KR20080098540A - Door assembly with integrated window sealing system - Google Patents

Abstract

The present invention door structure; A body in which one or more components are disposed; A first module having an upper cavity configured to at least partially surround a first side of the window glass and a lower cavity configured to at least partially engage the body; A second module configured to at least partially surround a second side of the window glass and configured to at least partially contact an upper cavity of the first module; And a trim module configured to at least partially cover the core module.

Description

DOOR ASSEMBLY WITH INTEGRATED WINDOW SEALING SYSTEM

The present invention relates to a door system. More specifically, embodiments of the present invention relate to automobile, in particular vehicle door systems, such as cars and trucks.

Conventional automotive doors include a number of individual pieces that are assembled to a frame or shell. Automotive doors can have between 50 and 100 individual parts, depending on the vehicle and the optional package. Such components may include various hardware and electrical components and seals. Exemplary hardware components may include handles, mirrors, window adjusters, window tracks, windows, door locks, and impact bolsters. Certain electrical components may include wire harnesses, speakers, window motors, and external mirror motors. Exemplary sealing parts include glass run channels, beltline seals, lower chassis seals, plugs, grommets, and body-to-door seals.

Each part is usually supplied by another vendor or supplier, some of which are known in the industry as Tier 1, Tier 2 and Tier 3 suppliers. In most cases, Original Equipment Manufacturers (OEMs) produce door frames and outer skins that are typically stamped separately in cold rolled steel, welded together, and painted to provide a door shell. The frame and skin can be stamped from one blank to form a door shell. Numerous discrete components from Tier 1, 2 and 3 suppliers are typically assembled on OEM door shells on OEM assembly lines.

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

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

Thus, the door fabrication process is intensive and time consuming. The assembly process also requires a high degree of logistics planning to ensure that all the parts are available and assembled in the correct manner and order. Other incidental costs include ordering, storage, management, transportation, functional testing and quality control, in addition to the floor space for assembling the various components. All of these factors eventually make the final product very expensive.

Initial cost reduction and component integration ideas attempted to use prefabricated mounting panels in which all or part of the hardware and electrical components were assembled, as shown in FIG. 2. 2 schematically depicts a conventional door 200 having a prefabricated mounting panel 210. Inner door handle 215, handle link cable 220, window motor 225, window adjuster 230, speaker 235, window guide rail 240, drum pulley 245, cable 250, And a number of parts including the door lock unit 260 are assembled to the mounting panel 210.

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

Some examples of prefabricated mounting panels are believed to be productive. However, the number of parts and required assembly time remain unchanged. The cost benefits for OEMs are largely due to the logistics cost savings absorbed by phased suppliers.

Thus, there is a need for a door assembly with fewer individual parts. There is also a need for door assemblies that minimize the number of individual components that require assembly.

The present invention is a door system,

a) door structure,

b) a body in which one or more parts are placed,

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

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

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

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

2 is a schematic view of a conventional door having a prefabricated mounting panel used in the prior art;

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

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

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

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

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

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

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

8B is an enlarged cross-sectional view of the window trim module on line B-B in FIG. 8A;

8C is an enlarged cross-sectional view of the window trim module on line C-C in FIG. 8A;

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

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

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

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

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

14 is a schematic representation of an exemplary reinforcing member in which one or more reinforcing structures having a diamond-like pattern are disposed;

15 is a schematic representation of an exemplary reinforcing member in which one or more reinforcing structures having a honeycomb pattern are disposed;

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

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

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

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

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

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

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

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

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

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

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

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

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

29 is an enlarged fragmentary sectional view taken along line A-A of the sliding mechanism shown in FIG. 28;

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

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

32 is an enlarged fragmentary sectional view taken along line A-A of the sliding mechanism shown in FIG. 31;

Detailed description will now be provided. Each of the claims defines an individual invention, which is considered to include equivalents of various elements or limitations specified in the claims for the purpose of infringement. Depending on the context, all the following references to "invention" may refer to only certain embodiments in some cases. In other instances, references to "invention" will be considered to refer to the subject matter described in one or more claims rather than the entirety of the claims. While each of the inventions, including specific embodiments, variations, and examples, will now be described in more detail below, the invention is included to enable those skilled in the art to make and use the information when the information is combined with the available information and techniques. It is not limited to these Examples, modifications, or examples.

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

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

As used herein, the term "door" is intended to encompass any door. For example, the term “door” may be hinged, sliding, lifting or any other for any vehicle, including vehicles, trucks, SUVs, trains, boats, airplanes, etc., whether personal, leisure or commercial. It may refer to one or more passenger doors, lift gates, tailgates and hatchbacks that perform alternative opening and closing movements.

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

As shown in FIG. 3, the trim panel 700 includes one or more speaker covers 710, armrests 720, door handles 730, window switches 740, door lock switches 750, side mirror controls 760. ), Map pocket 770 and inner light 780 may be further provided. Trim panel 700 may provide a housing or substrate to which other electrical, mechanical and sealing components are attached, integrally molded or insert molded. Exemplary components include airbags, air vents, switches; Door handles; Door locks; elbow rest; Map pockets; Speaker cover or grille; speaker; Beltline seals; plug; Grommets; And core-to-frame seals. Exemplary switches include window glass controls, window locks, exterior mirror positioning controls, door locks, seat positioning controls, and stereo controls.

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

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

The door structure 300 has a first side or interior side 310 facing the passenger compartment of the vehicle. The inner side 310 of the door structure 300 may have a concave cavity 315, which at least a portion of the core module 400 may be concave cavity of the door structure 300 when assembled. It is sized and shaped to resemble the dimensions of core module 400 to fit in 315. In one or more embodiments, the core module 400 has a peripheral seal (not shown in this figure) that can be integrally formed together or attached separately. This seal creates a wet / dry barrier between the door structure 300 and the core module 400, assists in shaping-free assembly formation, assists in reducing noise transfer, and assists in compensation of thermal expansion. The door structure 300 also has a second side or outer side (not shown in this figure) to which side mirrors and external door handles (not shown in this figure) can be attached. As used herein, the term "interior" refers to the orientation or direction towards the interior or passenger compartment of the vehicle, and the term "exterior" refers to the orientation or orientation facing away from the interior or passenger compartment of the vehicle. Refers to.

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

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

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

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

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

Still referring to FIG. 5B, it is preferable that the pillar A side of the lower portion 352A has an “L” shaped profile, such as the pillar B side of the lower profile 35B. The “L” shaped profile 355 is in contact with the outer (ie outer) periphery of the window glass. As will be discussed in more detail later, the core module 400 may be configured with a complementary profile (ie, open or “L”) such that the matching profile contacts the inner (ie, inner) periphery of the window glass to guide the window glass upon assembly. "Shaped profile). Such a sealing system comprises a method in which opposing profiles (ie, seals) on the upper portion 351 of the window trim module 325 and the glass run channel 350 work together to form a seal on the upper portion of the window glass. similar.

Considering the core module 400 in more detail, FIG. 6 is a schematic diagram of a core module 400 in accordance with one or more embodiments herein. As mentioned above, the core module 400 includes one or more hardware components, electrical components, and sealing members (ie, "seals"). Exemplary components assembled to the core module 400 include window adjusters, motors, tracks, impact bolsters, wire harnesses, speaker boxes or receptacles, speakers, window motors, external mirror motors, beltline seals, plugs, grommets, and Core to frame seals are included, but are not limited to these. However, for simplicity and ease of illustration, the core module 400 may include one or more bolster or crash pads 410, a speaker box 425, a window track 440, a motor support 445, a window in FIG. 6. It is shown having glass 460, beltline seal 465, and glass run channel 470. It should be appreciated that the core module 400 may have any other component that is conventional in automotive 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 (not shown) for heating or cooling.

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

The side bolster 410 may be a foam member such as a foam block. Side bolster 410 may also be 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 double shot molded into the core module 400 using a multi-injection molding technique.

In one or more embodiments, the core module 400 further includes a reinforcing member 450. The reinforcement member 450 adds strength and rigidity to the core module 400 and the entire door system upon assembly. As mentioned above, conventional doors have a reinforcing bar attached to the door frame. In the embodiment shown in FIG. 6, the core module 400 and the reinforcement member 450 can be integrally formed to reduce the number of parts in the door and / or to test the installation and function of the door assembly, in particular the window lift system. It may be assembled to the core module 400 to facilitate. The reinforcement member 450 may be disposed on an inner side (“first side”) of the core module 400 or on an outer side (“second side”) of the core module 400. The reinforcement member 450 is shown on the inner side of the core module 400 in FIG. 6.

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

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

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

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

The integration of the glass run channel 470 and the beltline reinforcement integration (ie, the reinforcement member 450) to the core module 400 are complete of the window lift system including the window glass 460 as shown in FIG. 6. Pre-installation can be allowed. The use of internal and external core modules allows the complete glass run channel to be fully integrated into the door module and pre-tested. A small number of parts need to be supplied to the assembly line and assembled on the assembly line. Thus, the window mechanism and control can be tested at the Tier 1 supplier of the assembly of core modules 400, thereby reducing the time and cost of OEM assembly. In order to test the correct function of the glass run channels, the glass run channels are composed of several extruded profiles of different shapes that are interconnected by corner moldings and / or connected to end moldings by welding or bonding. Deviation from the extruded two-dimensional shape of the profile can be produced in the post-treatment step.

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

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

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

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

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

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

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

In one or more embodiments above or elsewhere herein, the cover plate 455 can slide onto the reinforcing member 450. For example, cover plate 455 may have a profile edge configured to slide across the engagement profile edge of reinforcement member 450, as shown in FIG. 12. 12 shows a partial cross section of a cover plate 455 having a reinforcing member 450 and a profile edge configured to slide in conjunction with it. The profile protrusion 457 of the reinforcing member 450 engages with the profile edge 455A of the cover plate 455 acting as a rail or guide that the cover plate 455 can slide about. The gap between the profile protrusion 455A of the cover plate 455 and the profile protrusion 457 of the reinforcing member 450 is kept in place without the cover plate 455 slipping into place in the future without vibration or shaking during use. It is preferable that just enough.

In one or more embodiments above or elsewhere herein, the reinforcement member 450 may have an insert or reinforcement structure 458 disposed in the concave section 453 as shown in FIG. 13. 13 is a schematic view of an exemplary reinforcing member 450 having one or more inserts 458. Preferably, the insert 458 has one or more fingers or ribs 458A that can be formed by overmolding the plastic structure in the recessed section 453 of the reinforcing member 450. Insert 458 increases resistance to deformation. Insert 458 can provide significantly higher energy absorption and buckling resistance. After overmolding the insert 458, the cover plate 455 may be disposed thereon to provide additional strength as described above with reference to FIGS. 10-12.

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

In one or more embodiments above or elsewhere herein, the insert 458 is disposed within the concave section 453 of the reinforcing member 450 using various techniques, such as those shown in FIGS. 16-18. Or it can be attached to this concave section. Each of FIGS. 16, 17, and 18 shows a schematic view of a reinforcing member 450 having various ways to hold or hold the insert 458. For example, the reinforcing member 450 may have one or more recesses or depressions 450A to provide location or fixation for at least a portion of the insert 458 as shown in FIG. 16. It can be provided. Accordingly, the insert 458 may have engagement projections (not shown) for fitting into the recess 450A of the reinforcing member 450 to contact the main body of the core module 400. Thus, the insert 458 can be held in place during assembly. If optional cover plate 455 is used, insert 458 may be held in place with recess 450A until cover plate 455 is secured in place.

In one or more embodiments above or elsewhere herein, one or more openings 450B may be formed in the concave section 453 of the reinforcing member 450, as shown in FIG. 17. The opening 450B allows the material of the insert 458 to flow through the reinforcing member 450 during the overmolding injection process. Thus, the material of the insert 458 stays in the reinforcing member 450 and is fixed in place.

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

In any of the embodiments described above with reference to FIGS. 16, 17, and 18, the insert 458 may be retained in place on the reinforcement section 450 and ready for use. Alternatively, the insert 458 may be held in place on the reinforcement section 450 for a time at which the adhesive of the cover plate 455 will reach sufficient strength, thus placing the insert 458 in place during use. Relies on cover plate 455 to retain. In addition, the described embodiment may retain the insert 458 in place on the reinforcement section 450 for a time that the cover plate 455 may be mechanically fastened to the reinforcement member 450 or the core module 400. Let it be. Some examples of suitable mechanical fasteners include clip screws, heat stakes, rivets, blind rivets, and bolts. Spot welding can also be used.

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

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

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

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

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

The first extending member 524 is pivotally connected to the second extending member 526 at the pivot point 515. The first end 526A of the second elongate member 526 is in communication with the track 545. The second end 526B of the second elongate member 526 is attached to the adjuster 530. The track 545 may be integrally formed with the core module 400 through injection molding, or the track 545 may be a separate part, such as a railed member attached to or inserted into the core module 400. have. As the motor 505 drives the tooth member 522, the extension members 524, 526 work together via the pivot point 515 to elevate the adjuster 530 and the window glass 535. The window glass 535 is supported by the adjusting device 530 and the glass run channel.

24, 25 and 26 schematically illustrate another embodiment of the window lift system 600. 24 is a simplified schematic diagram of core module 400 with window lift system 600. The window lift system 600 includes a motor housing 620, and two or more adjusters 610A, 610B, each of which is configured on track members 615A, 615B. As shown in FIG. 25, a motor 605 is attached to the motor housing 620 on the core module 400. The motor housing 620 may be formed on the inner side or the outer side of the core module 400. Preferably, the motor housing or receptacle 620 is injection molded on 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 controls 610A, 610B by one or more fasteners and / or adhesive materials (not shown). Adjusters 610A, 610B and window tracks 615A, 615B may each be configured to have an engagement profile guided along the profile of each track when combined, as shown in FIG. 26.

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

material

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

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

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

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

d) polymethacrylate resins such as polymethyl methacrylate and polyethylacrylate;

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

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

g) polyimide resins such as aromatic polyimides;

h) polysulfones;

i) polyacetal;

j) polyactone;

k) polyphenylene oxides and polyphenylene sulfides;

l) styrene-maleic anhydride;

m) aromatic polyketones;

n) polycarbonate (PC);

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

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

In one or more embodiments above or elsewhere herein, the material may include one or more fillers for additional strength. The filler may be present in one embodiment in an amount of 0.001 wt% to 50 wt%, in another embodiment in an amount of 0.01 wt% to 25 wt%, and in another embodiment 0.2 It may be present in an amount of wt% to 10 wt%. Preferred fillers include titanium dioxide, silicon carbide, silica [and other oxides of silica (precipitated or not)], antimony oxide, lead carbonate, zinc white, lidofone, zircon, corundum, spinel, apatite, barites ( Barytes) powders, barium sulfate, magnesite, carbon black, dolomite, calcium carbonate, sand, glass beads, mineral masses, talc, and Mg, Ca, or Zn ions with Al, Cr, or Fe and hydrated or not CO ₃ and Hydrotalcite compounds of HPO ₄ ; Quartz powder, magnesium hydrogen carbonate, short glass fiber, long glass fiber, glass fiber, polyethylene terephthalate fiber, wollastonite, mica, carbon fiber, nanoclay, nanocomposite, magnesium hydroxide sulfate trihydrate, clay, alumina, and other Metal oxides and carbonates, metal hydroxides, chromium, phosphorus and brominated flame retardants, antimony trioxide, silicon, and any combinations and mixtures thereof, including, but not limited to. Other exemplary 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.

The material may also include nanocomposites that are a mixture of a polymer and one or more organic-clays. Exemplary organo-clays include ammonium, first alkylammonium, second alkylammonium, third alkylammonium, fourth alkylammonium, aliphatic, aromatic or arylaliphatic amines, phosphonium derivatives of phosphines or sulfides or aliphatic, aromatic or aryl And one or more of sulfonium derivatives of aliphatic amines, phosphines or sulfides. In addition, the organo-clay may be montmorillonite, sodium montmorillonite, calcium montmorillonite, magnesium montmorillonite, nontronite, Weidelite, volconscote, laponite, hectorite, saponite , Soconite, margotite, kenyatite, sovokite, svindordite, stevensite, vermiculite, halosite, aluminum oxide, hydrotalcite, illite, recolite, tarosobite, radiciite and / or May be selected from one or more of florin mica.

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

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

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

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

In one or more embodiments above or elsewhere herein, the plastomer may be an ethylene derived unit and a copolymer of at least one of C 3 to C 10 α-olefin derived units. Preferably, the copolymer has a density of less than 0.915 g / cm 3. The amount of comonomer (C3 to C10 α-olefin derived unit) present in the plastomer is 2 wt% to 35 wt% in one embodiment, 5 wt% to 30 wt% in another embodiment, and 15 wt% to another embodiment. 25 wt%, and in another embodiment 20 wt% to 30 wt%.

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

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

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

In addition to the materials and polymers described above, areas or components that need to have sealing properties include one or more thermoplastic vulcanizates (TPV), thermoplastic elastomers (TPE), thermoplastic olefins (TPO), polyurethanes (PU), or EPR or EPDM. Elastomers such as can be used. These materials can be used in a dense (non-foamed) state or in a foamed state. Most preferably, TPV is selected due to the inherent mechanical properties that provide excellent sealing performance and injection molding capability. Another aspect of these materials would be the commercialization of structural and sealing materials or the ability to adhere to each other. The material of the structural and / or sealing system can be functionalized or have secondary additives or components added to the material to provide good adhesion.

Assembly order

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

In the assembly line, the completed core sub-assembly is attached to the door structure 300, the trim panel 700 is attached to the assembly, and then all connections between the core 400 and the door structure 300 (mechanical and electrical Or otherwise). Alternatively, trim panel 700 may be attached to the finished core sub-assembly, which is then attached to door structure 300. The door assembly is then ready to be assembled to the vehicle.

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

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

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

As shown in FIG. 29, the core module 400 may have 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 track or rail system 935 having an engagement profile for engaging with the profile of the track system 930 of the core module 400. The sliding mechanism 920 may be moved from the first position or retracted position shown in FIG. 27 to the second position or assembled position shown in FIG. 28 after the core module 400 is attached to the door structure 300. .

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

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

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

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

As mentioned above, the degree of integration described can significantly reduce the cost and assembly complexity of the finished door. Assembly errors are not eliminated but are reduced. Since the majority of the functionality can be tested before final assembly (ie pre-testing), the cost of functional testing after final assembly is also reduced or eliminated. In addition, the use of plastic materials in door assembly can provide lower overall weight, better component integration, improved noise rejection, and greater design freedom, ie, by using replaceable inserts in injection molding tools. It will allow for design variations.

In addition, the described arrangement of the reinforcement sections and the seal system allows for easy installation and assembly of the door system. In particular, the placement of the reinforcement sections and the seal system provides easy access to the various parts of the door, including the window and the window lift system. This arrangement also allows the operating parts of the door, in particular the window lift system, to be functionally tested before the final installation of the door to the vehicle. Thus, valuable time and logistics problems are significantly reduced.

In addition, the provided door system reduces the number of assembly steps and individual components (ie parts) required to manufacture the finished door. The integration of the reinforcement sections alone makes the assembly of parts easier, reduces the weight of the door and enables the functional testing of the various assembled components and parts. In addition, the integrated parts can be placed correctly, thus reducing human error and omission.

In another embodiment, the present invention relates to the following:

1. In a door system,

Door structure,

Body in which one or more parts are placed,

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

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

A trim module configured to at least partially cover the core module

Door system.

2. The method of paragraph 1,

The body includes at least one reinforcing member disposed on the first side thereof.

Door system.

3. Paragraph 1 or 2 above,

The body further comprises a glass run channel disposed at least on its second side.

Door system.

4. The method of clause 3,

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

Door system.

5. The method according to any one of items 1, 2, 3 or 4,

The at least one component is injection molded on the body

Door system.

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

At least one seal is disposed on the body.

Door system.

7. The method of clause 6, wherein

The at least one seal is injection molded on the body

Door system.

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

The reinforcing member comprises a first flange and a second flange, each flange configured to be in contact with the first side of the body;

Door system.

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

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

Door system.

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

The reinforcing member further comprises an insert disposed therein, wherein the insert comprises one or more reinforcing members.

Door system.

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

The reinforcing member further comprises a cover plate disposed thereon to form a hollow cavity between the reinforcing member and the reinforcing member.

Door system.

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

The one or more components may include window adjusters, window tracks, window glasses, window switches, door locks, door handles, door lock switches, armrests, map pockets, impact bolsters, wire harnesses, speakers, window motors, external mirror motors, plugs, Grommets, or combinations thereof

Door system.

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

Wherein said at least one seal comprises a glass run channel seal, a beltline seal, a lower chassis seal, a core to frame seal, or a combination thereof.

Door system.

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

The at least one component is integrally formed on the body

Door system.

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

The at least one component comprises a window adjuster, window track, impact bolster, air channel, window motor housing, map pocket, speaker box, plug, grommets, or combinations thereof.

Door system.

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

The body is characterized in that it comprises polypropylene

Door system.

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

The body is characterized in that the injection molding of polypropylene

Door system.

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

The body comprises at least one engineering resin

Door system.

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

The body is characterized in that the injection molding of one or more engineering resins

Door system.

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

The main body may be polyamide resin, polyester resin, polynitrile resin, polymethacrylate resin, cellulose resin, fluorine resin, polyimide resin, polysulfone, polyacetal, polyactone, polyphenylene oxide, polyphenylene sulfide, At least one engineering resin selected from the group consisting of styrene-maleic anhydride, aromatic polyketones, and polycarbonates.

Door system.

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

The main body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET / PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal poly Esters, polyoxalkylene diimide diacid / polybutyrate terephthalate copolymers, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymers (AS), methacrylonitrile-styrene copolymers Injection molding into at least one engineering resin selected from the group consisting of methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene-styrene (ABS), derivatives thereof, and mixtures or mixtures thereof.

Door system.

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

The first module is configured to be assembled on a door structure

Door system.

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

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

Door system.

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

The body is configured to cover the lower cavity of the first module

Door system.

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

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

Door system.

26. The door system,

Door structure,

At least one window glass,

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

A second module having an upper cavity configured to at least partially surround a first side of the window glass and a lower cavity configured to be at least partially coupled with the first module,

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

And a trim panel configured to cover the first module.

Door system.

27. The method of clause 26,

The first side of the main body faces an interior compartment of the vehicle

Door system.

28. The method of paragraph 26 or 27,

The glass run channel extends at least beyond the beltline of the body.

Door system.

29. The method according to any one of items 26, 27 or 28,

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

Door system.

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

The at least one component is injection molded on the body

Door system.

31. The method of paragraph 26 or 30,

At least one seal is disposed on the body.

Door system.

32. The method of clause 31, wherein

The at least one seal is injection molded on the body

Door system.

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

The reinforcing member comprises a first flange and a second flange, each flange configured to be in contact with the first side of the body;

Door system.

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

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

Door system.

35. The method of clause 34,

The reinforcing member further comprises an insert disposed therein, wherein the insert comprises one or more reinforcing members.

Door system.

36. The method of clause 35,

The reinforcing member further comprises a cover plate disposed thereon to form a hollow cavity between the reinforcing member and the reinforcing member.

Door system.

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

The one or more components may include window adjusters, window tracks, window glasses, window switches, door locks, door handles, door lock switches, armrests, map pockets, impact bolsters, wire harnesses, speakers, window motors, external mirror motors, plugs, Grommets, or combinations thereof

Door system.

38. The method of paragraph 31, wherein

Wherein said at least one seal comprises a glass run channel seal, a beltline seal, a lower chassis seal, a core to frame seal, or a combination thereof.

Door system.

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

At least one of the one or more components is injection molded on the body

Door system.

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

The at least one component comprises a window adjuster, window track, impact bolster, air channel, window motor housing, map pocket, speaker box, plug, grommets, or combinations thereof.

Door system.

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

The body is characterized in that it comprises polypropylene

Door system.

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

The body is characterized in that the injection molding of polypropylene

Door system.

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

The body comprises at least one engineering resin

Door system.

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

The body is characterized in that the injection molding of one or more engineering resins

Door system.

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

The main body may be polyamide resin, polyester resin, polynitrile resin, polymethacrylate resin, cellulose resin, fluorine resin, polyimide resin, polysulfone, polyacetal, polyactone, polyphenylene oxide, polyphenylene sulfide, At least one engineering resin selected from the group consisting of styrene-maleic anhydride, aromatic polyketones, and polycarbonates.

Door system.

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

The main body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET / PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal poly Esters, polyoxalkylene diimide diacid / polybutyrate terephthalate copolymers, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymers (AS), methacrylonitrile-styrene copolymers Injection molding into at least one engineering resin selected from the group consisting of methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene-styrene (ABS), derivatives thereof, and mixtures or mixtures thereof.

Door system.

47. The method of any of paragraphs 26 to 46, wherein

The second module is configured to be assembled on a door structure

Door system.

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

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

Door system.

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

The body is configured to cover the lower cavity of the second module

Door system.

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

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

Door system.

51. The method of any of paragraphs 26-50,

At least one window track is injection molded on the second side of the body

Door system.

52. The method of any of paragraphs 26-51,

At least one impact bolster is injection molded on the first side of the body

Door system.

53. The method of any of paragraphs 26-52,

The window glass slides between a first module and a second module

Door system.

54. The door system,

Door structure,

At least one window glass,

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

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

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

And a trim panel configured to cover the first module.

Door system.

55. The method of clause 54,

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

Door system.

56. The method of clause 54 or 55,

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

Door system.

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

The at least one component is injection molded on the first module

Door system.

58. The method according to any one of items 54, 55, 56 or 57,

At least one seal is arranged on the first module

Door system.

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

The at least one seal is injection molded on the first module

Door system.

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

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

Door system.

61. The method according to any one of items 54 to 60,

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

Door system.

62. The method of paragraph 61,

The reinforcing member further comprises an insert disposed therein, wherein the insert comprises one or more reinforcing members.

Door system.

63. The method of paragraph 62,

The reinforcing member further comprises a cover plate disposed thereon to form a hollow cavity between the reinforcing member and the reinforcing member.

Door system.

64. The method of any of paragraphs 54 to 63, wherein

The one or more components may include window adjusters, window tracks, window glasses, window switches, door locks, door handles, door lock switches, armrests, map pockets, impact bolsters, wire harnesses, speakers, window motors, external mirror motors, plugs, Grommets, or combinations thereof

Door system.

65. The method of clause 64,

At least one of the one or more components is injection molded on the first module

Door system.

66. The method of any one of 54-65, wherein

The at least one component comprises a window adjuster, window track, impact bolster, air channel, window motor housing, map pocket, speaker box, plug, grommets, or combinations thereof.

Door system.

67. The method of any of paragraphs 54 to 66, wherein

The second module comprises polypropylene

Door system.

68. The method according to any one of items 54 to 67,

The second module is injection molded from polypropylene

Door system.

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

The second module comprises one or more engineering resins

Door system.

70. The method according to any one of items 54 to 69,

Wherein the second module is injection molded from one or more engineering resins

Door system.

71. The method of any of paragraphs 54 to 70, wherein

The second module is made of polyamide resin, polyester resin, polynitrile resin, polymethacrylate resin, cellulose resin, fluorine resin, polyimide resin, polysulfone, polyacetal, polyactone, polyphenylene oxide, polyphenylene At least one engineering resin selected from the group consisting of sulfides, styrene-maleic anhydrides, aromatic polyketones, and polycarbonates.

Door system.

72. The method of any of paragraphs 54 to 71, wherein

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

Door system.

73. The method of any of paragraphs 54 to 72, wherein

The second module is configured to be assembled on a door structure

Door system.

74. The method of any of paragraphs 54 to 73, wherein

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

Door system.

75. The method of any one of paragraphs 54 to 74, wherein

The first module is configured to cover the lower cavity of the second module

Door system.

76. The method of any of paragraphs 54 to 75, wherein

At least one window track is injection molded on the second side of the first module

Door system.

77. The method of any of paragraphs 54 to 76, wherein

At least one impact bolster is injection molded on the first side of the first module

Door system.

78. The method of any of paragraphs 54 to 77, wherein

The window glass slides between a first module and a second module

Door system.

Those skilled in the art will appreciate that the door system described above can be used as a complete system or as separate mini-systems or modular units, respectively, to assist in the integration of two or more parts, if their individual parts are required.

Particular embodiments and features have been described using numerical upper and lower sets. Unless stated otherwise, it is to be understood that the range from any lower limit to an upper limit is considered. Certain lower limits, upper limits, and ranges appear in one or more claims below. All values are "about" or "approximate" values of the indicated values, and take into account experimental errors and deviations that would be expected by those skilled in the art.

Various terms have been defined above. To the extent the terminology used in the claims is not limited above, those terms reflected in at least one published publication or published patent should be accorded the broadest limitations provided by those skilled in the art. In addition, all patents, test procedures, and other documents, including priorities, cited herein are incorporated in their entirety to the extent that the disclosure is not inconsistent with the present application, and so to all rights to which such use is permitted.

While the foregoing is directed to embodiments of the invention, other and further embodiments of the invention may be considered within its basic scope, the scope of which is determined by the claims that follow.

Claims (60)

In the door system, Door structure, Body in which one or more parts are placed, A first module having an upper cavity configured to at least partially surround a first side of the window glass and a lower cavity configured to at least partially engage the body; A second module configured to at least partially surround a second side of the window glass and configured to at least partially contact an upper cavity of the first module, and A trim module configured to at least partially cover the core module Door system. The method of claim 1, The body includes at least one reinforcing member disposed on the first side thereof. Door system. The method according to claim 1 or 2, The body further comprises a glass run channel disposed at least on the second side thereof. Door system. The method of claim 3, wherein A glass run channel disposed at least on the second side of the body has an open profile. Door system. The method according to any one of claims 1, 2, 3 or 4, The at least one component is injection molded on the body Door system. The method according to any one of claims 1 to 5, At least one seal is disposed on the body. Door system. The method of claim 6, The at least one seal is injection molded on the body Door system. The method according to any one of claims 2, 3, 4, 5, 6, or 7, The reinforcing member comprises a first flange and a second flange, each flange configured to be in contact with the first side of the body; Door system. The method according to any one of claims 2, 3, 4, 5, 6, 7, or 8, The reinforcing member comprises a first flange, a second flange and a recess between the flanges Door system. The method according to any one of claims 2 to 9, The reinforcing member further comprises an insert disposed therein, wherein the insert comprises one or more reinforcing members. Door system. The method according to any one of claims 2 to 10, The reinforcing member further comprises a cover plate disposed thereon to form a hollow cavity between the reinforcing member and the reinforcing member. Door system. The method according to any one of claims 1 to 11, The one or more components may include window adjusters, window tracks, window glasses, window switches, door locks, door handles, door lock switches, armrests, map pockets, impact bolsters, wire harnesses, speakers, window motors, external mirror motors, plugs, Grommets, or combinations thereof Door system. The method according to any one of claims 6 to 12, Wherein said at least one seal comprises a glass run channel seal, a beltline seal, a lower chassis seal, a core to frame seal, or a combination thereof. Door system. The method according to any one of claims 1 to 13, The at least one component is integrally formed on the body Door system. The method according to any one of claims 1 to 14, The at least one component comprises a window adjuster, window track, impact bolster, air channel, window motor housing, map pocket, speaker box, plug, grommets, or combinations thereof. Door system. The method according to any one of claims 1 to 15, The body is characterized in that it comprises polypropylene Door system. The method according to any one of claims 1 to 16, The body is characterized in that the injection molding of polypropylene Door system. The method according to any one of claims 1 to 17, The body comprises at least one engineering resin Door system. The method according to any one of claims 1 to 18, The body is characterized in that the injection molding of one or more engineering resins Door system. The method according to any one of claims 1 to 19, The main body may be polyamide resin, polyester resin, polynitrile resin, polymethacrylate resin, cellulose resin, fluorine resin, polyimide resin, polysulfone, polyacetal, polyactone, polyphenylene oxide, polyphenylene sulfide, At least one engineering resin selected from the group consisting of styrene-maleic anhydride, aromatic polyketones, and polycarbonates. Door system. The method according to any one of claims 1 to 20, The main body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET / PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal poly Esters, polyoxalkylene diimide diacid / polybutyrate terephthalate copolymers, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymers (AS), methacrylonitrile-styrene copolymers Injection molding into at least one engineering resin selected from the group consisting of methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene-styrene (ABS), derivatives thereof, and mixtures or mixtures thereof. Door system. The method according to any one of claims 1 to 21, The first module is configured to be assembled on a door structure Door system. The method according to any one of claims 1 to 22, The second module is assembled to an upper portion of the core module and is configured to be in contact with at least a portion of the first module Door system. The method according to any one of claims 1 to 23, The body is configured to cover the lower cavity of the first module Door system. The method according to any one of claims 1 to 24, And a wet / dry barrier disposed on the second module and the body. Door system. In the door system, Door structure, At least one window glass, A first module in which one or more components are disposed, comprising: a body having a first side and a second side, a reinforcement member disposed on the first side of the body, and a glass run disposed on the second side of the body and having an open profile A first module comprising a channel, A second module having an upper cavity configured to at least partially surround a first side of the window glass and a lower cavity configured to be at least partially coupled with the first module, A third module configured to at least partially surround a second side of the window glass and configured to at least partially contact an upper cavity of the second module, and And a trim panel configured to cover the first module. Door system. The method of claim 26, The first side of the main body faces an interior compartment of the vehicle Door system. The method of claim 26 or 27, The glass run channel extends at least beyond the beltline of the body. Door system. The method according to any one of claims 26, 27 or 28, A glass run channel disposed at least on the second side of the body has an open profile. Door system. The method according to any one of claims 26 to 29, The at least one component is injection molded on the body Door system. The method of claim 26 or 30, At least one seal is disposed on the body. Door system. The method of claim 31, wherein The at least one seal is injection molded on the body Door system. The method according to any one of claims 26 to 32, The reinforcing member comprises a first flange and a second flange, each flange configured to be in contact with the first side of the body; Door system. The method according to any one of claims 26 to 33, The reinforcing member comprises a first flange, a second flange and a recess between the flanges Door system. The method of claim 34, wherein The reinforcing member further comprises an insert disposed therein, wherein the insert comprises one or more reinforcing members. Door system. 36. The method of claim 35 wherein The reinforcing member further comprises a cover plate disposed thereon to form a hollow cavity between the reinforcing member and the reinforcing member. Door system. The method according to any one of claims 26 to 36, The one or more components may include window adjusters, window tracks, window glasses, window switches, door locks, door handles, door lock switches, armrests, map pockets, impact bolsters, wire harnesses, speakers, window motors, external mirror motors, plugs, Grommets, or combinations thereof Door system. The method of claim 31, wherein Wherein said at least one seal comprises a glass run channel seal, a beltline seal, a lower chassis seal, a core to frame seal, or a combination thereof. Door system. The method according to any one of claims 26 to 38, At least one of the one or more components is injection molded on the body Door system. The method according to any one of claims 26 to 39, The at least one component comprises a window adjuster, window track, impact bolster, air channel, window motor housing, map pocket, speaker box, plug, grommets, or combinations thereof. Door system. The method according to any one of claims 26 to 40, The body is characterized in that it comprises polypropylene Door system. The method according to any one of claims 26 to 41, The body is characterized in that the injection molding of polypropylene Door system. The method according to any one of claims 26 to 42, The body comprises at least one engineering resin Door system. The method according to any one of claims 26 to 43, The body is characterized in that the injection molding of one or more engineering resins Door system. The method according to any one of claims 26 to 44, The main body may be polyamide resin, polyester resin, polynitrile resin, polymethacrylate resin, cellulose resin, fluorine resin, polyimide resin, polysulfone, polyacetal, polyactone, polyphenylene oxide, polyphenylene sulfide, At least one engineering resin selected from the group consisting of styrene-maleic anhydride, aromatic polyketones, and polycarbonates. Door system. The method according to any one of claims 26 to 45, The main body is polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET / PEI copolymer, polyacrylate (PAR), polybutylene naphthalate (PBN), liquid crystal poly Esters, polyoxalkylene diimide diacid / polybutyrate terephthalate copolymers, polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymers (AS), methacrylonitrile-styrene copolymers Injection molding into at least one engineering resin selected from the group consisting of methacrylonitrile-styrene-butadiene copolymer, acrylonitrile-butadiene-styrene (ABS), derivatives thereof, and mixtures or mixtures thereof. Door system. The method according to any one of claims 26 to 46, The second module is configured to be assembled on a door structure Door system. The method according to any one of claims 26 to 47, The third module is assembled to an upper portion of the first module and is configured to be in contact with at least a portion of the second module Door system. 49. The method of any of claims 26 to 48, The body is configured to cover the lower cavity of the second module Door system. The method according to any one of claims 26 to 49, Further comprising a wet / dry barrier configured to cover the second and third modules. Door system. The method according to any one of claims 26 to 50, At least one window track is injection molded on the second side of the body Door system. The method according to any one of claims 26 to 51, At least one impact bolster is injection molded on the first side of the body Door system. The method of any one of claims 26 to 52, The window glass slides between a first module and a second module Door system. In the door system, Door structure, At least one window glass, A first module in which one or more components are disposed, comprising: a body having a first side and a second side, a reinforcing member disposed on the first side of the body, and a glass disposed on the second side of the body and having an open profile A first module comprising a run channel, A second module configured to enclose an inner surface of the door structure, the second module having an annular body through which a support member is disposed to form an upper cavity and a lower cavity; A third module configured to at least partially surround a second side of the window glass and configured to at least partially contact an upper cavity of the second module, and And a trim panel configured to cover the first module. Door system. The method of claim 54, wherein The glass run channel extends beyond at least the beltline of the first module. Door system. The method of claim 54 or 55, A glass run channel disposed at least on the second side of the first module has an open profile. Door system. 57. The method of any one of claims 54, 55 or 56, The at least one component is injection molded on the first module Door system. The method of any one of claims 54, 55, 56 or 57, At least one seal is arranged on the first module Door system. The method according to any one of claims 54 to 58, The at least one seal is injection molded on the first module Door system. 60. The compound of any one of claims 54 to 59, The reinforcing member comprises a first flange and a second flange, each flange configured to contact the first side of the first module Door system.

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