Door module system

Abstract

A door module and a method of packaging and assembling the door module ( 10 ) to a vehicle door ( 12 ) is disclosed. The door module ( 10 ) comprises a non-structural substrate carrier ( 14 ), a door trim panel ( 15 ) configured to be coupled to the substrate carrier, a door trim interface member ( 32 ) integrally molded with the carrier ( 14 ) as a single unitary article, and a carrier interface member ( 33 ) extending from the door trim panel ( 15 ). The door trim panel is releasably coupled to the carrier by releasable engagement of the door trim interface member ( 32 ) and the substrate carrier interface member ( 33 ). The carrier ( 14 ) may also have an integrally molded impact absorber ( 24, 26 ) or an integrally molded pull cup support ( 28 ). The method of preparing a module vehicle door ( 12 ) for transportation to a location for assembly of a vehicle door comprises mounting the trim panel ( 15 ) to the carrier ( 14 ) by engaging a projection ( 33 ) on the trim panel ( 15 ) with a retainer ( 32 ) integrally molded with the carrier ( 14 ). The method of assembling the door module to a structural frame of a vehicle door comprises receiving the carrier and the trim panel at the location for assembly of the vehicle door, removing the trim panel from the non-structural carrier, coupling the carrier to the structural frame ( 42, 44 ), and mounting the trim panel to the non-structural carrier ( 14 ).

1 . A door module kit for transportation to the location of assembly of a vehicle door comprising: 
 a non-structural substrate carrier;    a door trim panel configured to be coupled to the substrate carrier;    a door trim interface member integrally molded with the carrier as a single unitary article;    a carrier interface member extending from the door trim panel;    wherein the door trim panel is releasably coupled to the carrier during transportation to the location of assembly of the vehicle door by releasable engagement of the door trim interface member and the substrate carrier interface member.    
   
   
       2 . The door module of  claim 1  wherein the door trim interface member is a retainer that defines a space for at least partially receiving the carrier interface member.  
   
   
       3 . The door module kit of  claim 2  wherein the retainer is a “U”-shaped loop.  
   
   
       4 . The door module kit of  claim 1  wherein the carrier interface member is a projection that extends from the door trim panel and engages the door trim interface member.  
   
   
       5 . The door module kit of  claim 4  wherein the carrier interface member is a hook extending from the door trim panel.  
   
   
       6 . The door module kit of  claim 1  wherein the carrier interface member is integrally molded with the door trim panel.  
   
   
       7 . The door module kit of  claim 1  wherein the substrate carrier further comprises an integrally molded impact absorber.  
   
   
       8 . The door module kit of  claim 1  wherein the substrate carrier further comprises an integrally molded pull cup support.  
   
   
       9 .- 10 . (canceled)  
   
   
       11 . A method of assembling a vehicle door having a non-structural carrier, a trim panel, and a structural frame, the method comprising: 
 receiving the carrier and the trim panel at the location for assembly of the vehicle door;    removing the trim panel from the non-structural carrier;    coupling the carrier to the structural frame; and    mounting the trim panel to the non-structural carrier    
   
   
       12 . The method of  claim 11  further comprising the step of coupling the trim panel to an assembly line fixture when the carrier is coupled to the frame.  
   
   
       13 . The method of  claim 11  wherein the step of mounting the trim panel to the carrier comprises engaging the retainer member with the projection.  
   
   
       14 . The method of  claim 11  wherein the projection extends from the trim panel and the retainer member is integrally molded with the carrier as a unitary article.  
   
   
       15 . A door module kit for a vehicle door comprising: 
 a non-structural substrate carrier having a first interface member and an integrally molded impact absorber;    a door trim panel configured to be coupled to the substrate carrier and having a second interface member;    wherein the door trim panel is releasably coupled to the carrier during transportation to the location of assembly of the vehicle door by releasable engagement of the first interface member and the second interface member.    
   
   
       16 . The door module kit of  claim 15  wherein the first interface member comprises a retainer integrally molded with the carrier and defines a space for at least partially receiving the substrate carrier interface member.  
   
   
       17 . The door module kit of  claim 16  wherein the second interface member is a projection that extends from the door trim panel and engages space defined by the retainer.  
   
   
       18 . The door module kit of  claim 15  wherein the first interface member and the second interface member are integrally molded with the door trim panel.  
   
   
       19 . The door module kit of  claim 15  wherein the integrally molded impact absorber comprises an upper integrally molded impact absorber and a lower integrally molded impact absorber.  
   
   
       20 . The door module kit of  claim 19  wherein the upper impact absorber comprises a series of projections extending from the carrier.  
   
   
       21 . The door module kit of  claim 19  wherein the lower impact absorber comprises a plurality of walls.  
   
   
       22 . The door module kit of  claim 15  wherein the substrate carrier further comprises an integrally molded pull cup support.  
   
   
       23 . A method of assembling a vehicle door having a non-structural carrier, a trim panel, and a structural frame, the method comprising: 
 receiving the carrier and the trim panel at the location for assembly of the vehicle door;    coupling the trim panel to an assembly line fixture;    coupling the carrier to the structural frame; and    removing the trim panel from the assembly line fixture and mounting the trim panel to the non-structural carrier    
   
   
       24 . The method of  claim 23  wherein the carrier and trim panel are received at the location for assembly of the vehicle door releasably coupled together.  
   
   
       25 . The method of  claim 24  further comprising the step of removing the trim panel from the non-structural carrier before coupling the trim panel to the assembly line fixture.  
   
   
       26 . The method of  claim 23  wherein the step of mounting the trim panel to the carrier comprises engaging a retainer member with a projection, wherein the projection extends from the trim panel and the retainer member is integrally molded with the carrier as a unitary article.