WO2004060705A1

WO2004060705A1 - Exterior vehicle wall assembly

Info

Publication number: WO2004060705A1
Application number: PCT/US2004/000026
Authority: WO
Inventors: Daniel F. White; Mark A. Pattok
Original assignee: Johnson Controls Technology Company
Priority date: 2003-01-02
Filing date: 2004-01-02
Publication date: 2004-07-22

Abstract

An exterior vehicle wall assembly (10, 110) for use on a vehicle having an interior includes a frame (12, 112), a panel (16, 116) and at least one panel retainer (17). The frame (12, 112) has an inner side (22) adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side (24). The panel (16, 116) has an inner side (26) adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side (28). The at least one panel retainer (17) is actuatable from the outer side (28) of the panel (16, 116) between a first state in which the panel (16, 116) is substantially immovable relative to the frame (12, 112) and a second state permitting the panel (16, 116) to be moved relative to the frame (12, 112).

Description

EXTERIOR VEHICLE WALL ASSEMBLY

[0001] The present application claims priority under 35 U.S.C. Section 1 1 9(e) from co-pending U.S. Provisional Patent Application Serial No. 60/437,700 filed in January 2, 2003 by Daniel F. White and Mark A. Pattok and entitled, Exterior Vehicle Wall Assembly, the full disclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to exterior walls of vehicles. In particular, the present invention relates to exterior and trim panels for such structures as tailgates, liftgates, cargo doors, doors and the like. More particularly, the present invention relates to methods by which exterior body panels are supported by a structural member or frame of a vehicle.

BACKGROUND

[0003] Exterior walls of vehicles generally include a frame which serves as a support structure for an exterior panel and an interior trim panel. In addition to supporting the interior and exterior panels, the frame may additionally support various vehicle components, such as speakers, window actuators, airbag systems, handle and locking mechanisms, air-conditioning vents or ducts, and lighting systems, which are mounted to the frame by fasteners extending outwardly through the frame and into the components. In such assemblies, the exterior panel is typically hemmed to the frame by having a flange folded over the frame and secured to the frame by adhesive or welding. In alternative assemblies, the exterior panel is mounted to the frame by threaded studs which extend from the exterior panel inwardly through the frame, wherein nuts are threaded onto the studs. The interior trim panel, which includes such interior structures as armrests and the like, is usually mounted to the inner side of the frame with uni-directional anchoring devices such as plastic fasteners extending towards the exterior.

[0004] Such conventional exterior wall assemblies have several drawbacks. First, with such assemblies, servicing of the vehicle's hardware or interior components, trim and glass is very complicated. To access the interior vehicle components requires that the interior trim first be removed. Because the interior trim panel is typically secured by uni-directional fasteners which are simply snapped into place into the frame, removal of the interior trim panel is time consuming and potentially harmful to the interior trim and other door components if not done properly. Once the interior trim has been removed, accessing the fasteners to disconnect the door componentry from the frame is difficult since such fastener heads are typically located in blind holes and in difficult to reach locations. As a result, the servicing and repair of the interior vehicle components, the interior trim panel and glass is complicated, time consuming and expensive.

[0005] Second, the assembly of such exterior vehicle wall assemblies is very complicated. In particular, the interior components or hardware typically need to be passed through holes in the frame to the proper position. This typically requires poor ergonomic assembly positions and frequent blind operations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIGURE 1 is the front perspective view of one example of a wall assembly of the present invention.

[0007] FIGURE 1 A is a perspective view of components of the wall assembly of FIGURE 1 supported by a carrier.

[0008] FIGURE 1 B is a top plan view of the wall subassembly of the wall assembly of FIGURE 1 .

[0009] FIGURE 1 C is a bottom plan view of the wall subassembly of FIGURE

1 B.

[0010] FIGURE 2 is a perspective view of the wall assembly of FIGURE 1 with an exterior panel exploded away. [001 1] FIGURE 3 is a perspective view of the wall assembly of FIGURE 2 illustrating components exploded away.

[0012] FIGURE 4 is a sectional view of the wall assembly of FIGURE 1 taken along Line 4—4.

[0013] FIGURE 4A is a sectional view of the wall assembly of FIGURE 4 taken along Line 4A--4A.

[0014] FIGURE 5 is an exploded view of the wall assembly of FIGURE 4.

[0015] FIGURE 6 is a sectional view of the wall assembly of FIGURE 1 taken along Line 6—6.

[0016] FIGURE 7 is an exploded view of the wall assembly of FIGURE 6.

[0017] FIGURE 8 is a sectional view schematically illustrating the alternative embodiment of the wall assembly of FIGURE 1 .

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] FIGURE 1 schematically illustrates an exemplary exterior wall assembly 1 0 configured or adapted for use on a vehicle having an interior in which occupants or cargo -may be positioned. In the particular embodiments illustrated, wall assembly 1 0 comprises a door configured to be pivotably mounted to the vehicle so as to move between an open state and a closed state. Although the door is illustrated as being pivotably mounted to the vehicle by a forward hinge, wall assembly 1 0 may alternatively comprise a door that is pivotably mounted to the vehicle by a rearward hinge. Wall assembly 10 may also comprise a door that is pivotably mounted to the vehicle by a top hinge such as with a gull-wing door. In alternative embodiments, wall assembly 10 may comprise a door configured to move relative to the vehicle in other fashions such as by sliding relative to the vehicle (e.g. a sliding van door) or otherwise moving relative to the vehicle such as disclosed in U.S. Patent Application Serial No. 09/928,393, the full disclosure of which is hereby incorporated by reference. In yet additional embodiments, wall assembly 1 0 may be employed in other fashions such as tailgates, lift gates, cargo doors, hatches or removable roof components. In yet other embodiments, wall assembly 10 may be utilized to form stationary walls of the vehicle.

[0019] Wall assembly 10 generally includes frame 1 2, vehicle hardware or components 1 4, exterior panel 1 6, exterior panel retainers 1 , concealment members 1 8 and interior trim panel 20. Frame 1 2 generally comprises a rigid structural member generally configured to provide strength to wall assembly 1 0 and to protect the vehicle's occupants or cargo against collisions or impacts. Frame 1 2 may additionally or alternatively provide arm rests or a structure for supporting a door handle and the loads or forces encountered during movement of the handle. In the particular embodiment illustrated in which wall assembly 1 0 additionally houses interior components 1 4, frame 1 2 is further configured to directly or indirectly support such components 1 4. Frame 1 2 generally has an inner side 22 adapted to face the interior of the vehicle when wall assembly 10 is formed as part of the vehicle, and an opposite outer side 24. Although frame 1 2 is schematically illustrated as being generally flat or two-dimensional, as well as including a window portion, frame 1 2 preferably is three-dimensional and variously configured. Frame 1 2 may alternatively omit the window portion and also may alternatively be formed from one or a single integral sheet or a plurality of sheets or sections fastened, welded, bonded, adhered, or otherwise coupled to one another. Such sections coupled to one another may have the same thickness or differing thicknesses. Although frame 1 2 preferably has a central opening into which components 1 4 are positioned, frame 1 2 may alternatively be substantially imperforate, wherein the components are mounted to one side of frame 1 2, wherein necessary connections are alternatively made through frame 1 2 or along the side of frame 1 2.

[0020] In the particular embodiment illustrated, frame 1 2 is formed from a rigid material such as metal including steel, aluminum or various alloys. In alternative embodiments, frame 1 2 may be formed from other rigid metals or from polymeric materials (e.g. a polymeric space frame) or their components. [0021] Components 1 4 generally refers to the hardware mounted or supported in the interior of wall assembly 1 0. Components 14 may comprise any one of a variety of well-known conventional interior vehicle components or future developed components. Examples of such interior components include one or more of the following: glass, glass run, window seal, latch, handle assembly, window actuators or regulators, speakers, wire harnesses, switches, lights, speakers, microphones, locks or lock assemblies, airbag actuation systems, lights, electronics and the like.

[0022] Components 14 may be assembled as part of wall assembly 1 0 in any of a variety of different fashions, including individually mounting components 1 4 to frame 1 2 or trim panel 20, or providing components 14 as part of various subassemblies which are in turn mounted to frame 1 2. For example, in the particular embodiment illustrated, components 1 4 are mounted to a carrier so as to form a hardware cartridge, cassette or module that is mounted to frame 1 2. FIGURE 1 A illustrates one example of a hardware module 21 4 (also known as a hardware cassette) that includes carrier 21 6 and various components 1 4 including window regulator 21 8, glass 21 9 (shown in FIGURE 1 C), glass run 220, window seal 222, wire harness 224, latch 226, handle assembly 228 (shown in FIGURE 1 B) and speaker 230. In alternative embodiments, module 214 may include a greater or fewer number of such components 14 deported by carrier 21 6. This subassembly or module may be assembled at one location and supplied to a vehicle manufacturer, wherein the vehicle manufacturer assembles the module to the other components of the wall such as the frame and the interior trim.

[0023] Alternatively, vehicle components 1 4 may be mounted to interior trim panel 20. FIGURES 1 B and 1 C illustrate a "level 2 system" in which vehicle components 1 4 are secured to trim panel 20 to form a subassembly. This subassembly may be produced and assembled at a first location and then supplied to the vehicle manufacturer, wherein the vehicle manufacturer attaches this entire subassembly to the frame. As a result, the number of subassemblies that the vehicle manufacturer must inventory and assemble is reduced to achieve cost savings for the vehicle manufacturer. [0024] In what would be known as a "level 3 system," components 14, interior trim panel 20 and frame 1 2 may all be produced and assembled as a subassembly at a first location. This subassembly, generally comprising substantially the entire door or other vehicle wall structure, may be produced at a first location and supplied to the vehicle manufacturer, wherein the vehicle manufacturer would simply assemble this subassembly to the vehicle itself. [0025] In alternative embodiments, vehicle components 1 4 may be sandwiched between frame 1 2 and trim panel 20, wherein components 14 are cooperatively supported by both such members. The above discussion describes but a few vehicle assembly approaches. The exterior panel 1 6, exterior panel retainers 1 7 and concealment members 1 8 of wall assembly 1 0 may be used in any of the aforementioned assembly approaches or other conventionally known or future developed assembly approaches. For example, panel 1 6, retainer 1 7 and concealment members 1 8 may be employed as part of a door or as part of a vehicle wall which was assembled using a "level 1 system" or a "level 2 system," or provided as part of a "level 3 system." Panel 1 6, retainer 1 7 and concealment members 1 8 may also be utilized with other system configurations. Although not illustrated, the "level 1 system" and the "level 2 system" illustrated in FIGURES 1 A, 1 B and 1 C may include openings, attachment bosses or other structures configured to facilitate the fastening of the exterior panel 1 6 to frame 1 2, a fastener such as exterior panel retainer 1 7 which are actuatable from an outer side of panel 1 6.

[0026] Exterior panel 1 6 generally comprises a relatively thin panel positioned along outer side 24 of frame 1 2. Panel 1 6 has an inner side 26 adapted to face the interior of the vehicle when wall assembly 1 0 is formed as part of the vehicle and an opposite outer side 28. Outer side 28 provides the exterior aesthetic appearance of wall assembly 1 0 and at least a portion of the vehicle in which wall assembly 10 is employed. Outer side 28 is provided with one or more colors provided by applied paint, applied coatings, applied laminates or by molded trim. In other applications, panel 1 6 itself may be formed from a colored material which provides the appearance of outer side 28. Alternatively, outer side 28 may comprise a painted metal which forms panel 1 6. [0027] Although exterior panel 1 6 is preferably a stamped panel formed from one or more metals or an injection molded panel formed from one or more polymeric materials, panel 1 6 may alternatively be formed using a combination of metals and polymers and may alternatively be deformed or otherwise shaped employing various other conventional methods (e.g. extrusion, rolling, compression molding, thermoforming, blow molding, injection molding) or future developed shaping procedures. Although exterior panel 1 6 preferably has a substantially uniform thickness throughout, panel 1 6 may alternatively have a varying thickness. Although exterior panel 1 6 is preferably a single section of material configured to be aligned in a coplanar relationship with adjacent body panels of a vehicle, panel 1 6 may alternatively be formed from a plurality of different sections bonded, fastened, welded, adhered, or otherwise joined to one another, and may alternatively form a projection or a recess relative to adjacent body panels of the vehicle in which it is employed.

[0028] Panel 1 6 is coupled to frame 1 2 by one or more panel retainers 1 7 which are accessible from the outer side 28 of panel 1 6. For purposes of this disclosure, the term "coupled" means any direct or indirect joining of two components either by integral unitary bodies or by attachments. In the particular embodiment illustrated, panel 1 6 is directly attached to frame 1 2. Alternatively, panel 1 6 may be joined to interior trim panel 20 which is itself joined to frame 1 2.

[0029] Panel retainers 1 7 couple exterior panel 1 6 to frame 1 2 and are generally actuatable from the outer side 28 of panel 1 6. Retainers 1 7 are actuatable between a first state in which panel 1 6 is held substantially immovable relative to frame 1 2 and a second state which permits panel 1 6 to be moved relative to frame 1 2. Retainers 1 7 preferably comprise separate independent fasteners which extend through panel 1 6. Alternatively, retainers 1 7 may be integrally formed as part of or permanently affixed to panel 1 6. Although assembly 1 0 is illustrated as including four such retainers 1 7, assembly 1 0 may include a plurality of retainers 1 7 located at various positions along panel 1 6.

[0030] Concealment members 1 8 extend adjacent to panel 1 6 and are configured to at least partially cover and conceal retainers 1 7. Concealment members 1 8 may be affixed to panel 1 6 or may extend from structures adjacent to panel 1 6. In the particular embodiment illustrated, concealment members 1 8 comprise seals as commonly provided in conventional door assemblies. In particular, concealment member 1 8, adjacent to the window opening, comprises a window seal, while the concealment member 1 8 is a door edge seal. Such seals are preferably formed from a flexible elastomeric material which enables the material to be elastically deformed or moved to provide access to retainers 1 7.

[0031] In alternative embodiments, concealment members 1 8 may be configured to be moved such as by sliding relative to panel 1 6 to expose retainers 1 7. In lieu of comprising seals, concealment members 1 8 may alternatively comprise other structures that are presently used or used in the future, whether used for the same purposes or for alternative purposes. Examples of other concealment members include cladding, fascias, emblems, splash guards, bevels, wood panels. Although preferably providing both a concealment function and another function, concealment members 1 8 may alternatively be employed solely for the purpose of concealing retainers 1 7. Both the location of retainers 1 7 and the location of concealment members 1 8 may be varied depending upon the overall configuration of the door panel. For example, retainer 1 7 may additionally be located along an intermediate portion of panel 1 6 between the window seal and the door edge seal, wherein one or more additional intermediate concealment members 1 8 are provided between the window seal and the door edge seal so as to cover and conceal the intermediate retainers. Such an additional intermediate concealment member 1 8 may be provided by an external door trim that longitudinally extends along the exterior of panel 1 6. In addition, a concealment member may alternatively comprise a component of the door latch or side mirror assembly. In alternative applications, retainer 1 7 may be partially inset or recessed within a channel or dimple, wherein the concealment member comprises a strip of material, such as a racing stripe, extending over the dimple or channel. The concealment member may alternatively comprise a small flap which pivots or slides between a retainer concealing position and a retainer exposing position.

[0032] FIGURES 2 and 3 schematically illustrate one of the many benefits of assembly 1 0. First, assembly 1 0 is easily manufactured and assembled. Because retainers 1 7 are actuated from the exterior side of panel 1 6, they are more easily accessed as to prior assemblies in which fasteners had to be actuated from the interior side of the frame. In particular, assembly ergonomics, reach clearance and visibility during such assembly are all improved. [0033] Second, assembly 1 0 provides a more robust fastening scheme for trim panel 20. The use of screws extending outwardly through the trim panel and into the frame presents several styling issues. As a result, plastic fasteners are typically employed for mounting the trim panel to the frame. In contrast, assembly 1 0 enables metal fasteners to be employed since the fasteners extend inwardly through the frame and into the trim panel such that the fasteners are concealed. The use of metal fasteners enables the trim panel 20 to more securely and robustly be mounted to frame 1 2.

[0034] Third, assembly 1 0 facilitates easy disassembly and repair. As shown by FIGURE 2, concealment members 1 8 may be moved, either by complete separation from assembly 1 6 as shown or by being pealed or flexed so as to enable access of retainers 1 7 (shown in FIGURE 1 ) . Once retainers 1 7 are exposed, retainers 1 7 may be actuated from the first state to the second state, allowing panel 1 6 to be moved relative to the frame. Although panel 1 6 is illustrated as being preferably completely separated from frame 1 2, panel 1 6 may alternatively be pivoted or slid relative to frame 1 2 so as to expose components 14. As shown by FIGURE 3, components 14 may then be easily accessed from the exterior of assembly 1 0 for repair or replacement. Depending upon the construction of assembly 1 0 and components 1 4, components 1 4 may be completely removed from frame 1 2 as a single cartridge or module or may be repaired or replaced while remaining independently mounted to frame 1 2. As a result, components 1 4 may be easily repaired or replaced without having to reach and work through small openings or in poor ergonomic positions and without having to necessarily remove trim panel 20. In addition, panel 1 6 may be easily removed for repair, replacement or painting without having to remove trim panel 20.

[0035] FIGURES 4-7 schematically illustrate one preferred embodiment of assembly 1 0 in greater detail. In particular, FIGURE 4 is a sectional view of assembly 1 0 taken along line 4—4 of FIGURE 1 . FIGURE 4A is a sectional view of assembly 1 0 taken along 4A - 4A of FIGURE 4. FIGURE 5 illustrates assembly 1 0 of FIGURE 4 exploded. FIGURE 6 illustrates assembly 1 0 taken along line 6- 6 of FIGURE 1 . FIGURE 7 illustrates assembly 1 0 of FIGURE 6 with the removal of panel 1 6. As shown by FIGURES 4-7, frame 1 2 includes an internal opening 40 configured to receive at least a portion of door components 1 4 (which are schematically shown) . Component retainers 42 join and secure components 1 4 to frame 1 2. Component retainers 42 are generally actuatable from the outer side 24 of frame 1 2 between a first state in which one or more of door components 14 are substantially immovable relative to frame 1 2 and a second state which permits door components 1 4 to be moved relative to frame 1 2. In the second state, component retainers 42 preferably permit door components 1 4 to be substantially if not completely separated from frame 1 2. Alternatively, in the second state, retainers 42 permit component 1 4 to be slid, pivoted or moved in other fashions relative to frame 1 2. Because component retainers 42 are actuatable from the outer side 24 of frame 1 2, door components 1 4 may be easily installed as well as easily removed or moved for repair or replacement once panel 1 6 or portions of panel 1 6 are moved or removed. Although assembly 1 0 is shown as including internal opening 40, assembly 10 may alternatively omit opening 40 wherein components 14 are secured along a side of frame 1 2.

[0036] In the particular embodiment illustrated, the plurality of door components 1 4 (schematically shown) are supported and carried by a cartridge, cassette or module 43 which is itself mounted to frame 1 2 by component retainers 42. Carrier 41 generally comprises a rigid structural member formed from a metal or polymeric material that is configured to interconnect and support a plurality of components 1 4 such that the plurality of components 14 may be transported and assembled to frame 1 2 as a single unit. Although carrier 41 is illustrated as extending on one side of components 1 4, carrier 41 may alternatively surround or at least partially surround components 1 4. In alternative applications, each component 14 may be individually mounted to frame 1 2 by component retainers 42. In particular embodiments, components 1 4 may be secured to frame 1 2 both individually and as part of one or more such modules 43.

[0037] In the particular embodiment illustrated, component retainers 42 preferably comprise separate independent fasteners that extend through carrier 41 (or alternatively components 1 4) . Although such fasteners are illustrated as comprising threaded fasteners, component retainers 42 may alternatively comprise various other fasteners such as snaps, clips and the like. Moreover, component retainers 42 may alternatively be integrally formed as part of or permanently affixed to module 43, the individual components 14 or frame 1 2 so long as such retainers 42 are actuatable from the outer side 24 of frame 1 2. [0038] Although component retainers 42 are illustrated as being utilized in conjunction with panel retainers 1 7, wherein panel retainers 1 7 are actuatable from the outer side of panel 1 6, component retainers 42 may alternatively be utilized in a wall assembly having an exterior panel that is movably or removably coupled to frame 1 2 by one or more retainers that are actuatable from the inner side of panel 1 6. Although less desirable, this alternative configuration would still facilitate easier installation or easier repair or replacement of components 14. Likewise, panel retainers 1 7 may alternatively be employed in wall assemblies wherein the components 1 4 are coupled to frame 1 2 by retainers actuatable from the inner side of frame 1 2.

[0039] As further shown by FIGURES 4-7, retainers 1 7 preferably comprise threaded fasteners (screws) which extend through frame 1 6 and extend through frame 1 2 in threaded engagement with at least frame 1 2. Upper concealment member 1 8 is provided by a window seal which conceals and surrounds retainer 1 7 and provides a seal between panel 1 6 and window pane 44. Lower concealment member 1 8, provided by door edge seal, extends about a lower end of panel 1 6 and frame 1 2 to substantially seal about and conceal retainer 1 7. In addition to concealing retainer 1 7, concealment members 1 8 also seal and prevent the ingress of water and other contaminants in the opening panel 1 6 and frame 1 2 receiving retainer 1 7. As shown by FIGURE 4, assembly 1 0 additionally includes seal 47 sealing about frame 1 2 and trim 20 and against window 44.

[0040] As best shown by FIGURES 6 and 7, panel 1 6 is further retained in place adjacent to frame 1 2 by means of a hook 48 and an edge guard 50. Hook 48 is coupled to panel 1 6 and preferably integrally formed as panel 1 6. Hook 48 is configured to receive an edge of frame 1 2. Opposite hook 48, panel 1 6 includes an end 52 which is configured to extend adjacent to frame 1 2 and to be received within edge guard 50. Edge guard 50 joins end 52 and adjacent portion of frame 1 2 and forms a seal against such edges. In particular embodiments, additional retainers may be provided or may extend from end 52 into frame 1 2, wherein guard 50 serves as a concealment member for such additional retainers. To remove panel 1 6, guard 50 is either removed or loosened so as to enable panel 1 6 to be moved in the direction indicated by arrow 54 once retainers 1 7 are actuated to the second state. [0041 ] As further shown by FIGURES 6 and 7, accessory 1 0 additionally includes interior trim panel retainers 57 which are actuatable from the outer side of frame 1 2 between a first state in which the interior trim panel is substantially immovable relative to the frame, and a second state permitting the interior trim panel to be relative to the frame. Although retainers 57 are illustrated as extending through interior trim panel 20, retainers 57 may alternatively extend into blind holes which are configured to be engaged by retainers 57. Although less desirable, accessory 1 0 may alternatively include other fasteners or other retaining members that are permanently affixed to frame 1 2, or integrally formed as part of a single unitary body with frame 1 2, or that engage trim panel 20 in various other fashions. Because retainers 57 engage trim panel 20 and are actuatable from the outer side of trim panel 20, trim panel 20 may be easily moved or removed for repair, replacement or access to the interior side of frame 1 2. Moreover, because retainers 57 are actuatable from the exterior of frame 1 2, retainers 57 may be provided by stronger, more reliable fasteners or retaining mechanisms as compared to conventional uni-directional mechanisms which extend outwardly from a trim panel into engagement wiτh the frame. [0042] In summary, the following is a list of advantages or benefits attained because panel 1 6 is removable by actuating retainer 1 7 from the exterior side of panel 1 7 without requiring removal of trim panel 20.

[0043] 1 . Improved assembly due to fully accessible inner panel through removal of outer panel;

[0044] 2. Improves service due to fully accessible inner panel through removal of outer panel;

[0045] 3. Allows for replacement of outer panel if outer panel is damaged;

[0046] 4. Improved water drainage through enlarged drain holes at bottom;

[0047] 5. Allows for styling flexibility across different vehicle lines with., common inner panel;

[0048] 6. If a plastic outer panel is used then reduced investment in outer panel tooling;

[0049] 7. If a plastic outer pane! with decorative film then elimination of paint equipment investment;

[0050] 8. Reduces service time and ambiguity of different trim attachment methodologies;

[0051 ] 9. Reduces R/1000 of door trim panel because adjustment and repairs of door hardware do not require removal of trim panel; [0052] 1 0. Allows for the elimination of two-piece fasteners (high warranty item root cause) and use screws to fasten door trim panel to door driven from the outboard side of door with outer panel removed;

[0053] 1 1 . Paint match out outer panel after service (replacement) is improved;

[0054] 1 2. Allows for improved outer panel fit to adjacent body panels; and

[0055] 1 3. Robust attachment of door panel trim with hidden fasteners.

[0056] FIGURES 1 -7 illustrate one preferred embodiment of an exterior vehicle wall assembly. FIGURE 8 is a sectional view illustrating an assembly 1 1 0 having an alternatively contoured or shaped exterior panel 1 1 6 and secured to frame 1 1 2 by retainers 1 7 (discussed above) which are concealed by concealment member 1 8 (discussed above) and an alternative trim panel 1 20 coupled to frame 1 1 2 by retainers 57 (discussed above) that extend inwardly through frame 1 1 2 and into trim panel 1 20. An exterior fascia or cladding 1 1 5 is also shown. Such cladding 1 1 5 may also serve as a concealment member for retainers 1 7.

Claims

WHAT IS CLAIMED IS:

1 . An exterior vehicle wall assembly for use on a vehicle having an interior, the assembly comprising: a frame having an inner side adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side; a panel having an inner side adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side; and at least one panel retainer, wherein the at least one panel retainer is actuatable from the outer side of the panel between a first state in which the panel is substantially immovable relative to the frame and a second state permitting the panel to be moved relative to the frame.

2; The assembly of claim 1 wherein the assembly includes at least one vehicle component supported by the frame and wherein the at least one panel retainer, in the second state, permits the panel to be sufficiently moved relative to the frame to allow access to the at least one vehicle component.

3. The assembly of claim 1 wherein the at least one panel retainer, in the second state, permits the panel to be completely separated from the frame.

4. The assembly of claim 1 wherein the assembly is configured to be movably mounted to the vehicle to move between an open state and a closed state.

5. The assembly of claim 4 wherein the assembly comprises one of a forwardly hinged door, a rearwardly hinged door, a top hinged door, a bottom hinged door, a sliding door, a rear tailgate, a gull-wing door, a movable roof component and a hatch.

6. The assembly of claim 5 wherein the assembly comprises a door configured to be pivotably mounted to the vehicle.

7. The assembly of claim 1 wherein at least a portion of the at least one panel retainer on the outer side of the panel is concealed.

8. The assembly of claim 7 wherein an entirety of the at least one panel retainer on the outer side of the panel is concealed.

9. The assembly of claim 7 including a seal extending over the at least one panel retainer.

10. The assembly of claim 9 wherein the seal is a window seal.

1 1 . The assembly of claim 9 wherein the seal is a door edge seal.

1 2. The assembly of claim 1 wherein the at least one panel retainer extends through the panel.

1 3. The assembly of claim 1 wherein the at least one panel retainer comprises at least one fastener.

1 4. The assembly of claim 1 including at least one door component supported by the frame.

1 5. The assembly of claim 1 wherein the panel has a substantially uniform thickness throughout.

1 6. The assembly of claim 1 including: internal trim on the inner side of the frame; and i at least one trim fastener extending through the frame and fastened to the internal trim.

1 7. The assembly of claim 1 6 wherein the fastener extends in the direction from the outer side of the frame to the inner side of the frame.

1 8. The assembly of claim 1 wherein the panel is made using one of the following shaping methods: stamping, extrusion, injection molding, thermoforming, blow molding.

1 9. The assembly of claim 1 wherein the panel is adapted to be aligned and coplanar with adjacent body panels of the vehicle.

20. The assembly of claim 1 wherein the assembly- includes: at least one vehicle component; and at least one component retainer, wherein the at least one component retainer is actuatable from the outer side of the frame between a first state in which the at least one component is substantially immovable relative to the frame and a second state permitting the at least one component to be moved relative to the frame.

21 . The assembly of claim 20 wherein the at least one component retainer, in the second state, permits the at least one component to be completely separated from the frame.

22. An exterior vehicle wall assembly for use on a vehicle having an interior, the assembly comprising: a frame having an inner side adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side; a panel having an inner side adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side; at least one panel retainer actuatable between a first state in which the panel is substantially immovable relative to the frame and a second state permitting the panel to be moved relative to the frame; at least one component; and at least one component retainer, wherein the at least one component retainer is actuatable from the outer side of the frame between a first state in which the at least one component is substantially immovable relative to the frame and a second state permitting the at least one component to be moved relative to the frame.

23. The assembly of claim 22 wherein the at least one component includes a plurality of components and wherein the assembly further includes a module interconnecting the plurality of components as a unit, wherein the at least one component retainer couples the module to the frame.

24. The assembly of claim 22 wherein the at least one panel retainer is actuatable from the outer side of the panel between a first state in which the panel is substantially immovable relative to the frame and a second state permitting the panel to be moved relative to the frame.

25. The assembly of claim 24 wherein the at least one panel retainer, in the second state, permits the panel to be completely separated from the frame.

.

26. The assembly of claim 24 wherein the assembly is configured to be movably mounted to the vehicle to move between an open state and a closed state.

27. The assembly of claim 24 wherein the assembly comprises one of a forwardly hinged door, a rearwardly hinged door, a top hinged door, a bottom hinged door, a sliding door, a rear tailgate, a gull-wing door, a movable roof component and a hatch.

28. The assembly of claim 27 wherein the assembly comprises a door configured to be pivotably mounted to the vehicle.

29. The assembly of claim 24 wherein at least a portion of the at least one panel retainer on the outer side of the panel is concealed.

30. The assembly of claim 29 wherein an entirety of the at least one panel retainer on the outer side of the panel is concealed.

31 . The assembly of claim 29 including a seal extending over the at least one panel retainer.

32. The assembly of claim 31 wherein the seal is a window seal.

33. The assembly of claim 31 wherein the seal is a door edge seal.

34. The assembly of claim 24 wherein the at least one panel retainer extends through the panel.

35. The assembly of claim 24 wherein the at least one panel retainer comprises at least one fastener.

36. The assembly of claim 24 including at least one door component supported by the frame.

37. The assembly of claim 24 wherein the panel has a substantially uniform thickness throughout.

38. The assembly of claim 24 including: internal trim on the inner side of the frame; and at least one trim fastener extending through the frame and fastened to the internal trim.

39. The assembly of claim 38 wherein the fastener extends in the direction from the outer side of the frame to the inner side of the frame.

40. The assembly of claim 24 wherein the panel comprises an extrusion.

41 . The assembly of claim 24 wherein the panel is adapted to be aligned and coplanar with adjacent body panels of the vehicle.

42. An exterior vehicle wall assembly for use on a vehicle having an interior, the assembly comprising: a frame having an inner side adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side; an exterior panel having an inner side adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side; an interior trim panel having an inner side adapted to face the interior of the vehicle when mounted to the vehicle and an opposite outer side; at least one exterior panel retainer actuatable between a first state in which the exterior panel is substantially immovable relative to the frame and a second state permitting the exterior panel to be moved relative to the frame; and at least one trim panel retainer, wherein the at least one trim panel retainer is actuatable from the outer side of the interior trim panel between a first state in which the interior trim panel is substantially immovable relative to the frame and a second state permitting the interior trim panel to be moved relative to the frame.