13, you may have a rectangular pattern similar to a checker board. In one or more embodiments, the brazing material 458A may have a diamond pattern as shown in FIG. In one or more embodiments, the spider 458A may have a honeycomb or polygonal pattern as shown in FIG. Other patterns include tubular and circular shapes and may depend on the stiffness and strength required by the application and design considerations.

In one or more embodiments described above or elsewhere herein, as shown in FIGS. 16-18, the insertion portion 458 can be formed using a variety of techniques to provide a recessed portion 453 of the reinforcement portion 450. Can be provided in or otherwise attached to. 16, 17 and 18 are schematic views of the reinforcing portion 450 with various ways of holding the insertion portion 458, respectively. For example, the reinforcing portion 450 may have one or more indentations or indentations 450A for positioning the insertion portion 458 or securing at least a portion thereof, as shown in FIG. Accordingly, the insertion portion 458 may include a pair of protruding portions (not shown) that fit within the recess 450A of the reinforcing portion 450 and contact the main body of the core module 400. As such, the insertion portion 458 can be held in place during assembly. If an optional cover plate 455 is used, the insertion portion 458 can be held by the recess 450A until the cover plate 455 is secured.

In one or more embodiments described above or elsewhere herein, one or more holes 450B may be formed in the recessed portion 453 of the reinforced portion 450, as shown in FIG. . During the overmold injection molding process, the holes 450B allow the material of the insert portion 458 to flow through the reinforced portion 450. Accordingly, the material of the insertion portion 458 remains in the reinforcement portion 450 and is retained therein.

In one or more embodiments described above or elsewhere herein, as shown in FIG. 18, the reinforcement portion 450 is one or more slits or openings that can receive the protruding portion 458B of the insertion portion 458. 450C may be included. The protruding portion 458B of the insertion portion 458 may be a simple extension of one or more brazing materials. One or more slits 450C of the reinforcing portion 450 may be deflected to hold the insertion portion 458 or otherwise designed to provide a friction fit.

In any of the embodiments described above with respect to FIGS. 16, 17 and 18, the insert portion 458 may be retained on and used on the reinforcing portion 450. Alternatively, the insertion portion 458 is retained on the reinforcing portion 450 until the adhesive force of the cover plate 455 is sufficiently strong, so that the cover plate 455 causes the insert portion 458 to be in place during use. Hold it. Further, the described embodiment allows the insertion portion 458 to be held in position on the reinforcement portion 450 for a sufficiently long time so that the cover plate 455 is mechanically secured to the reinforcement portion 450 or the core module 400.

Raising some of the suitable mechanical fasteners include clip screws, heat stake, rivets, blind rivets, and bolts. Spot welding can also be used.

Preferably the cover plate 455 and the reinforcing portion 450 are clipped together. For example, FIG. 19 is a partial enlarged cross-sectional view of a reinforced portion 450 having one or more clips provided thereon for engaging and holding the cover plate 455. A simple design in which the clip 456 contacts the back side of the cover plate 455 and thereby holds the cover plate 455 may be employed. In one or more embodiments described above or elsewhere herein, a layer of adhesive 459 may be used to hold the cover plate 455 in place. Thus, the clip 456 can also be designed to have sufficient structural integrity to hold the cover plate 455 until the adhesive (eg, glue) layer 459 is dry. The adhesive layer 459 is preferable in terms of preventing noise due to rattling and vibration.

FIG. 20 is a schematic explanatory diagram of a cover plate 455 having one or more fasteners 456A formed thereon. One or more fasteners 456A may be injection molded over the cover plate 455 or otherwise attached thereto. Other methods of securing the cover plate 455 to the reinforced portion 450 can be readily conceived, including “Christmas tree” type fasteners commonly used to attach decorative panels to door structures. These fixtures may be injection molded on the cover plate 455 to achieve a higher degree of integration of the components and a reduction in assembly time.

21, 22, and 23 are explanatory views of a window raising / lowering system 500 that can be used integrally with the core module 400. In at least one embodiment, the window lifting system 500 includes a motor housing 507, a brace lifter 520, a regulator 530, and window tracks 545 550. The brace lifter 520 includes a gear or toothed portion 522, a first extension portion 524, and a second extension portion 526.

The raising motor 505 may be attached to the core module 400 as shown in FIG. The motor 505 may be attached to either the inner side surface or the outer side surface of the core module 400. The motor housing or container 507 can be easily mounted on either side of the core module 400, and the motor 505 can be snap fasteners, rivets, adhesives, screws, or other for fastening components (not shown). It can be easily attached or assembled to the motor housing 507 that is integrally formed by using any of the fixing tools.

Referring again to FIGS. 21 and 22, the motor 505 drives the toothed portion 522 around the rotation axis 515 in a clockwise or counterclockwise direction. Toothed portion 522 is attached to or integral with first extension portion 524. The first extension 524 has a first end 524 A attached to the regulator 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 inside an integrally formed track 550. The track 550 is formed from the core module 400 by injection molding using one or more techniques of single material molding, 2-K molding, in-mold labeling, and insert molding, as described above. It is formed integrally.

The adjuster 530 and the window track 550 can each be formed to have a pair of molds 532 and 552 so that when engaged, the adjuster 530 has a shape of the track 550 as shown in FIG. Guided along 552.

The first extension portion 524 is rotatably connected to the second extension portion 526 at the rotation shaft 515. The first end 526 A of the second extension portion 526 is in communication with the track 545. A second end 526 B of the second extension 526 is attached to the regulator 530. The track 545 is formed integrally with the core module 400 by injection molding, or the track 545 is a separate part, such as a rail-like part attached to the core module 400, or is insert molded into the core. Also good. As the motor 505 drives the toothed portion 522, the extension portions 524 and 526 operate simultaneously about the rotating shaft 515 to raise and lower the adjuster 530 and raise and lower the window glass 535. The window glass 535 is supported by a regulator 530 and a groove 323 through which the glass moves.

24, 25 and 26 show a schematic diagram of another embodiment of a window lift system 600. FIG. FIG. 24 is a simplified diagram of a core module 400 having a window lifting system 600.

The window lift system 600 includes a motor housing 620 and two or more adjusters (610A and 610B), each adjuster configured to be attached to a track portion 615A, 615B.

The motor 605 is attached to a motor housing 620 on the core module 400 as shown in FIG. The motor housing 620 may be formed on either the inner side surface or the outer side surface of the core module 400. Preferably, the motor housing or container 620 is injection molded into the core module 400.

The motor 605 can be easily mounted or assembled to the integrally formed motor housing 620 using clip snap connections, rivets, screws, adhesives or any other fasteners (not shown).

Window 625 is secured to regulators 610A, 610B by one or more fixtures and / or adhesive type materials (not shown). The adjusters 610A and 610B and the window tracks 615A and 615B can be formed to have cross sections that match each other. When engaged, the adjusters are guided along the shape of each track as shown in FIG. The

The window lift system 600 further has one or more Bowden cables (two are shown as 640 and 645 in FIG. 24). Cables 640 and 645 are connected to regulators 610A, 610B. Regulators 610A, 610B raise or lower window 625 as motor 620 alternately pulls cables 640 and 645. Window 625 is supported by regulators 610A, 610B in communication with tracks 615A and 615B. These tracks are formed integrally with the core module 400 and are insert-molded or assembled to the core module 400.

The components described above include the door component 300, the outer core module 325, the core module 400, the window decorative panel 525 and the decorative panel 700, for example, any material having essential properties such as stiffness and strength. Can be made from Suitable materials include, but are not limited to, propylene homopolymer, propylene copolymer, ethylene homopolymer, ethylene copolymer and any one or more of the following polymer resins. That is,
a) Polyamide resin such as 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 copolymer;
b) Polyester resins such as polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET / PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal Polyesters, polyoxalkylene diimide diacid / polybutyrate terephthalic acid copolymers and other aromatic polyesters
c) Polynitrile resins such as polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), methacrylonitrile-styrene copolymer, methacrylonitrile-styrene-butadiene copolymer and acrylonitrile-butadiene styrene (ABS);
d) polymethacrylate resins such as polymethyl methacrylate and polyethyl acrylate
e) Cellulose resins, such as cellulose acetate and cellulose acetate butyrate;
f) Fluororesin, such as vinylidene fluoride (PVDF), polyvinyl fluoride (PVF),
Polychlorofluoroethylene (PCTFE), and tetrafluoroethylene / ethylene copolymer (ETFE);
g) polyimide resin, for example aromatic polyimide;
h) polysulfone;
i) polyacetal;
j) polyacetone;
k) Polyphenylene oxide and polyphenylene sulfide
1) styrene maleic anhydride;
m) aromatic polyketone,
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, etc .; and
p) Any number of mixtures from a) to o) above.
In one or more embodiments described above or elsewhere herein, the material may include one or more fillers to further increase strength. The filler is present in an amount from 0.001% to 50% by weight based on the weight of the composition in certain embodiments and from 0.01% to 25% by weight in other embodiments. In still other embodiments, it may be present in an amount of 0.2% to 10% by weight. Desirable fillers include titanium dioxide, silicon carbide, silica (and other oxides, whether precipitated or not), antimony oxide, lead carbonate, zinc white, lithopone, zircon, corundum, spinel, phosphorus. Alite, barite powder, barium sulfate, magnesite, graphite, dolomite, calcium carbonate, sand, glass beads, mineral aggregates, talc, and whether hydrated, Al, Cr, or Fe and CO ₃ and / or HPO4 and Mg, Ca, or Zn ion hydrotalcite compound, quartz powder, magnesium hydrogen carbonate, short glass fiber, long glass fiber, glass fiber, polyethylene terephthalate fiber, wollastonite, Mica, carbon fiber, nanoclay, nanocomposite, magnesium sulfate trihydrate, clay, alumina, and other metal oxides and carbonates Including, but not limited to, salts, metal hydroxides, chromium, phosphorous acid and brominated flame retardants, antimony trioxide, silicon, and any combinations and blends thereof. Examples of other fillers include one or more polypropylene fibers, polyamide fibers, para-aramid fibers (eg Kevlar or Twaron), meta-aramid fibers (eg Nomex), polyethylene fibers (eg Dyneema) and combinations thereof. May be included.

The material may also include a nanocomposite that is a blend of a polymer and one or more organoclays. Examples of organoclays include one or more ammonia, primary alkyl ammonia, secondary alkyl ammonia, tertiary alkyl ammonia, quaternary alkyl ammonia, aliphatic, aromatic or aryl aliphatic amine, phosphine, or Sulfide phosphonium derivatives, aliphatic, aromatic or arylaliphatic amines, phosphines, or sulfide sulfonium derivatives may be included. Furthermore, the organic clay is one or more of montmorillonite, sodium montmorillonite, calcium montmorillonite, magnesium montmorillonite, nontronite, beidellite, bolcon scoreite, laponite, hectorite, saponite, soconite, magadite, Kenyanite, sobokite, swindleite ( svindordite), stevensite, vermiculite, halloysite, aluminate oxide, hydrotalcite, illite, rectolite, talosobite, ladykite and / or florine mica.

When organoclay is present, the organoclay is preferably included in the nanocomposite from 0.1 to 50% by weight based on the total weight of the nanocomposite. In order to provide a stabilizing function, it may be selected from one or more 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, usually present in the nanocomposite from 1 to 70% by weight, based on the total weight of the nanocomposite.

It is desirable to use reinforced polypropylene (PP) for the region, part or component of the door system 300 that provides the structure. Most desirable is PP reinforced with PET fibers or any other material that is light in weight, stiff, has a good balance of impact strength, and has a low coefficient of linear thermal expansion (CLTE) Good.

In one or more embodiments described above or elsewhere herein, the polymer can improve impact properties to increase impact resistance. Impact modifiers include, but are not limited to, plastomers, ethylene propylene rubber (EPR), ethylene-propylene diene monomer rubber (EPDM), and also include maleic acid polypropylene, maleic acid polyethylene and other maleated polymers. , But may be used in combination with a compatibilizer such as polypropylene hydroxide and other hydroxylated polymers, derivatives thereof and any combination thereof, but the compatibilizer is not limited thereto.

In other embodiments, the material may include a plastomer, preferably a propylene plastomer blend. The term “plastomer” as used herein is from 0.85 g / cm ³ to 0.915 g / cm ³ according to ASTM D-4703, Method B or ASTM D-1505.
And one or more polyolefin polymers and / or copolymers having a melt index (MI) between 0.10 dg / min and 30 dg / min at 190 ° C., 2.1 kg ASTM D-1238. Preferred plastomers have a melt index (MI) as measured by ASTM D-1238 of between 0.10 dg / min and 20 dg / min in some embodiments and 0.2 dg / min to 10 dg / min in other embodiments. In yet other embodiments, from 0.3 dg / min to 8 dg / min. Preferred plastomers are 10,000 to 800,000 in embodiments with an average molecular weight and 20,000 to 700,000 in other embodiments. Desirable plastomer molecular weight distributions (Mw / Mn) range from 1.5 to 5 in some embodiments and from 2.0 to 4 in other embodiments. Preferred plastomers have a 1% secant flexural modulus (ASTM D-790) of 10 Mpa to 150 Mpa in some embodiments and 20 Mpa to 100 Mpa in other embodiments. Furthermore, preferred plastomers have a melting point (Tm) of 30 ° C. to 80 ° C. (first melting point peak) and 50 ° C. to 125 ° C. (second melting point peak) in certain embodiments, and other embodiments. In this case, the temperature is from 40 ° C. to 70 ° C. (first melting point peak) and from 50 ° C. to 100 ° C. (second melting point peak).

In one or more embodiments described above or elsewhere herein, the plastomer may be a copolymer of ethylene derived units and at least one C3 to C10 alpha olefin derived unit. Preferably, the copolymer is 0.915 g / cm ³
It is better to have a density less than. The amount of comonomer (C3 to C10 alpha olefin derived units) present in the plastomer ranges from 2% to 35% by weight in some embodiments and from 5% to 30% by weight in other embodiments. In yet another embodiment, it is 15% to 25% by weight, and in yet another embodiment, 20% to 30% by weight.

In one or more embodiments described above or elsewhere herein, the plastomer comprises ethylene derived units and higher alpha olefin derived units such as propylene, 1-butene, 1-hexene and 1-octene. Or a copolymer produced by one or more metallocene catalysts. Preferably, the plastomer contains sufficient one or more of these comonomer units and has a density between 0.860 g / cm ³ and 0.900 g / cm ³ . An example of a commercially available plastomer is EXACT 4150, a copolymer of ethylene and 1-hexene, with 1-hexene derived units accounting for 18% to 22% by weight of the plastomer, a density of 0.895 g / cm ³ and Has an MI of 3.5 dg / min (available from ExxonMobil Chemical Company); there is also EXACT 8201, a copolymer of ethylene and 1-octene, where 1-octene accounts for 26-30% by weight of the plastomer, 0.882 g It has a density of / cm ³ and an MI of 1.0 dg / min (available from ExxonMobil Chemical Company).

Preferred blends used as molding materials in the present invention typically comprise from about 15%, 20% or 25% to about 80%, 90% or 100% polymer by weight, optionally about 0% by weight. %, 5%, or 10% to about 35%, 40%, or 50% filler, and optionally about 0%, 5%, or 10% to about 35%, 40%, or 50 by weight Contains% plastomer. In one or more embodiments, a preferred blend has one or more of the stated ranges from about 15%, 20% or 25% of its lower limit to about 80%, 90% or 100% of its upper limit by weight. Contains polymer. In one or more embodiments, preferred blends comprise at least about 1%, 5%, 10%, 15%, or 20% plastomer by weight. In one or more embodiments, preferred blends comprise at least about 1%, 5%, 10%, 15%, or 20% filler by weight.

Preferably, the blend used in the present invention should have a tensile strength of at least 6,500 MPa, at least 7,500 MPa, or at least 9,000 MPa. Furthermore, preferred blends have a flexural modulus of greater than 1,750 Mpa, such as greater than about 1,800 MPa, or greater than about 2,000 Mpa.

In addition to the materials and polymers listed above, one or more thermoplastic vulcanizates (TPV), thermoplastic elastomers (TPE), thermoplastic urethane (TPO), polyurethane (PU) or elastomers such as EPR or EPDM are sealed It can be used for areas or components that need to have properties. These materials can be used in a dense (non-foamed) or foamed state. Most preferably, the TPV is selected because of its excellent sealing ability and inherent mechanical properties that it can be injection molded. Other required properties of the material include structural and sealing material compatibility or ability to adhere to each other. The material of the structure and / or sealing system may be functionalized to obtain good adhesion, or a second additive or component may be added to the material.

Assembly Sequence Referring again to FIG. 3, the door system can be easily assembled. In at least one particular embodiment, the door system can be assembled in the following order: First, a desired component is inserted into an injection mold in order to manufacture the core module 400. The core module 400 and the inserted component are injection molded with the first material. A second material, such as polypropylene, polyethylene and / or thermoplastic vulcanizate (TPV), is injected to make a flexible component (seal, plug, grommet or skin soft part) on the core module 400. It may be molded. Gas or water assisted molding may be used to create a hollow shape where necessary to obtain further structural strength. Foaming agents can also be used to minimize sink marks or to create a foam structure with increased stiffness. The core module 400 having components integrally formed thereon is taken out from the tool. Components that are not yet integrated into the core module are then assembled. The window glass 535 is assembled to the core module 400.

The window decoration panel 525 and the external core module 325 are assembled to the core module 400. The window glass 535 is then adjusted appropriately if necessary. The completed core subassembly is functionally tested and delivered to the assembly line.

In the assembly line, the completed core subassembly is attached to the door structure 300, the decorative panel 700 is attached to the door assembly, and everything between the core 400 and the door structure 300 (mechanical, electrical or other). Are connected. Alternatively, the decorative panel 700 may be attached to the completed core subassembly, and the core subassembly is then attached to the door structure 300. Then, the door assembly is ready to be assembled to the vehicle.

27, 28, and 29 are partial cross-sectional illustrations of one embodiment of a door assembly that uses a sliding lock assembly 900 to facilitate assembly. The sliding lock assembly 900 may place the lock in a first (“retracted”) position during transport and while the core module 400 is attached to the door structure 300. The lock assembly 900 can then be actuated or moved to a second (“assembled”) position.

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

Referring to FIG. 27, the locking mechanism 800 is coupled or attached to a sliding mechanism 920 (ie, a sled or slider) that allows the locking mechanism 800 to move while the core module 400 is assembled to the door structure 300. Make it possible. The sliding mechanism 920 is adapted to move laterally along two horizontal planes, eg, the x-axis and y-axis, but preferably the sliding mechanism 920 is adapted to move laterally within a single plane. It is good to be. At least a portion of the locking mechanism 800 can be adhesively attached to the sliding mechanism 920, welded, screwed, bolted, riveted, clipped, or attached by any other technique.

The sliding mechanism 920 may also be part of the locking mechanism 800 if necessary.

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 have a pair of track or rail systems 935 that engage the shape of the track system 930 of the core module 400. The sliding mechanism 920 can move the locking mechanism 800 from the retracted or first position shown in FIG. 27 to the second or assembled position 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 locking mechanism 800 from the first position to the second position. For example, a simple tool may be inserted through a hole where the locking mechanism 800 contacts the door structure 300. The tool is applied to engage the locking mechanism 800 and is used to operate (ie, pull) the locking mechanism 800 to a second or assembled position where the locking mechanism 800 is attached to the door structure 300. Also good.

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

With reference to FIGS. 30-32, the sliding lock assembly 1000 includes a sliding mechanism 1010 in communication with a handle or lever 1020 for operating the locking 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 shown in FIGS. The handle 1020 may be injection-molded integrally with the sliding mechanism 1010 as shown in the sectional view of FIG. Preferably, the sliding mechanism 1010 is coupled to the locking mechanism 800 using one or more legs or anchors 1010A (three shown) that are at least partially disposed within the locking mechanism 800 as shown in FIG. .

The operation of the lock assembly 1000 is similar to that described above with respect to FIGS. 27-29 except that the handle 1020 is used to operate the sliding mechanism 1010 and thus the locking mechanism 800. Of course, if necessary, a tool (not shown) can also be used to help move the sliding mechanism 1010 from the first position shown in FIG. 30 to the second position shown in FIG.

As noted above, the described level of integration can dramatically reduce the cost of the finished product door and complex assembly procedures. Errors in the assembly can be reduced if not eliminated. Since most functions can be tested before final assembly (ie, tested in advance), the cost of functional testing after final assembly can also be reduced or eliminated.

In addition, the use of plastic materials for the door assembly can reduce the overall weight, integrate more parts, more effectively shield noise, and increase design freedom. And design changes can be made at a lower cost (ie by using a replaceable insert in the injection molding tool).

Further, the placement of the reinforcement system and the seal system as already described facilitates the installation and assembly of the door system. In particular, the placement of the reinforcement and seal system facilitates access to many door components, including windows and window lift systems. Such an arrangement also allows functional testing of the door-operating components, most notably the window lift system, prior to the final installation of the door on the vehicle. Thus, valuable time and procurement concerns are greatly reduced.

Furthermore, the door system described herein reduces the number of individual components (ie, parts) and the assembly steps required to produce a finished door. Even the integration of the reinforced portion alone facilitates assembly of the parts, reduces the weight of the door, and allows functional testing of various assembled components and parts. Furthermore, the integrated parts are properly placed in place, thus reducing errors or leaks due to human work.

In other embodiments, the invention relates to:
1. Door system, including:
Door structure;
A body comprising one or more components installed thereon;
A first module having an upper cavity and a lower cavity, wherein the upper cavity is adapted to at least partially surround the first side of the glazing and the lower cavity is adapted to at least engage the body;
A second module adapted to at least partially surround the second side of the glazing, adapted to at least partially contact the upper cavity of the first module; and core A decorative panel adapted to at least partially cover the module.

2. The door system of claim 1, wherein the body includes one or more reinforcing portions disposed on a first side thereof.

3. 3. The door system according to claim 1 or 2, wherein the body further includes at least a glass moving groove disposed on a second side surface thereof.

4). 4. The door system according to claim 3, wherein the glass-moving groove installed on at least the second side surface of the body has an opening shape.

5). 5. The door system according to any one of items 1 to 4, wherein the one or more components are injection molded on a body.

6). 6. The door system according to any one of items 1 to 5, wherein the body includes one or more seals installed thereon.

7. The door system of claim 6, wherein the one or more seals are injection molded onto the body.

8). 8. The door system of any one of paragraphs 2 to 7, wherein the reinforcing portion includes a first flange and a second flange, each flange adapted to contact the first side of the body. Has been.

9. 9. The door system of any one of claims 2 to 8, wherein the reinforcing portion includes a first flange, a second flange, and a recessed portion between the flanges.

10. The door system of any one of paragraphs 2-9, wherein the reinforcing portion further includes an insertion portion provided therein, the insertion portion including one or more stiffening portions.

11. The door system according to any one of Items 2 to 10, wherein the reinforcing portion further includes a cover plate provided thereon, and a cavity is formed between the reinforcing portion and the cover plate.

12 The door system according to any one of Items 1 to 11, wherein the one or more components are a window adjuster, a window track, a window glass, a window switch, a door lock, a door handle, a door lock switch, Includes armrests, map pockets, impact bolsters, wire harnesses, speakers, window motors, external mirror motors, plugs, grommets or combinations thereof.

13. The door system according to any one of Items 6 to 12, wherein the one or more seals are a seal for a groove in which glass moves, a beltline seal, a seal for a lower window frame, a seal between a core and a frame, or the like. Including a combination of

14 14. The door system according to any one of items 1 to 13, wherein the one or more components are integrally formed with the body.

15. 15. The door system according to any one of items 1 to 14, wherein the one or more components are a window adjuster, a window track, an impact bolster, an air groove, a window motor housing, a map pocket, and a speaker box. , Plugs, grommets, or combinations thereof.

16. 16. The door system according to any one of items 1 to 15, wherein the body includes polypropylene.

17. The door system according to any one of Items 1 to 16, wherein the body is injection-molded from polypropylene.

18. 18. The door system according to any one of items 1 to 17, wherein the body includes one or more engineering resins.

19. 19. The door system according to any one of items 1 to 18, wherein the body is injection-molded from one or more engineering resins.

20. 20. The door system according to any one of items 1 to 19, wherein the body includes a polyamide resin, a polyester resin, a polynitrile resin, a polymethacrylate resin, a cellulose resin, a fluorine resin, a polyimide resin, polysulfone, polyacetal, poly One or more engineering resins selected from acetone, polyphenylene oxide, polyphenylene sulfide, styrene maleic anhydride, aromatic polyketone, and polycarbonate.

21. Item 21. The door system according to any one of Items 1 to 20, wherein the body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene isophthalate (PEI), PET / PEI copolymer. , Polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal polyester, polyoxyalkylene diimide diacid / polybutyrate terephthalic acid copolymer, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), meta From the group consisting of acrylonitrile-styrene copolymer, methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene styrene (ABS), derivatives thereof and mixtures or blends thereof. Is injection molded from one or more engineering resins to be-option.

22. 22. The door system according to any one of items 1 to 21, wherein the first module is adapted to be assembled on a door structure.

23. 23. The door system of any one of paragraphs 1 to 22, wherein the second module is adapted to be assembled on an upper portion of a core module and is at least a portion of the first module. Adapted to come into contact with.

24. 24. The door system according to any one of items 1 to 23, wherein the body is adapted to cover a lower cavity of the first module.

25. 25. The door system according to any one of items 1 to 24, further comprising a moisture / drying barrier installed on the second module and the body.

26. Door system, including:
Door structure;
At least one window glass;
A first module having one or more components installed thereon, the first module including:
Body with first and second sides;
A reinforced portion installed on the first side of the body; and a glass moving groove installed on the second side of the body, the glass moving groove having an opening shape;
A second module having an upper cavity and a lower cavity, wherein the upper cavity is adapted to at least partially surround the first side of the glazing and the lower cavity is adapted to at least engage the first module Has been;
A third module adapted to at least partially surround the second side of the glazing, and adapted to at least partially contact the upper cavity of the second module: and A decorative panel adapted to cover one module.

27. 26. The door system of clause 26, wherein the first side of the body faces the interior of the vehicle.

28. 28. The door system according to item 26 or 27, wherein the groove in which the glass moves extends at least beyond the belt line of the body.

29. 29. The door system according to any one of items 26 to 28, wherein a groove in which the glass moves provided at least on the second side surface of the body has an opening shape.

30. 30. The door system of any one of items 26 to 29, wherein the one or more components are injection molded onto the body.

31. 26. The door system of any one of paragraphs 26 to 30, wherein the body includes one or more seals disposed thereon.

32. 32. The door system of paragraph 31, wherein the one or more seals are injection molded onto the body.

33. 33. The door system of any one of paragraphs 26 to 32, wherein the reinforcing portion includes a first flange and a second flange, each flange adapted to contact the first side of the body. Has been.

34. 34. The door system of any one of clauses 26 to 33, wherein the reinforcing portion includes a first flange, a second flange, and a recessed portion between the flanges.

35. The door system of paragraph 34, wherein the reinforcing portion further includes an insertion portion disposed therein, the insertion portion including one or more stiffening portions.

36. 36. The door system of paragraph 35, wherein the reinforced portion further includes a cover plate disposed thereon, and a cavity is formed between the reinforced portion and the cover plate.

37. 26. The door system according to any one of items 26 to 36, wherein the one or more components are a window adjuster, a window track, a window glass, a window switch, a door lock, a door handle, a door lock switch, Includes armrests, map pockets, impact bolsters, wire harnesses, speakers, window motors, external mirror motors, plugs, grommets or combinations thereof.

38. 32. The door system of paragraph 31, wherein the one or more seals include a glass moving groove seal, a beltline seal, a lower window frame seal, a core-to-frame seal, or a combination thereof.

39. 40. The door system according to any one of items 26 to 38, wherein the at least one component is injection-molded on the body.

40. 40. The door system according to any one of items 26 to 39, wherein the one or more components are a window adjuster, a window track, an impact bolster, an air groove, a window motor housing, a map pocket, and a speaker box. , Plugs, grommets, or combinations thereof.

41. Item 41. The door system according to any one of Items 26 to 40, wherein the body includes polypropylene.

42. Item 26. The door system according to any one of Items 26 to 41, wherein the body is injection-molded from polypropylene.

43. The door system according to any one of items 26 to 42, wherein the body includes one or more engineering resins.

44. The door system according to any one of items 26 to 43, wherein the body is injection-molded from one or more engineering resins.

45. Item 46. The door system according to any one of Items 26 to 44, wherein the body includes a polyamide resin, a polyester resin, a polynitrile resin, a polymethacrylate resin, a cellulose resin, a fluorine resin, a polyimide resin, polysulfone, polyacetal, poly One or more engineering resins selected from polyactone, polyphenylene oxide, polyphenylene sulfide, styrene maleic anhydride, aromatic polyketone, and polycarbonate.

46. 46. The door system according to any one of items 26 to 45, wherein the body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET / PEI copolymer. , Polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal polyester, polyoxyalkylene diimide diacid / polybutyrate terephthalic acid copolymer, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), meta A group consisting of acrylonitrile-styrene copolymer, methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene styrene (ABS), derivatives thereof, and mixtures or blends thereof. Is injection molded from one or more engineering resins selected.

47. 47. A door system according to any one of clauses 26 to 46, wherein the second module is adapted to be assembled on a door structure.

48. 48. The door system of any one of paragraphs 26 to 47, wherein the third module is adapted to be assembled on an upper portion of the first module, and at least of the second module. Adapted to contact some.

49. Item 49. The door system of any one of Items 26 to 48, wherein the body is adapted to cover a lower cavity of the second module.

50. 50. The door system of any one of paragraphs 26 to 49, further comprising a moisture / drying barrier adapted to cover the second module and the third module.

51. Item 26. The door system of any one of Items 26 to 50, wherein the one or more window tracks are injection molded on the second side of the body.

52. Item 26. The door system according to any one of Items 26 to 51, wherein the one or more impact bolsters are injection-molded on a first side surface of the body.

53. Item 26. The door system according to any one of Items 26 to 52, wherein the window glass slides between a first module and a second module.

54.
Door system, including:
Door structure;
At least one window glass;
A first module having one or more components installed thereon, the first module including:
Body with first and second sides;
A reinforced portion installed on the first side of the body; and a glass moving groove installed on the second side of the body, the glass moving groove having an opening shape;
A second module adapted to enclose the interior surface of the door structure, the second module having an annular housing with a support portion installed therethrough, thereby providing an upper cavity, a lower cavity Prescribe;
A third module adapted to at least partially surround the second side of the glazing, and adapted to at least partially contact the upper cavity of the second module: and first Decorative panel adapted to cover the module.

55. 54. The door system of paragraph 54, wherein the glass moving groove extends beyond at least the belt line of the first module.

56. 54. The door system according to Item 54 or 55, wherein a groove in which the glass moves at least installed on the second side surface of the first module has an opening shape.

57. 56. The door system of any one of clauses 54 to 56, wherein the one or more components are injection molded on a first module.

58. 58. The door system of any one of clauses 54 to 57, wherein the first module includes one or more seals disposed thereon.

59. 54. The door system of any one of clauses 54 to 58, wherein the one or more seals are injection molded onto the first module.

60. 60. The door system of any one of clauses 54 to 59, wherein the reinforcing portion includes a first flange and a second flange, each flange contacting a first side of the first module. Have been adapted.

61. 61. The door system of any one of clauses 54 to 60, wherein the reinforcing portion includes a first flange, a second flange, and a recessed portion between the flanges.

62. The door system of paragraph 61, wherein the reinforcing portion further includes an insertion portion disposed therein, the insertion portion including one or more stiffening portions.

63. 62. The door system of paragraph 62, wherein the reinforced portion further includes a cover plate disposed thereon, and a cavity is formed between the reinforced portion and the cover plate.

64. The door system according to any one of Items 54 to 63, wherein the one or more components are a window adjuster, a window track, a window glass, a window switch, a door lock, a door handle, a door lock switch, Includes armrests, map pockets, impact bolsters, wire harnesses, speakers, window motors, external mirror motors, plugs, grommets or combinations thereof.

65. 64. The door system of clause 64, wherein the at least one or more components are injection molded onto the first module.

66. The door system according to any one of Items 54 to 65, wherein the one or more components are a window adjuster, a window track, an impact bolster, an air groove, a window motor housing, a map pocket, and a speaker box. , Plugs, grommets, or combinations thereof.

67. 54. The door system of any one of clauses 54 to 66, wherein the second module includes polypropylene.

68. 68. The door system of any one of clauses 54 to 67, wherein the second module is injection molded from polypropylene.

69. The door system according to any one of Items 54 to 68, wherein the second module includes one or more engineering resins.

70. The door system according to any one of Items 54 to 69, wherein the second module is injection-molded from one or more engineering resins.

71. 54. The door system according to any one of items 54 to 70, wherein the second module includes a polyamide resin, a polyester resin, a polynitrile resin, a polymethacrylate resin, a cellulose resin, a fluororesin, a polyimide resin, polysulfone, One or more engineering resins selected from polyacetal, polyacetone, polyphenylene oxide, polyphenylene sulfide, styrene maleic anhydride, aromatic polyketone, and polycarbonate.

72. Item 54. The door system according to any one of Items 54 to 71, wherein the second module includes polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene isophthalate (PEI), PET. / PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystalline polyester, polyoxalkylene diimide diacid / polybutyrate terephthalic acid copolymer, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS) ), Methacrylonitrile-styrene copolymer, methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene styrene (ABS), derivatives thereof and mixtures or blends thereof Is injection molded from one or more engineering resins selected from that group.

73. 75. The door system of any one of clauses 54 to 72, wherein the second module is adapted to be assembled on a door structure.

74. 74. The door system of any one of clauses 54 to 73, wherein the third module is adapted to be assembled on an upper portion of the first module, and at least of the second module. It is made to come into contact with a part.

75. Item 54. The door system of any one of Items 54 to 74, wherein the first module is adapted to cover a lower cavity of the second module.

76. 54. The door system of any one of clauses 54 to 75, wherein the one or more window tracks are injection molded on the second side of the first module.

77. 78. The door system of any one of clauses 54 to 76, wherein the one or more impact bolsters are injection molded on a first side of a first module.

78. The door system according to any one of Items 54 to 77, wherein the window glass slides between a first module and a second module.

Those skilled in the art can use the door system described herein as a complete system, or individual components thereof can be individual mini-systems or two or more components integrated, if desired. It will be appreciated that they can be used individually as modular type units.

Certain embodiments and features are described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that a range combining any lower limit and any upper limit is contemplated unless otherwise noted. Certain lower limit values, upper limit values and ranges are recited in the claims. All numerical values are defined as “about” or “approximately” and should be taken into account experimental errors and deviations envisioned by those skilled in the art.

Various terms are defined. If a term used in the claims is not defined in the specification, it should be defined in the broadest sense that a person skilled in the art would have given to the term described in at least one publication or patent document. . In addition, all other patents cited in this specification, including all patents, test procedures, and priority documents, are legal systems that are allowed to be incorporated herein as long as they do not conflict with this specification. All of which are incorporated herein by reference.

The descriptions in this specification are intended to illustrate embodiments of the invention, and other and further embodiments of the invention may be devised without departing from the basic scope thereof. Therefore, the scope of the present invention is determined by the claims.

FIG. 1 is a schematic explanatory diagram of a conventional door used in the prior art. FIG. 2 is a schematic illustration of a conventional door including a pre-assembled mounting panel used in the prior art. FIG. 3 is a schematic illustration of an embodiment of an integrated door system in one or more embodiments described herein. FIG. 4 is a schematic illustration of an embodiment of a door structure in one or more embodiments described herein. FIG. 5A is a schematic illustration of an outer core module in one or more embodiments described herein. FIG. 5B is an enlarged cross-sectional view along the line AA of the groove in which the glass of FIG. 5A moves. FIG. 6 is a schematic illustration of a first side of a core module in one or more embodiments described herein. FIG. 7 is a schematic diagram of a second side of the core module shown in FIG. 6, and FIG. 6 is a schematic illustration of the core module in one or more embodiments described herein. FIG. 8A is a schematic illustration of an example embodiment of a window decoration panel in one or more embodiments described herein. FIG. 8B is an enlarged cross-sectional view along the line BB of the window decoration panel of FIG. 8A. FIG. 8C is an enlarged cross-sectional view taken along line CC of the window decorative panel of FIG. 8A. FIG. 9 is a schematic illustration of a reinforcement portion in one or more embodiments described herein. FIG. 10 is a schematic explanatory diagram of a reinforced portion to which a cover plate is attached. FIG. 11 is a schematic cross-sectional view of a reinforced portion having one or more clips for fixing the cover plate thereon. FIG. 12 is a schematic cross-sectional view of a reinforced portion having a special end shape formed thereon. FIG. 13 is a schematic explanatory diagram of a reinforced portion having one or more reinforcing structures thereon. FIG. 14 is a schematic explanatory view of a reinforcing part having one or more reinforcing structures disposed thereon, and the reinforcing structure has a diamond shape pattern. FIG. 15 is a schematic explanatory view of a reinforcing portion having one or more reinforcing structures disposed thereon, and the reinforcing structure has a honeycomb shape pattern. FIG. 16 is a schematic illustration of a reinforcement portion having one or more indentations for attachment to an insertion portion in one or more embodiments described herein. FIG. 17 is a schematic illustration of a reinforcement portion having one or more holes for attachment to an insertion portion in one or more embodiments described herein. FIG. 18 is an enlarged schematic view of a reinforcement portion having one or more slits or openings for attachment to an insertion portion in one or more embodiments described herein. FIG. 19 is an enlarged partial cross-sectional illustration of a reinforced portion having one or more clips provided thereon for engaging and retaining a cover plate in one or more embodiments described herein. It is. FIG. 20 is a schematic illustration of a cover plate having one or more clips formed thereon to secure the cover plate to the reinforcement portion in one or more embodiments described herein. FIG. 21 is a schematic illustration of one embodiment of a window lift system in one or more embodiments described herein. 22 is an enlarged partial cross-sectional view of the motor housing shown in FIG. FIG. 23 is an enlarged partial sectional view of the window track shown in FIG. FIG. 24 is a schematic illustration of another embodiment of a window lift system in one or more embodiments described herein. 25 is an enlarged partial cross-sectional view of the motor housing shown in FIG. FIG. 26 is an enlarged partial sectional view of the window track shown in FIG. FIG. 27 is a schematic illustration of a side view of an embodiment of a lock assembly having a sliding mechanism for the assembly, the sliding mechanism being located in a pre-assembled position. FIG. 28 is a schematic side view of the sliding mechanism shown in FIG. 27, and the sliding mechanism is disposed in a preassembled position. FIG. 29 is an enlarged partial sectional view taken along line AA of the sliding mechanism shown in FIG. FIG. 30 is a schematic side view of another embodiment of a lock assembly having a sliding mechanism for the assembly, wherein the sliding mechanism is located in a pre-assembled position. FIG. 31 is a schematic side view of the sliding mechanism shown in FIG. 30, and the sliding mechanism is disposed in a pre-assembled position. FIG. 32 is an enlarged partial cross-sectional view along the line AA of the sliding mechanism shown in FIG.

Claims (60)

Door system, including:
Door structure;
A body comprising one or more components installed thereon;
A first module having an upper cavity and a lower cavity, wherein the upper cavity is adapted to at least partially surround the first side of the glazing and the lower cavity is adapted to at least engage the body;
A second module adapted to at least partially surround the second side of the glazing, adapted to at least partially contact the upper cavity of the first module; and core A decorative panel adapted to at least partially cover a module. The door system of claim 1, wherein the body includes one or more reinforced portions disposed on a first side thereof. 3. The door system according to claim 1 or 2, wherein the body further includes a glass moving groove disposed on at least a second side surface thereof. 4. The door system according to claim 3, wherein the glass-moving groove installed on at least the second side surface of the body has an opening shape. 5. The door system according to any one of claims 1 to 4, wherein the one or more components are injection molded on a body. 6. The door system according to any one of claims 1 to 5, wherein the body includes one or more seals disposed thereon. 7. The door system of claim 6, wherein the one or more seals are injection molded onto the body. 8. A door system according to any one of claims 2 to 7, wherein the reinforcing portion includes a first flange and a second flange, each flange adapted to contact the first side of the body. The door system. 9. The door system according to any one of claims 2 to 8, wherein the reinforcing portion includes a first flange, a second flange, and a recessed portion between the flanges. 10. A door system according to any one of claims 2 to 9, wherein the reinforcing portion further includes an insertion portion provided therein, the insertion portion including one or more stiffening portions. . 11. The door system according to any one of claims 2 to 10, wherein the reinforcing part further includes a cover plate provided thereon, and a cavity is formed between the reinforcing part and the cover plate. The door system according to any one of claims 1 to 11, wherein the one or more components are a window adjuster, a window track, a window glass, a window switch, a door lock, a door handle, a door lock switch, The door system comprising an armrest, a map pocket, an impact bolster, a wire harness, a speaker, a window motor, an external mirror motor, a plug, a grommet, or a combination thereof. The door system according to any one of claims 6 to 12, wherein the one or more seals are a seal for a groove in which glass moves, a beltline seal, a seal for a lower window frame, a seal between a core and a frame, or the like. The door system comprising a combination of: 14. The door system according to any one of claims 1 to 13, wherein the one or more components are integrally formed with a body. 15. The door system according to any one of claims 1 to 14, wherein the one or more components are a window adjuster, a window track, an impact bolster, an air groove, a window motor housing, a map pocket, and a speaker box. The door system comprising a plug, a grommet, or a combination thereof. 16. A door system according to any one of claims 1 to 15, wherein the body comprises polypropylene. 17. A door system according to any one of claims 1 to 16, wherein the body is injection molded from polypropylene. 18. A door system according to any one of claims 1 to 17, wherein the body includes one or more engineering resins. 19. The door system according to any one of claims 1 to 18, wherein the body is injection molded from one or more engineering resins. The door system according to any one of claims 1 to 19, wherein the body includes a polyamide resin, a polyester resin, a polynitrile resin, a polymethacrylate resin, a cellulose resin, a fluorine resin, a polyimide resin, polysulfone, polyacetal, poly The door system comprising one or more engineering resins selected from acetone, polyphenylene oxide, polyphenylene sulfide, styrene maleic anhydride, aromatic polyketone, and polycarbonate. 21. The door system according to any one of claims 1 to 20, wherein the body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene isophthalate (PEI), PET / PEI copolymer. , Polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal polyester, polyoxyalkylene diimide diacid / polybutyrate terephthalic acid copolymer, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), meta The group consisting of acrylonitrile-styrene copolymer, methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene styrene (ABS), derivatives thereof and mixtures or blends thereof Is injection molded from one or more engineering resins et selected, the door system. 22. A door system according to any one of claims 1 to 21, wherein the first module is adapted to be assembled on a door structure. 23. The door system according to any one of claims 1 to 22, wherein the second module is adapted to be assembled on an upper portion of a core module and is at least part of the first module. Said door system adapted to contact with. 24. The door system according to any one of claims 1 to 23, wherein the body is adapted to cover a lower cavity of the first module. 25. The door system according to any one of claims 1 to 24, further comprising a moisture / drying barrier installed on the second module and the body. Door system, including:
Door structure;
At least one window glass;
A first module having one or more components installed thereon, the first module including:
Body with first and second sides;
A reinforced portion installed on the first side of the body; and a glass moving groove installed on the second side of the body, the glass moving groove having an opening shape;
A second module having an upper cavity and a lower cavity, wherein the upper cavity is adapted to at least partially surround the first side of the glazing and the lower cavity is adapted to at least engage the first module Has been;
A third module adapted to at least partially surround the second side of the glazing, and adapted to at least partially contact the upper cavity of the second module: and A decorative panel adapted to cover one module. 27. The door system of claim 26, wherein the first side of the body is directed into the interior of the vehicle. 28. The door system according to claim 26 or claim 27, wherein the glass moving groove extends beyond at least a belt line of the body. 29. The door system according to any one of claims 26 to 28, wherein the glass moving groove provided at least on the second side surface of the body has an opening shape. 30. The door system according to any one of claims 26 to 29, wherein the one or more components are injection molded onto a body. 31. A door system according to any one of claims 26 to 30, wherein the body includes one or more seals disposed thereon. 32. The door system of claim 31, wherein the one or more seals are injection molded onto the body. 33. A door system according to any one of claims 26 to 32, wherein the reinforcing portion includes a first flange and a second flange, each flange adapted to contact the first side of the body. The door system. 34. The door system according to any one of claims 26 to 33, wherein the reinforcing portion includes a first flange, a second flange, and a recessed portion between the flanges. 35. The door system of claim 34, wherein the reinforcing portion further includes an insertion portion disposed therein, and the insertion portion includes one or more stiffening portions. 36. The door system of claim 35, wherein the reinforcing portion further includes a cover plate disposed thereon, forming a cavity between the reinforcing portion and the cover plate. 37. The door system according to any one of claims 26 to 36, wherein the one or more components are a window adjuster, a window track, a window glass, a window switch, a door lock, a door handle, a door lock switch, The door system comprising an armrest, a map pocket, an impact bolster, a wire harness, a speaker, a window motor, an external mirror motor, a plug, a grommet, or a combination thereof. 32. The door system of claim 31, wherein the one or more seals include a glass moving groove seal, a beltline seal, a lower window frame seal, a core-to-frame seal, or a combination thereof. . 39. The door system according to any one of claims 26 to 38, wherein the at least one or more components are injection molded onto a body. 40. The door system according to any one of claims 26 to 39, wherein the one or more components are a window adjuster, a window track, an impact bolster, an air groove, a window motor housing, a map pocket, and a speaker box. The door system comprising a plug, a grommet, or a combination thereof. 41. The door system according to any one of claims 26 to 40, wherein the body comprises polypropylene. 42. The door system according to any one of claims 26 to 41, wherein the body is injection molded from polypropylene. 43. The door system according to any one of claims 26 to 42, wherein the body includes one or more engineering resins. 44. The door system according to any one of claims 26 to 43, wherein the body is injection molded from one or more engineering resins. 45. The door system according to any one of claims 26 to 44, wherein the body includes a polyamide resin, a polyester resin, a polynitrile resin, a polymethacrylate resin, a cellulose resin, a fluorine resin, a polyimide resin, polysulfone, polyacetal, poly The door system comprising one or more engineering resins selected from acetone, polyphenylene oxide, polyphenylene sulfide, styrene maleic anhydride, aromatic polyketone, and polycarbonate. 46. The door system according to any one of claims 26 to 45, wherein the body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET / PEI copolymer. , Polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal polyester, polyoxyalkylene diimide diacid / polybutyrate terephthalic acid copolymer, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymer (AS), meta Consists of acrylonitrile-styrene copolymer, methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene styrene (ABS), derivatives thereof and mixtures or blends thereof. Is injection molded from one or more engineering resins selected from, the door system. 47. A door system according to any one of claims 26 to 46, wherein the second module is adapted to be assembled on a door structure. 48. The door system of any one of claims 26 to 47, wherein the third module is adapted to be assembled on an upper portion of the first module, and at least of the second module. The door system adapted to contact a portion. 49. A door system according to any one of claims 26 to 48, wherein the body is adapted to cover a lower cavity of the second module. 50. The door system according to any one of claims 26 to 49, further comprising a moisture / drying barrier adapted to cover the second module and the third module. 51. The door system according to any one of claims 26 to 50, wherein the one or more window tracks are injection molded on the second side of the body. 52. The door system according to any one of claims 26 to 51, wherein the one or more impact bolsters are injection molded on a first side of the body. 53. The door system according to any one of claims 26 to 52, wherein the window glass slides between a first module and a second module. Door system, including:
Door structure;
At least one window glass;
A first module having one or more components installed thereon, the first module including:
Body with first and second sides;
A reinforced portion installed on the first side of the body; and a glass moving groove installed on the second side of the body, the glass moving groove having an opening shape;

A second module adapted to enclose the interior surface of the door structure, the second module having an annular housing with a support portion installed therethrough, thereby providing an upper cavity, a lower cavity Prescribe;
A third module adapted to at least partially surround the second side of the glazing, and adapted to at least partially contact the upper cavity of the second module: and first Decorative panel adapted to cover the module. 55. The door system of claim 54, wherein the glass moving groove extends beyond at least a belt line of the first module. 56. The door system according to claim 54 or claim 55, wherein the glass moving groove at least installed on the second side surface of the first module has an opening shape. 57. The door system according to any one of claims 54 to 56, wherein the one or more components are injection molded onto a first module. 58. The door system of any one of claims 54 to 57, wherein the first module includes one or more seals installed thereon. 59. A door system according to any one of claims 54 to 58, wherein the one or more seals are injection molded onto a first module. 60. The door system of any one of claims 54 to 59, wherein the reinforcing portion includes a first flange and a second flange, each flange contacting a first side of the first module. Said door system being adapted to.

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