U.S. patent application number 09/735227 was filed with the patent office on 2001-06-28 for door assembly module and method.
Invention is credited to Ponziani, Richard L..
Application Number | 20010005084 09/735227 |
Document ID | / |
Family ID | 23659667 |
Filed Date | 2001-06-28 |
United States Patent
Application |
20010005084 |
Kind Code |
A1 |
Ponziani, Richard L. |
June 28, 2001 |
Door assembly module and method
Abstract
This invention relates to a system and method for providing a
single module which has a plurality of integrally-molded features
and components, as well as is capable of receiving a plurality of
components required to be mounted on a door of a vehicle. In a
preferred embodiment, the module is used to provide a support
capable of supporting a plurality of tailgate components, such as a
windshield wiper motor, electric door latches and illumination
system for illuminating a license plate, stop light and even a
cargo area of the vehicle. The system and method provide a module
platform having an integrally-molded handle which permits an
operator to pick up the module with its various components
integrally-molded in or mounted thereon and situate the module
directly onto the door, thereby substantially reducing the number
of assembly steps and assembly time required in the past. The
module provides convenient apparatus for housing the various
components during transportation and reduces the amount of skilled
labor required during the assembly process. The module includes a
plurality of molded features such as guide and aligning wedge wings
which align the module on the door and which are also capable of
housing and securing a plurality of wires. A latch docking station
is also integrally-molded into the module to house a plurality of
electronic mounting latches during transportation. The latches are
later removed and then mounted onto the door of the vehicle during
an installation procedure. The one-piece module also has an area
for receiving a windshield wiper motor which drives a windshield
wiper blade. The module further includes a circuit board which is
mounted directly onto the module for controlling the operation of
the various electrical components associated with the door. An LED
illumination system for illuminating a license plate, stop light
and/or even a cargo area of the vehicle is provided directly on the
circuit board or is separately wired thereto. Once the components
are completely assembled and mounted onto the module, an assembler
may pick up the module using a module handle molded in the module
at a handle area where a plurality of overturning moments
associated with the module are or become substantially balanced to
assist the assembler in positioning the module onto the door.
Inventors: |
Ponziani, Richard L.;
(Centerville, OH) |
Correspondence
Address: |
MATTHEW R. JENKINS
Jacox, Meckstroth & Jenkins
2310 Far Hills Building
Dayton
OH
45419-1575
US
|
Family ID: |
23659667 |
Appl. No.: |
09/735227 |
Filed: |
December 12, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09735227 |
Dec 12, 2000 |
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09418811 |
Oct 15, 1999 |
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6174016 |
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Current U.S.
Class: |
296/56 ;
296/146.8 |
Current CPC
Class: |
E05B 83/16 20130101;
B60S 1/0419 20130101; B62D 29/043 20130101; B60S 1/583 20130101;
E05B 81/25 20130101; E05B 79/04 20130101; E05B 85/02 20130101; B62D
25/12 20130101; B60S 1/04 20130101; B60S 1/0416 20130101 |
Class at
Publication: |
296/56 ;
296/146.8 |
International
Class: |
B62D 025/00 |
Claims
What is claimed is:
1. An automotive assembly module comprising: an automotive module
having a handling area, said handling area defining an area where
said module may be handled for installation; and a handle situated
at said handling area for permitting a user to grab said module
during an installation procedure; said automotive module having a
center of gravity associated with said handling area at which a
plurality of weight-overturning moments are substantially
balanced.
2. The automotive assembly module as recited in claim 1 wherein
said handle is integrally-molded into said automotive module.
3. The automotive assembly module as recited in claim 1 wherein
said handle is integrally formed on said module at said handling
area such that said handle is aesthetically transparent after said
module is situated on said automobile.
4. The automotive assembly module as recited in claim 1 wherein
said tailgate assembly comprises at least one motor mounted on said
automotive module.
5. The automotive assembly module as recited in claim 1 wherein
said at least one motor is a windshield wiper motor.
6. The automotive assembly module as recited in said claim 3
wherein said automotive module is a tailgate assembly module.
7. The automotive assembly module as recited in claim 4 wherein
said tailgate assembly comprises at least one motor mounted on said
automotive module.
8. An automotive assembly module comprising: an automotive module
having a handling area, said handling area defining an area where
said module may be handled for installation; and a handle situated
at said handling area for permitting a user to grab said module
during an installation procedure; said automotive module having a
center of gravity associated with said handling area at which a
plurality of weight-overturning moments are substantially
balanced.
9. The automotive assembly module as recited in claim 8 wherein
said handle is integrally-molded into said tailgate module
platform.
10. The automotive assembly module as recited in claim 8 wherein
said at least one electric motor is a windshield wiper motor.
11. The automotive assembly module as recited in claim 8 wherein
said at least one electric motor comprises a power hatch
closer.
12. A method of providing a plurality of components on a door of an
automobile comprising the steps of: providing a module having a
handling area defining an area where said tailgate module may be
handled for installation; and providing a handle situated at said
handling area for permitting a user to grab said module during an
installation procedure so that said module can be situated on an
automobile or part thereof; wherein said module having a center of
gravity associated with said handling area at which a plurality of
weight-overturning moments are substantially balanced.
13. The method as recited in claim 12 wherein said method further
comprises the step of: providing a handle is integrally-molded into
said module.
14. The method as recited in claim 12 wherein said method further
comprises the step of: providing at least one motor mounted on said
module.
15. The method as recited in claim 14 wherein said method further
comprises the step of: providing a windshield wiper motor on said
module.
16. An automotive assembly module for mounting on a door of a
vehicle comprising: a platform module; a circuit board mounted on
said module, said circuit board comprising a stop light mounted
thereon and a microprocessor coupled to said stop light for
controlling the operation of said stop light, said microprocessor
being capable of flashing said stop light before said stop light is
fully actuated, said circuit board further comprising an
illuminating system for illuminating either a license plate mounted
on said door or a cargo area of said vehicle; a heater grid plug
mounted on said circuit board for electrically coupling a heater
grid associated with glass on said door to a circuit on said
circuit board; a latch docking area for detachably supporting
docking latches to be installed on said door of the automobile; at
least one guide for aligning said module on said door; a wire
storage system for storing wires during transit of said module; a
module handle situated on said module for permitting a user to grab
said module during an installation procedure; said automotive
module having a center of gravity associated with said handling
area at which a plurality of weight-overturning moments are
substantially balanced; and a door actuation handle
integrally-molded in said module.
17. The automotive assembly module as recited in claim 16 wherein
said handle is integrally-molded into said module.
18. The automotive assembly module as recited in claim 16 wherein
said tailgate assembly comprises a windshield wiper motor mounted
on said module.
19. The automotive assembly module as recited in claim 16 wherein
said at least one guide comprises a wedge wing, said door
comprising at least one wedge wing aperture for receiving said
wedge wing to facilitate aligning and securing said module on said
door.
20. The automotive assembly module as recited in claim 16 wherein
said module comprises a reflective material for reflecting light
generated by said illuminating system.
21. The automotive assembly module as recited in claim 16 wherein
said illuminating system comprises a plurality of LED's mounted on
said circuit board.
22. The automotive assembly module as recited in claim 16 wherein
said wire storage system is generally V-shaped in cross section and
comprises a plurality of wing receiving apertures.
23. The automotive assembly module as recited in claim 16 wherein
said at least one wedge wing is integrally-molded in said
module.
24. A method of mounting a plurality of components on a door of an
automobile comprising the steps of: providing a module for mounting
on said door, said module comprising a wiper motor and at least one
of the following components: an electric door latch, circuit board,
license plate illuminator, stop light, heater grid plug or cargo
area illuminator; and providing a handle on said module for
permitting a user to grab said module and mount said module on the
automobile.
25. The method as recited in claim 24 wherein said method further
comprises the step of: providing a handle integrally-molded into
said module.
26. The method as recited in said claim 24 wherein said module is a
tailgate assembly and said components are tailgate components.
27. The method as recited in claim 26 wherein said method further
comprises the step of: providing said at least one wiper motor
mounted directly on said module.
28. The method as recited in claim 26 wherein said method further
comprises the step of: providing a circuit board mounted on said
module.
29. The method as recited in claim 26 wherein said method further
comprises the step of: providing said license plate illuminator
mounted on said circuit board for illuminating a license plate
after said module is mounted on said door.
30. The method as recited in claim 26 wherein said method further
comprises the step of: providing said license plate illuminator
mounted on said circuit board for illuminating said cargo area
after said module is mounted on said door.
31. The method as recited in claim 24 wherein said method further
comprises the step of: providing at least one integrally-molded
guide for aligning said module on said door when said module is
mounted thereon.
32. The method as recited in claim 24 wherein said method further
comprises the step of: providing a latch docking area integrally
formed in said module for supporting a plurality of latches and
said module.
33. The method as recited in claim 24 wherein said method further
comprises the step of: providing a module comprising at least one
wire storage system for storing wires during transit of said
module.
34. The method as recited in claim 24 wherein said method further
comprises the step of: providing a module comprising at least one
guide for aligning said module on said door during a mounting
operation when said module is mounted on said door.
35. An automotive assembly module comprising: a module platform for
mounting on a door of an automobile; and a plurality of module
components either mounted on or integrally formed in said module;
said module facilitating mounting of said plurality of components
onto said door of said automobile.
36. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises a module handle
integrally-molded into said module platform.
37. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises at least one motor
mounted on said module platform.
38. The automotive assembly module as recited in claim 37 wherein
said at least one motor is a windshield wiper motor.
39. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises a circuit board
mounted directly on said module platform.
40. The automotive assembly module as recited in claim 39 wherein
said circuit board comprises a plurality of lights mounted thereon
for illuminating a license plate on said door when said module
platform is mounted on said door.
41. The automotive assembly module as recited in claim 39 wherein
said circuit board comprises a plurality of lights mounted thereon
for illuminating a cargo area of said automobile.
42. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises at least one wedge
wing integrally-molded in said module platform, said at least one
wedge wing facilitating aligning said module platform or said
door.
43. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises at least one latch
detachably mounted at a latch docking area of said module
platform.
44. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises a wire storage system
integrally-molded into said module platform.
45. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises at least one wedge
wing integrally-molded in said module platform.
46. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises a circuit board
comprising a stop illuminator for generating a stop light.
47. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises a stop reflector
mounted thereon.
48. The automotive assembly module as recited in claim 46 wherein
said circuit board comprises a microprocessor coupled to said stop
illuminator for intermittently energizing said stop illuminator
when a brake pedal of said automobile is depressed to stop the
automobile before said stop illuminator is fully energized.
49. The automotive assembly module as recited in claim 35 wherein
said plurality of module components comprises a door handle
integrally-molded in said module platform for unlocking said
door.
50. The automotive assembly module as recited in claim 49 wherein
said module comprises a circuit board attached thereto, said
circuit board comprising a door release switch and being
operatively positioned relative to said handle such when said door
handle is actuated to an unlock position, said door release switch
is actuated to unlock said door.
51. The automotive assembly module as recited in claim 36 wherein
said module platform is a one-piece molded construction.
52. The automotive assembly module as recited in claim 36 wherein
said plurality of module components comprises at least one motor
mounted on said module platform.
53. The automotive assembly module as recited in claim 52 wherein
said at least one motor is a windshield wiper motor.
54. The automotive assembly module as recited in claim 37 wherein
said plurality of module components comprises a module handle
integrally-molded into said module platform.
55. The automotive assembly module as recited in claim 54 wherein
said plurality of module components comprises a circuit board
mounted on said module platform.
56. The automotive assembly module as recited in claim 55 wherein
said circuit board comprises a plurality of lights mounted thereon
for illuminating a license plate on said door.
57. The automotive assembly module as recited in claim 55 wherein
said circuit board comprises a plurality of lights mounted thereon
for illuminating a cargo area of said automobile.
58. The automotive assembly module as recited in claim 56 wherein
said plurality of module components comprises at least one wedge
wing integrally-molded in said module platform, said at least one
wedge wing facilitating mounting said module to said door.
59. The automotive assembly module as recited in claim 57 wherein
said plurality of module components comprises at least one latch
detachably mounted on said module.
60. The automotive assembly module as recited in claim 56 wherein
said plurality of module components comprises a wire storage system
integrally-molded into said module.
61. The automotive assembly module as recited in claim 60 wherein
said plurality of module components comprises at least one wedge
wing integrally-molded in said module.
62. The automotive assembly module as recited in claim 37 wherein
said plurality of module components comprises a circuit board
comprising a stop illuminator for generating a stop light.
63. The automotive assembly module as recited in claim 62 wherein
said plurality of module components comprises a stop reflector
mounted thereon.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to components for a vehicle door and,
more particularly, to a door module for supporting a plurality of
components for easy installation and mounting onto a door of a
vehicle.
[0003] 2. Description of Related Art
[0004] In the field of door assemblies, such as a tailgate door
casting, various components are mounted onto the door. Such
components may include, for example, a tailgate windshield wiper
motor and associated blade. The motor is mounted directly on the
tailgate door of the vehicle. Further, to provide a center high
mounted stop light as is required by law, a light housing is
mounted onto the door. The light housing receives several
incandescent or LED devices, and is a separately molded housing
mounted directly onto the door using a plurality of screws. When
the light bulbs burnt out, they would have to be replaced and such
maintenance was dependant upon the useful life of the light
bulbs.
[0005] The door locking and unlocking mechanisms and linkage was
oftentimes expensive and complex. The latch linkage recently has
included an electrical actuator which actuates the linkage to
unlock the door in response to a mechanical actuation of a door
handle. In general, the mechanical latch linkage and electrical
actuator would work using a traditional mechanical fork bolt. The
unlatch function is achieved when the integrated motor is
energized. Motor actuation is achieved when the operator actuates
an electrical switch. This signal input is processed through a
logic device, such as a microprocessor. Outside inputs to this
device instruct whether the tailgate is locked or unlocked. If
deemed unlocked, the latch motor is activated.
[0006] Unfortunately, the plurality of components which were
assembled and mounted onto the door were typically separately
shipped to the assembly plant where the components were each
separately mounted onto the door. Thus, for example, the
incandescent light assembly, windshield wiper motor, door unlock
and lock linkage and electric actuator and the like would all be
separately mounted directly onto the door. After these components
were separately shipped to the assembly plant. Various other
components would also be separately mounted onto the door, such as
a license plate light socket assembly and/or cargo bay light socket
assembly.
[0007] Another problem with the prior art systems is that they
typically required numerous skilled assemblers to assemble and
mount the various pieces onto the door of the vehicle.
[0008] What is needed, therefore, is a system and method which can
facilitate reducing the assembly time and reduce the manufacturing
and assembly steps required during the manufacture and assembly of
a door of a vehicle.
SUMMARY OF THE INVENTION
[0009] It is, therefore, a primary object of the invention to
provide a system and method which facilitates reducing the assembly
time required during the assembly of a door.
[0010] Another object of the invention is to provide an assembly
module comprising an integrally-molded platform having a module
assembly handle which is situated at an area of the platform such
that any overturning moments for the various components which are
either molded into or mounted on the module are substantially
balanced such that an operator can easily hold and position the
module onto a door.
[0011] Another object of the invention is to provide a module
having a plurality of aligning guides or wedge wings which
facilitate the alignment and mounting of the module onto the
door.
[0012] Another object of the invention is to provide a module
having a docking station for docking one or more pre-wired and
tested latches during transportation and which can be easily
removed from the docking station so that they can be mounted onto
the door where desired.
[0013] Another object of the invention is to provide wire receiving
areas integrally-molded into the module for receiving and housing
various wires during transportation, as well as after the module is
mounted onto the door.
[0014] Another object of the invention is to provide a module which
is capable of receiving a windshield wiper motor.
[0015] Another object of the invention is to provide a control or
circuit board mounted directly onto the module for controlling the
operation of the various electrical components associated with the
door, as well as providing an illumination system for illuminating
a stop light, license plate and, if desired, a cargo area of the
vehicle.
[0016] Another object of the invention is to provide a circuit
board having switch control logic for controlling the operation of
a plurality of electrical latch mechanisms in response to the
actuation of a handle.
[0017] Another object of the invention is to provide a module
having an integrally-molded door handle which, when actuated,
engages a switch on the circuit board to unlock the door in
accordance with logic rules established by the switch control
logic.
[0018] Still another object of the invention is to provide an
integral one-piece molded construction having guide or wedge wings,
module and door handles and a docking station integrally-molded in
a one-piece molded construction and further capable of receiving
the various other components such as a windshield wiper motor and
circuit boards.
[0019] Yet another object of the invention is to provide a system
and method for assembling a plurality of components onto a
module.
[0020] Another object of the invention is to provide a module
having a plurality of components mounted thereon and which can be
aligned and mounted directly onto a door during assembly, thereby
reducing the need for separately mounting a plurality of parts onto
the door.
[0021] In one aspect, this invention comprises an automotive
assembly module comprising an automotive module having a handling
area, the handling area defining an area where the module may be
handled for installation; a handle situated at the handling area
for permitting a user to grab the module during an installation
procedure; the automotive module having a center of gravity
associated with the handling area at which a plurality of
weight-overturning moments are substantially balanced. It would
subsequently be covered by an interior trim panel.
[0022] In another aspect, this invention comprises an automotive
assembly module comprising an automotive module having a handling
area, the handling area defining an area where the module may be
handled for installation; a handle situated at the handling area
for permitting a user to grab the module during an installation
procedure; the automotive module having a center of gravity
associated with the handling area at which a plurality of
weight-overturning moments are substantially balanced.
[0023] In still another aspect, this invention comprises a method
of providing a plurality of components on a door of an automobile
comprising the steps of providing a module having a handling area
defining an area where the tailgate module may be handled for
installation; and providing a handle situated at the handling area
for permitting a user to grab the module during an installation
procedure so that the module can be situated on an automobile or
part thereof; wherein the module having a center of gravity
associated with the handling area at which a plurality of
weight-overturning moments are substantially balanced.
[0024] In yet another aspect, this invention comprises an
automotive assembly module for mounting on a door of a vehicle
comprising: a platform module; a circuit board mounted on the
module, the circuit board comprising a stop light mounted thereon
and a microprocessor coupled to selected lighting elements of the
stop light for controlling the operation of the stop light, the
microprocessor being capable of flashing the stop light before the
stop light is fully actuated, the circuit board further comprising
an illuminating system for illuminating either a license plate
mounted on the door or a cargo area of said vehicle; a heater grid
plug mounted on the circuit board for electrically coupling a
heater grid associated with glass on the door to a circuit on the
circuit board; a latch docking area for detachably supporting
docking latches to be installed on the door of the automobile; at
least one guide for aligning the module on said door; a wire
storage system for storing wires during transit of said module; a
module handle situated on the module for permitting a user to grab
the module during an installation procedure; the automotive module
having a center of gravity associated with the handling area at
which a plurality of weight-overturning moments are substantially
balanced; and a door actuation handle integrally-molded in the
module.
[0025] In another aspect, this invention comprises a method of
mounting a plurality of components on a door of an automobile
comprising the steps of providing a module for mounting on the
door, the module comprising a wiper motor and at least one of the
following components: an electric door latch, circuit board,
license plate illuminator, stop light, heater grid plug or cargo
area illuminator; and providing a handle on the module for
permitting a user to grab the module and mount the module on the
automobile.
[0026] Another aspect comprises a license plate illumination method
using white colored LEDs. This eliminates the need for means to
replace bulbs, as in the case of using traditional incandescent
bulbs. This also eliminates the need to electrically connect the
license plate lighting to the lighting circuit, instead making the
connection through the vehicle ignition, already available in the
module, thereby saving wiring.
[0027] Finally, in another aspect, this invention comprises an
automotive assembly module comprising a module platform for
mounting on a door of an automobile; and a plurality of module
components either mounted on or integrally formed in the module;
the module facilitating mounting of the plurality of components
onto said door of the automobile.
[0028] Other objects and advantages of the invention will be
apparent from the following description, the accompanying drawings,
and the appended claims.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0029] FIG. 1 is a fragmentary view of a vehicle showing a rear
tailgate door having a module of the present invention mounted
thereon;
[0030] FIG. 2 is a fragmentary sectional view taken along the line
2-2 in FIG. 1;
[0031] FIG. 3 is an exploded view of a one-piece molded platform
having a plurality of components;
[0032] FIG. 4 is a fragmentary view of the assembly module shown in
FIG. 3 as assembled and as positioned in operative relationship
with the inner surface of the door shown in FIG. 1;
[0033] FIG. 5 is a fragmentary view showing various details of the
door handle shown in FIGS. 1-4; and
[0034] FIG. 6 is a fragmentary exploded view of the latch
mechanisms, showing mounting means to the docking posts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] Referring now to FIG. 1, a tailgate 10 of an automobile is
shown. In the embodiment being described, the tailgate 10 comprises
an automotive assembly module 12 (FIGS. 3 and 4) comprising a
molded platform 48 on which a plurality of components capable of
performing a plurality of functions are mounted thereon. In the
embodiment being described, the assembly 12 comprises a plurality
of electronic door latches 14 and 16 which are, ultimately, secured
to the door 10 using flanges 14a and 16a, respectively. The
electric door latches 14 and 16 are under the control of a circuit
board 18 and switch control logic which lock and unlock the door
10. In the embodiment being described, suitable latches 14 and 16
are model number 100510 available from Value Security Systems of
France. The unlocking process will be described later herein.
[0036] As best illustrated in FIGS. 3 and 4, the module 12
comprises the circuit board 18 which contains various circuits for
controlling the various electrical components mounted on the door
10. In the embodiment being described and as best illustrated in
FIG. 2, the circuit board 18 comprises a switch 20 which, when
actuated, energizes latches 14 and 16 in accordance with switch
control logic 21 on circuit board 18. In order to actuate the
switch 20, the module 12 comprises a door handle 22 (FIGS. 2-4)
having a switch actuator 22a having an end 22b (FIG. 2) which
engages switch 20 when the door handle is pivoted to an open door
position in the direction of arrow A in FIG. 2. In this regard, the
handle 22 is integrally-molded into module 12 and has an associated
line of weakness 24 (FIGS. 3 and 4) so that the handle 22 may be
easily pivoted from a home or locked position, as shown in FIG. 2,
to an open switch actuated position wherein end 22b engages and
actuates switch 20. The circuit board 18 comprises the switch or
control logic 20 which defines the logic for energizing latches 14
and 16. For example, when an interior tailgate unlock switch is
actuated by an operator of the vehicle and the door handle 22 is
actuated such that the end 22b engages switch 20, then the latches
are energized and cause the door 10 to become unlocked so that it
can be opened for access to a cargo or passenger area (not shown)
of the vehicle.
[0037] If the operator of the vehicle fails to actuate the interior
tailgate door unlock switch then, when the handle 22 is actuated in
the direction of arrow A in FIG. 2, the switch control logic 20 on
circuit board 18 does not energize locks 14 and 16. In the
embodiment being described, the switch control logic 20 may
comprise logic to permit an operator to directly energize the
latches 14 and 16 to unlock the door without actuation of the
handle 22 if desired.
[0038] Notice that the circuit board 18 is coupled to the latches
14 and 16 via a plurality of wires 26. As best illustrated in FIG.
3, the module 12 further comprises a plurality of wedge wings 28
and 30 which are integrally-molded into the module and which define
wedge areas 28a and 30a, respectively, for receivably securing or
storing wires 26 to the module 12 during transportation and after
the module 12 is mounted to the door 10. Notice in FIGS. 3 and 4
that the wedge wings 28 and 30 are generally V-shaped in cross
section and are received in a plurality of openings 32 and 34 (FIG.
4) of tailgate 10. Because the platform 48 is an integral molded
one-piece plastic construction, it may be desirable to provide a
gap or distance D1 (FIG. 4) between wall 10a of door 10 and face
48a of platform 48 so that when a screw 40 is tightened, the wedge
wings 28 and 30 become press fit and taut in apertures 32 and 34.
The face 48a of platform 48 also is driven towards inner surface
10a of door 10 and torques as screw 40 is tightened to snugly
secure the module 12 to the door 10. Thus, when the module 12 is
mounted on the door 10, the wedge wings 28 and 30 are received in
openings 32 and 34, respectively, and either press or force fit
until taut. The module 12 comprises a plurality of detents 36 (FIG.
4) which are received in opening 38 to lock the module 12 to the
door 10. In the embodiment being described, the wedge wings 28 and
30 comprise a plurality of staggered ribs 28b and 30b,
respectively, which cooperate to provide the wire receiving areas
28a and 30a mentioned earlier herein. A screw 40 may also be used
to fasten the module 12 to the door 10.
[0039] It should be appreciated that the wedge wings 28 and 30
facilitate aligning the module 12 onto door 10 so that the module
12 can be easily aligned and mounted onto the door 10 during
installation. In order to facilitate handling, a module handle 44
is provided as an integrally-molded part of module 12. The module
handle 44 is situated at a handling area 46 of module 12. The
module handle 44 permits a user to grab the module handle 44 during
installation. In order to facilitate installation onto door 10, the
module handle 44 is situated at the handling area 46 such that,
when all the components of the module 12 are mounted on the module
12, the module handle 44 is situated at a position where a center
of gravity of the module 12 is substantially balanced so that a
plurality of weight overturning moments, such as the moments
illustrated by arrows B, C, D, E, F and G, are substantially
balanced. This facilitates permitting an assembler to simply grab
handle 44 and easily maneuver and position module 12 relative to
the door 10 and so that wings 28 and 30 are received and press fit
into apertures 32 and 34, respectively.
[0040] In the embodiment being described the wedge wings 28 and 30,
door handle 22 and module handle 44 are an one-piece molded
construction integrally-molded into platform 48 of module 12.
[0041] In the embodiment being described and as best illustrated in
FIGS. 3 and 4, the module 12 further comprises a wiper motor 50
which is mounted onto module 12 at a wiper motor receiving area 52
using bolts 54. The wiper motor 50 drives a wiper blade 56 (FIG. 1)
from an inwipe position 58 to an outwipe position 60. The wiper
motor 50 is electrically coupled to and powered by the circuit
board 18 which comprises a wiper control circuit 19 (not shown) for
controlling the operation of the wiper motor 50. The microprocessor
(not shown) on circuit board 18 may be programmed for controlling
operation of the wiper motor 50.
[0042] The platform 48 of module 12 further comprises a plurality
of integrally-molded docking posts 56 and 58 for receiving lock
mechanisms 14 and 16, respectively. In this regard, the latch
mechanisms 14 and stored 16 both comprise latches (not shown) which
are seated and stored on the docking posts 57 and 59 during
transportation. When it is desired to mount the latches 14 and 16
to the door 10, as illustrated in FIG. 1, then the latches 14 and
16 are removed from the docking posts 57 and 59, respectively, and
mounted at their respective positions on the door 10.
[0043] In the embodiment being described, the circuit board 18
comprises an illumination system 60 comprising a plurality of light
emitting diodes (LEDs) 62 which generate light through a plurality
of openings 64 and through reflector 66 which in the embodiment
being described is red and is mounted on platform 48. Notice that
the platform 48 of module 12 is thus capable of providing a center
high mounted stop light area 68 which cooperates with the LEDs 62
on circuit board 18 to provide a center high mounted stop light on
the door 10, as best illustrated in FIGS. 1, 3 and 4.
[0044] The illuminating system 60 may further comprise a pair of
light emitting diodes 69 and 70 either hand wired to or mounted on
circuit board 18 which provide illumination through openings 72 and
74 in handle 22 (FIGS. 3 and 4) which illuminates a license plate
76 (FIG. 1).
[0045] In the embodiment being described, the circuit board 18
comprises the above-mentioned microprocessor and suitable memory
(not shown) which are coupled to and control the operation of the
LEDs to provide stop light illumination and license plate
illumination in response to the operation of the vehicle by an
operator. Also, the microprocessor can energize the LEDs 62, 69 and
70 so that the lights can be flashed on and off, for example, in a
first actuation or in an emergency situation or to provide
illumination to a cargo area (not shown) of the vehicle 10 as
desired. In this regard, the circuit board 18 may have cargo LEDs
(not shown) mounted on or coupled to the circuit board to
facilitate illuminating the cargo area of the vehicle when, for
example, a cargo area light switch (not shown) is actuated to an
"on" position. For example, the circuit board 18 may comprise a
plurality of LEDs 76 which provide illumination in the direction of
arrow H in FIG. 4 to illuminate the cargo area of the vehicle.
[0046] A method of mounting a plurality of components on the door
10 can be described as providing the module 12 having the platform
48 with a plurality of components either mounted on or
integrally-molded as part of the assembly 12 as described earlier.
The method further comprises the steps of providing a windshield
wiper motor 50 mounted on the module 12 with the bolts 54, the
electric door latches 14 and 16 detachably mounted on the docking
posts 57 and 59, respectively. The circuit board 18 is also mounted
on the platform 48 prior to installing using conventional means
such as screws (not shown) such that the LEDs 62, 69 and 70
described earlier herein become operatively aligned with the
opening 64, 72 and 74. The wiper motor 50, latches 14 and 16,
reflector 66, and circuit board 18 are mounted directly on the
platform 48, and the other components are integrally-molded as a
one-piece molded construction. Notice that the reflector 66 is
situated on a face 48a of platform 48 using a suitable adhesive or
fasteners.
[0047] The circuit board 18 may further comprise a heater plug 80
and a heater control circuit (not shown) for coupling to a
conventional heating grid 19 (FIG. 1) which is used to defrost
window 82.
[0048] Thus, it should be appreciated that what was once a
plurality of components separately assembled onto a door may be
provided in a convenient one-piece assembly with all the components
either mounted or integrally-molded thereon. The circuit board 18
may be optionally coupled to and programmed to control the
operation of the components.
[0049] Various advantages to this assembly include the ability to
provide a one-piece module 12 assembly which can be properly and
quickly aligned using the wedge wings 28 and 30 in cooperation with
the apertures 32 and 34, respectively. Once aligned, the center
high mounted stop light comprising the LEDs 62 are properly
positioned in association with the opening 64, reflector 66 and
window 82 of the door 10.
[0050] The latches 14 and 16 are conveniently stored during transit
on the docking posts 57 and 59. Once the module 12 is mounted onto
door 10 using detents 36 and screw 40, the assembler is free to
remove the lock mechanisms 14 and 16 and mount them onto the door
10, as shown in FIG. 1.
[0051] As mentioned earlier, the invention further comprises the
convenient one-piece door handle 22 molded directly into platform
48 of module 12 so that when the handle 22 is actuated in the
direction of arrow A (FIGS. 2 and 5), the end 22b engages switch 20
on circuit board 18 to electronically actuate latches 14 and 16 as
controlled by the switch control logic 20 on circuit board 18.
[0052] It should also be appreciated that the illumination system
60 provides permanent illumination under the control of
microprocessor or circuit board 18 so that the license plate 76
(FIG. 1) and the stop light reflector 66 may be illuminated when
appropriate. Advantageously, the use of the LEDs on the circuit
board 18 provide long-lasting light which reduces or eliminates the
need for replacement incandescent light bulbs as is required in
many of the illumination systems of the past.
[0053] In the embodiment being described, the illumination system
and aforementioned LEDs 62, 68, 70 and 76 may all be placed under
microprocessor control so that they can be powered and controlled
either directly from circuit board 18 or directly wired to the
vehicle ignition system which, in turn, eliminates the need for
separate wiring to, for example, a light socket which receives
incandescent lights.
[0054] It should be appreciated that the circuit board 18 may be
coupled to the ignition system or electronic control system of the
vehicle and provides microprocessor controlled operation for the
illumination system, wiper motor 50 and latches 14 and 16, although
other operations may be controlled by the circuit board 18 such as
the energization of the heating grid 79 via plug 80.
[0055] Once the module 12 is mounted onto door 10, an aesthetically
pleasing interior door cover (not shown) is mounted on the cover to
hide the module 12 and its components. Notice also that the handle
22 extends through the door 10 and is covered by a door handle
cover 84 (FIGS. 1 and 2) so that the handle 22 is not visible when
viewed at the level or in the direction of, for example, arrow RI
in FIG. 2.
[0056] Advantageously, many of the mechanical logic and latch
linkage required by door assemblies of the prior art are eliminated
which, in turn, eliminates several of the assembly steps and
maintenance problems associated with the latch mechanisms known by
the prior art. Also, the one-piece molded module 12 provides a
convenient platform for holding a plurality of components in a
balanced manner so that they can be easily transported. Once the
module 12 is molded and the various components are mounted thereon,
the assembly can be easily positioned on the door 10 and fastened
to the door 10.
[0057] In the embodiment being described, the circuit board 18,
switch control logic 21 and associated microprocessor (not shown)
and memory (not shown) and illumination system 60 are available on
a one-piece circuit board available from Valeo Electrical Systems,
Inc. currently of Dayton, Ohio who is the assignee of the present
invention.
[0058] While the forms of apparatus herein described constitute
preferred embodiments of the invention, it is to be understood that
this invention is not limited to these precise forms of apparatus,
and that changes may be made therein without departing from the
scope of the invention which is defined in the appended claims.
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