Structural Door

Abstract

A structural door module for a motor vehicle door body includes a carrier plate forming a first and second surface. The structural door module also includes a plurality of door hardware components mounted to at least one of the first and second surface in a pre-configured orientation. A handle support is integrally formed from the carrier plate, and provides a cavity to receive a door handle assembly on the first surface.

What is claimed is: 
     
         1 . A structural door module for a motor vehicle door body, comprising:
 a carrier plate forming a first and second surface;   a plurality of door hardware components mounted to at least one of the first and second surface in a pre-configured orientation; and   a handle support integrally formed from the carrier plate, the handle support providing a cavity to receive a door handle assembly on the first surface.   
     
     
         2 . The structural door module of  claim 1 , wherein the door handle assembly is mounted to the handle support prior to the door module being mounted to the motor vehicle door. 
     
     
         3 . The structural door module of  claim 2 , wherein a latch assembly is mounted to the carrier plate and the door handle assembly is connected to the latch assembly prior to the door module being mounted to the motor vehicle door. 
     
     
         4 . A structural door module for a motor vehicle door body, comprising:
 a carrier plate forming a first surface and a second surface;   an inner handle support forming a handle chamber that is open from the first surface away from the second surface, wherein the handle chamber includes an inner handle support to receive a handle, the handle forming part of a handle assembly.   
     
     
         5 . The structural door module of  claim 4 , wherein the handle mount comprises two opposing pivot holes to pivotally mount handle using pins, screws or the like. 
     
     
         6 . The structural door module of  claim 4 , further comprising a lock switch chamber that is open from the first surface away from the second surface. 
     
     
         7 . The structural door module of  claim 4 , wherein the handle assembly further includes a hinged mount that secures the handle to the inner handle support, while permitting the handle to pivot within the handle chamber. 
     
     
         8 . The structural door module of  claim 6 , wherein the lock switch chamber is adapted to receive a door lock switch. 
     
     
         9 . The structural door module of  claim 4 , wherein the handle chamber further includes a connecting rod passage open between the first surface and the second surface of carrier plate, and an articulated rod passing through the rod passage to connect a rod arm extending from the handle to a latch assembly connected to the carrier plate. 
     
     
         10 . The structural door module of  claim 6 , wherein the lock switch chamber further includes an electrical access passage, and a cable from an electrical harness assembly passing through the electrical access passage to door lock switch in the lock switch chamber. 
     
     
         11 . The structural door module of  claim 4 , wherein the inner handle support is further adapted to receive a fitted piece of trim on the first surface that includes an opening to provide access to handle through the fitted piece of trim. 
     
     
         12 . The structural door module of  claim 4 , wherein the handle assembly is assembled as part of the structural door module prior to the structural door module being mounted to a motor vehicle door body. 
     
     
         13 . The structural door module of  claim 12 , wherein the handle assembly is pre-tested on the structural door module before the structural door module is mounted to a motor vehicle door body.