U.S. patent application number 09/790313 was filed with the patent office on 2002-01-24 for vehicle door and process of assembling the vehicle door.
Invention is credited to Kawamoto, Chikashi, Nishikawa, Ikuo, Ogawa, Kenichi, Shouno, Noboru.
Application Number | 20020007598 09/790313 |
Document ID | / |
Family ID | 18575018 |
Filed Date | 2002-01-24 |
United States Patent
Application |
20020007598 |
Kind Code |
A1 |
Nishikawa, Ikuo ; et
al. |
January 24, 2002 |
Vehicle door and process of assembling the vehicle door
Abstract
A vehicle door includes an outer door panel, an inner door panel
formed with an aperture and a plastic mounting panel to which
functional devices of the vehicle door and door parts are installed
and which is installed to the inner door panel to enclose the
aperture thereof, the mounting panel having a plastic panel, a
plastic structural part appendant to the plastic panel, and a
breakable joint connecting the plastic structural part to the
plastic panel as one whole piece. The structural part is separated
from the plastic panel by breaking away the joint from the plastic
panel and installed to the plastic panel after having installed the
plastic panel to the vehicle door in order to cover an access
opening which provides access to the interior of the vehicle door
for assembling for example an exterior door handle and window
glass.
Inventors: |
Nishikawa, Ikuo; (Hiroshima,
JP) ; Kawamoto, Chikashi; (Hiroshima, JP) ;
Ogawa, Kenichi; (Hiroshima, JP) ; Shouno, Noboru;
(Hiroshima, JP) |
Correspondence
Address: |
RALPH E. SMITH
Brooks & Kushman P.C.
22nd Floor
1000 Town Center
Southfield
MI
48075-1351
US
|
Family ID: |
18575018 |
Appl. No.: |
09/790313 |
Filed: |
February 21, 2001 |
Current U.S.
Class: |
49/502 ;
49/506 |
Current CPC
Class: |
B60J 5/0451 20130101;
E05Y 2600/10 20130101; B60J 5/0416 20130101; E05Y 2201/684
20130101; B60J 5/0425 20130101 |
Class at
Publication: |
49/502 ;
49/506 |
International
Class: |
B60J 005/04 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 29, 2000 |
JP |
2000-53666 |
Claims
What is claimed is:
1. A vehicle door comprising an outer door panel, an inner door
panel formed with an aperture, and a mounting panel to which
functional devices of the vehicle door and door parts are inaled
and which is installed to the inner door panel to cover up the
aperture of the inner door panel, said mounting panel compnsing: a
plastic panel formed in conformity with the aperture of the inner
door panel; a plastic strtctur part appendant to said plastic
panel; and a breakable joint connectng said plastic seal part to
said plastic panel; wherein said plastic panel said plastic s o
part and said joint are formed as one piece and said part is
separated from said plastic panel by breaking away said joint from
said plastic panel during installing work of said mounting panel to
said inner door panel.
2. A vehicle door as defined in claim 1, wherein said plastc strual
part is one of said door parts bat is inslled to said mounting
panel.
3. A vehicle door as defined in claim 2, wherein said plastic panel
is formed with an opening for an access to an inside of the vehicle
door for assembling the vehicle door, said opening being covered by
said structural part when said plastic strtctural part is installed
to said plastic panel afler installation of said plastic panel to
the inmer door panel.
4. A vehicle door as defined in 1, wherein said inner door panel
has a substantial wall section forming part of a side wall of a
passenger compartment of the vehicle and said plastic structural
part before separation from said plastic panel occupies a location
where said plastic structural part overlaps said substantial wall
section when said mounting panel is ied.
5. A vehicle door as defined in claim 4, wherein said plastic
structural part is one of said door parts that is installed to said
mounting panel.
6. A vehicle door as defined in claim 5, wherein said platc panel
is formed with an opening for an access to an inside of the veticle
door for assembling the vehicle door, said opening being covered by
said swtrlpart intled to the platc panel after isalton of said
platc panel to the inner door panel,
7. A vehicle door as defined in clam 6, wherein said stutrdpart is
formed with ribs operative to absorb shocks from the outer door
pnL.
8. A door assembling process of assembling a vehicle door for a
vehicle which comprises an outer door panel, an inner door panel
formed Nwith an aperft=r an a mounting panel to which fainctional
devices of the vehicle door and door parts are installed and which
is installed to the inner door panel to close up the aperture of
the inner door panel, said assembling process comprising the steps
of preparing a door panel subassembly of the vehicle door
comprising the outer door panel and the inner door panel; preparing
the mounting panel comprising a plastic panel formed in conformity
with the aperture of the inner door panel, a plastic st al part
appendant to said plastic panel, and a breakable joint connecting
said plastic sexual part to said plastic panel as one whole piece;
and separating said plastic structural part from said plastic panel
by breaking away said joint from said plastic panel and installing
said plastic structual part to the mounting panel at a specified
location dring installing operation of the mounting panel to said
door panel subassembly of the vehicle door.
9. A door assembling process as defined in claim 8, wherein said
plastic structural part is separated from said plastic panel and
installed to the plastic panel at a specified location after
installation of the plastic panel to said inner door panel.
10. A door assembling process of assembling a vehicle door for a
vehicle which comprises an outer door panel, an inner door panel
formed with an aperture and a mounting panel to which functional
devices of the vehicle door and door parts are installed and which
is installed to the inner door panel to close up the aperture of
the inner door panel, said assembling process comprising the steps
of, preparing a door sub-assembly of the vehicle door comprising
the outer door panel and the inner door panel; preparing the
mounting panel comprising a plastic panel formed in conformity with
the aperae of the inner door panel and formed with an opening for
an access to an inside of the vehicle door for assembling the
vehicle door, a plastic cover for covering said opening, and a
breakable joint connecting said plastic cover to said plastic panel
as one whole piece; and installing the functional devices of the
vehicle door and the door parts to the mounting panel; installing
the mounting panel to said door subassembly of the vehicle door so
as to close up the aperture of the inner door panel; and separaimng
said plastic cover from said plastic panel by brealang away said
joint from said plastic panel and installig said cover to the
mounting panel so as to cover said opening.
Description
BACKGROUND OF TlE PRESENT INVENT
[0001] 1. Field of the Invention
[0002] The present invention relates to a lightweight door of a
vehicle which is easy to assemble and comprises a decreased number
of parts and a method of assembling the door.
[0003] 2. Description of the Related Art
[0004] Typically, vehicle doors are made up of a door panel
assembly comprising a steel inner door panel and a steel outer door
panel to which various functional part and devices, such as a
window regulator and a door lock/unlock mechanism, are directly
mounted. In recent years, m order to decrease the number of
internal constituent parts of such a vehicle door and to lighten
such a door, it has been proposed to use a plastic panel to which
various functional parts and devices are mounted. The plastic panel
is attached to the steel inmer door panel such that it closes up an
opening of the inner door panel. One of the vehicle doors is known
from, for example, Japanese Unexamined patent application No.
9-157374.
[0005] Because using the plastic mounting panel Prepared sepaately
from the door panel assembly allows the inner door panel to take
even various complicated forms without restraint it is possible to
elimin fixmng members such as clips that are used to fix internal
constituent parts and devices to the door panel assembly. Further,
because using the plastic panel allows internal constituent parts
and devices to be disposed at various locations, a significant
effect is produced in terms of increasing the degree of freedom for
laying out the internal constituent parts
[0006] The plastic panel is fonned by press molding or ninjction
molding. In the case here one piece panel member is used to form
the almost entire part of the inner door panel as disclosed in
Japanese Unexamined patent application No. 9-157374, it is almost
inevitable that the inner door panel is large in siz. In
consequence, when using a plastic panel member that is attached to
a door panel assembly, a large size of mold is necessary. This
needs a large amount of plastic material and results in application
of considerably high molding pressure or injection pressure. It is
undesirable to use a large siue of molding equipment and a large
amount of material for simply preparing the one piece plastic panel
in light of production efficiency.
SUUMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to
provide a vehicle door winch includes a plastic panel to be intled
thereto, the platc panel being formed with lugh efficiency of
production.
[0008] It is another object of the present invention to provide a
process of assembling a vehicle door which includes a plastic panel
intled to the vehicle door, wit high efficiency of assembling.
[0009] The above objects of the present invention are accomplished
by a vehicle door comprising an outer door panel, and an imner door
panel formed with an aperture, a mounting panel to which
fuinctional devices of the vehicle door and door parts are mounted
and which is installed to the inner door panel to close up the
apertur of the inner door panl. The mounting panel comprss a
plastic panel formed in conformity with the aperture of the inner
door panel, a plastic stutrlpart apeat to the platc panel, and a
breakable joint connecting the plastic stuctual part to the plastic
panel which are formed as one piece by, for example, injection
molding. The plastic structural part is separated from the plastic
panel by breaking away the joint from the plastic panel during
installing work of the mounting panel to the imner door panel.
[0010] The plastic structural part is one of the door parts that
are mounted or fitted to the mounting panel, such as a cover for
covering an opening formed in the plastic panel which provides an
access to the inside of the vehicle door for assembling the vehicle
door The plastic structual part is mounted or fitted to the plastic
panel desirably after inatallation of the plastic panel to the
inner door panel.
[0011] The inner door panel has a substantial wall section fonning
part of a side wall of a passenger compartment of the vehicle and
the plastic structual part before separation from the plastic panel
occupies a location where it overlaps the substantial wall section
of the inner door panel when the mounting panel is installed.
[0012] According to the vehicle door of the present invention, the
plastic mounting panel is formed as one piece including a
structural part which is separated from the plastic mounting plate
and installed to the plastic mounting panel after having been
assembled to the vehicle door. This configuration of the plastic
mounting panel enables putfng a large amount of plastic material
and a large si molding apparatus to efficient use, so as to
increase the productivity of the mounting panel.
[0013] Owing to the configuration of the plastic mounting panel Mat
the plastic struual part before separation from the plastic panel
occupies a location where it overlaps the substantal wall section
of the inner door panel when the mounting panel is installed, while
the plastic mounting panel is formed so as to have the plastic
panel in conformity with the aperture of the inner door panel, the
plastic structural part is formed as one of the door parts at a
location where the plastic panel is in non-occupation. As a result,
the plastic mounting panel can be configured in the form of
substantially rectangular flat plate, so that it is easy to pile up
a number of the plastic mounting panels and to convey a stack of
the plastic mounting panels safely and reliably, without separating
the appendant parts. For example, in the case where the plastic
panel has a shape like a generally rectangle with one of the comers
cut off, the plastic structural part is formed in a generally
rectangular panel by locating the plastic structural part as an
appedant part to the plastic panel at the cutff comer. Moreover,
because the plastic structural part is one of the door parts that
be installed to the mounting panel, the plastic structural part can
be always along with the plastic panel until the plastic panel is
installed to the door panel and is separated from the plastic panel
immediately before the plastic structural part is intended to be
installed to the plastic panel. In consequence, it is not feared
that the plastic st al part is missing before assembling such as
during conveyance thereof
[0014] In the case where the plastic structural part is formed as a
cover for covering an opening formed in the plastic panel which
provides an access to the inside of the vehicle door for assembling
the vehicle door, the plastic s part is always along with the
plastic panel until the assembling work is finished, so as to make
it reliable to cover the acess opening in the plastic panel,
thereby completing the vehicle door.
[0015] According to the process of assembling the vehicle door of
the present invention, the plastic structural part is separated and
then installed to the plastic panel during assembling work of the
vehicle door or after the plastic panel has been installed to the
door panel. Desirably, the plastic structural part is separated and
then installed to the plastic panel after having installed the
plastic panel to the door panel. In consequence, the plastic
structural part is always along with the plastic panel until the
assembling work is finished, so that it is not feared that the
plastic structural part is missing before assembling such as during
conveyance thereof, which makes it reliable to install the plastic
structural part to the plastic panel in order to complete the
vehicle door. The process elnates the fear that the plastic
strucral part is missing and provides reliable installation of the
plastic structural part to the plastic panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and other objects and features of the present
invention will be clearly understood from the following description
with respect to the preferred embodiments thereof when considered
inconjunction with the accompanying drawings, in which:
[0017] FIG. 1 is an exploded view of a vehicle door in accordance
with a preferred embodiment of the present invention;
[0018] FIG. 2 is a front view of a plastic panel as viewed from a
passenger compartment;
[0019] FIG. 3 is a rear view of the plastic panel as viewed from
the outside of the passenger compartment;
[0020] FIG. 4 is a longitudinal-sectional view of a completed
vehicle door taken along a vertical center line;
[0021] FIG. 5 is an exploded view of a window glass regulator rail
of a window regor;
[0022] FIG. 6 is a longitudinal-sectional view of a rear lower part
of the completed vehicle door;
[0023] FIG. 7 is an exploded view of an interior door handle;
[0024] FIG. 8 is a cross-sectional view showing a linkage stricture
between an interior door handle and handle linig cable;
[0025] FIG. 9 is a perspective view of a door latch unit cover;
[0026] FIG. 10 is a tnsverse-sectional view of a door latch unit
and its associated parts;
[0027] FIG. 11 is a perspective view of a reinforcement plate;
[0028] FIG. 12 is a cross-sectional view of window glass guide;
[0029] FIG. 13 is a cross-sectional view showing a speaker mounting
structure;
[0030] FIG. 14 is a perspective view showing a harness fitting
structure;
[0031] FIG. 15 is a perspective view showing a cable fitting
structure;
[0032] FIG. 16 is a cross-sectional view of the plastic panel with
a cover for an exterior door handle access opening leftjoined;
[0033] FIG. 17 is a cross-sectional view of the plastic panel with
a cover for a window glass access opening lefjoined;
[0034] FIG. 18 is a cross-sectional view of the cover fitted in the
exterior door handle access opening; and
[0035] FIG. 19 is a cross-sectional view of the cover fitted inthe
window glass access opeming.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0036] Although the following description is directed to a front
door of a vehicle by way of example, the present invention is
applicable to a rear door and a back door with the same
effects.
[0037] Referring to the drawings in detail, and, in particular, to
FIGS. 1 to 3 showing a front door of a vehicle )which will be
referred to as a vehicle door for simplicity) in accordance with a
preferred embodiment of the present invention, the vehicle door is
made up of a door panel sub-assembly D comprising a steel inmer
panel D1, a steel outer panel D2 and a steel window sash D3,
aplastic mounting panel P, and a trim unit T which forms a side
wall of a passenger compartmet The window sash D3, which is shaped
such as to have a front part inclined rearward as viewed from the
front of the vehicle, receives an window glass W therein. The door
panel D at its front end is provided upper and lower hinges 1 and
2. The inner panel D1has a generally rectangular aperture 3 formed
below a belt line and has a front top corner D1a uncut. An upper
mounting panel Portion D1b above the belt line and integral with
the uncut part D1a provides the inner panel D1 with structural
rigidity at least necessary for an inmer panel. The inner panel D1
is formed with a plurality of holes 4 arranged around the aperture
3 for fastening clips and set screws (not shown) for attaching the
plastic mourning panel P and the trm unit T to the door panel
subassembly D.
[0038] The door panel subassembly D is equipped with an impact bar
6 extending in a lengthwise direction of the vehicle between the
imner panel D1 and the outer panel D2 in order to provides the door
panel subassembly D with increased rigidity against side impact
thereon. The outer panel D2 is provided with an exterior door
handle 7 at its rear top comer thereof The plastic mounting panel P
has an overall shape im almost conformity to the aperture 3 of the
inner panel D1. The plastic mounting panel P is formed with a
plurality of holes 11 arranged along the peripheral margin so as to
correspond in position to the holes 4 of the inner panel D1.
Further, the plastic mounting panel P at its center portion is
formed with an opening 12 for an access to the inside of the door
panel subassembly D for installing the window glass W to a window ;
regulator R The plastic mounting panel P at its rear top comer is
formed with an opening 13 for an access to the inside of the door
panel subassembly D for connecting a wire cable and its associated
parts to the exterior door handle 7. The plastic mounting panel P
is further formed with a speaker mount 14, a pocket 15 and a side
crash pad 16, all of which are arranged in the lengthwise direction
at a lower portion of the plastic plate P and project toward the
passenger compartment, and a bracket 17 positioned at a center
thereof The trim unit T is fixed to the plastic mounting panel P.
and hence the door panel sub-assembly D, through the bracket
17.
[0039] As shown in detail in FIG. 3 showing an apperance of the
plastic mounting panel P as viewed from the outside of the
passenger compartment, the plastic mounting panel P is formed and
provided with various constituent parts including at least a window
glass guide rail 18, a sealing member 19, and access opening covers
22 and 23. Specifically, the window glass guide rail 18 is attached
to a front portion of the plastic mounting panel P so as to guide
up and down movement ofthe window glass W The sealing member 19,
which is made of, for example, waterproof rubber strip, attached to
the plastic mounting panel P so as to extend along the periphery
except an upper side of the plastic mounting panel P. The access
opening cover 22 is fonned as an appendant part to the plastic
mounting panel P at a front upper cutaway comer so as to be easily
separated from the plastic mounting panel P by braking away joints
20 after it has been attached to the plastic mounting panel P to
cover up the access opening 13. Similarly, the access opening cover
23 is formed as an appendant part to the plastic mounting panel P
at the front upper cutaway comer so as to be easily separated from
the plastic mounting panel P by breaking away joints 21 after it
has been attached to the plastic mounting panel P to cover up the
access opening 12. The access opening cover 22 is formed with a
shock absorbing lattice structure comprising ribs 22a and installed
to the plastic mounting panel P such that, when the plastic
mounting panel P is installed to the door panel sub assembly D, the
access opening cover 22 absorbs impact from the exterior door
handle 7.
[0040] The plastic mounting panel P is additionally provided with
vanous finchonal parts and devices including at least an interior
door handle 30, a handle linking cables 31, a motor R1 of the
window regulator R and a front speaker 32 which are at the inner
side of the plastic mounting panel P as viewed from the passenger
compartment, and a guide rail R2, a drum pulley R3 and a cable R4
forming parts of the window regulator R and a door latch unit 33
(schematically depicted in FIG. 2) which are at the outer side of
the plastic mounting panel P as viewed from the passenger
compartment These functional parts and devices are attached to the
plastic mouning panel P before the plastic mounting panel P is
installed to the door panel subs assembly D. Specifically, the
intror door handle 30 isinstalled to an upper portion of the inner
side of the plastic mounting panel P as viewed from the passenger
compartment The handle cable 31 extends from the interior door
handle 30 and the door latch unit 33. The motor Rl is installed to
the center portion of the plastic mounting panel P The front
speaker 32, which forms a part of an audio system, is mounted to
the speaker mount 14. The guide rail R2, the drum pulley R3 and the
cable R4 are installed to the center portion of the plastic
mounting panel P The door latch unit 33, which is engaged by a body
striker (not shown), is installed to a rear portion of the plastic
mounting panel P The plastic mounting panel P is additionally
provided with harnesses H for supplying electric power to various
electric constituent parts. The harnesses extend passing through a
center hole 34, front half portions thereof extending on the outer
side of the plastic mounting panel P as depicted by a solid line in
FIG. 3 and rear half portions thereof extending on the inner side
of the plastic mounting panel P as depicted by solid line in FIG.
2.
[0041] As seen in FIG. 1, the trim unit T is instlled to the door
panel sub-assembly D after the plastic mounting panel P is
installed so as to form a side wall of the passenger comparment The
trm unit T is formed and provided with various parts and devices
including a switch unit 40 having a plumality of switches for
actuating at least a powerrven window regulator and a powerdnven
door lock/unlock mechanisrn an assist grip 41 and an ann rest 42
extending behind the switch unit 40. In addition, a speaker cover
43 and a pocket wall 44 are formed as appendant parts to the trim
unit T. The speaker cover 43 is fitted on the speaker mount 14 so
as to cover the front speaker 32. The pocket wall 44 closes one
side of the pocket 15 facing the passenger companment. The window
glass W is installed to the door panel subassembly D aftr the
plastic mounting panel P is installed. Specifically, the window
glass W is inserted into the door panel sub-assembly D, i.e.,
between the inner panel D1 and the outer panel D2, from the side of
the window sash D3, and then, installed to the window regulator R
on the plastic mounting panel P.
[0042] Details of the respective parts and devices of the vehicle
door will be described below in conjunction with FIGS. 4 through
19.
[0043] FIG. 4 shows a completed vehicle door in longitudial-secion
along a vertical center line thereof In an interior space of the
door panel suiassembly D fonned between the inner panel D1 and the
outer panel D2 there is disposed the guide rail R2 of the window
regulator R instlled to the plastic mounting panel P such as to
extend in a direction of height of the vehicle. The window glass W
is located on the outer side of the guide ral R2 so as to be guided
by the guideil R2. The impact bar 6 is disposed on the outer side
of the window glass W such as to extend in the lengthwise
direction. In order to provide the passenger compartment with
reliable watertiglitness, the waterproof sealing strips 19 are
finrly caught between the plastic mounting panel P and the inner
panel DI, specifically the upper mounting panel Porton D1b and a
lower mounting panel Portion Dlc below the aperture 3 ofthe inner
panel D1, respectively, so as to block the aperture 3. The guide
rail R2 is supported from the outer side thereofby the a fixing rib
45, a fixing boss 46 and an engaging boss 47 fixedly attached to or
formed as an integral part with the plastic mounting panel P and is
installed to the plastic mounting panel P through a fixing bolt 50
at an upper extreme end and a L-shaped tongue 51 at a lower extreme
end thereof The trim unit T is inserted at its upper end Ta between
the upper mounting panel Portion D1b of the inner panel D1 and the
window glass W and is fixed at its lower end Th to the lower
mounting panel Portion D1c of the inner panel D1 so as thereby to
be installed to the door panel sub-assembly D and to cover the
plastic mounting panel P The pocket wall 44 is formed as an
integral part with the trim unit T and fonns an inner side wall of
the pocket 15 when the tn unit T is installed to the door panel
subassembly D so as thereby to complete a box-shaped pocket 53 for
small articles.
[0044] As shown in FIG. 5, in the installing process of installing
the guide rail R2 of the window regulator R to the plastic mounting
panel P, after temporarily keeping the guide rail R2 in position
relative to the plastic mounting panel P first by inserting the
L-shaped tongue 51 ofthe guide rail R2 into a slot 47a of the
engagement boss 47, positioning and engaging pins 46a extending
from the fixing bosses 46 are engaged within holes R2a formed in
the guide rail R2, respectively. Finally, the fixing bolt 50 is
passed through one of the holes R2b and fastened into one of the
fixing bosses 46 so as thereby to firmly fix the guide rail R2 to
the plastic mounting panel P In this manner, the assembling work of
the guide rail R2 is made easy.
[0045] FIG. 6 shows a rear lower part of the completed vehicle door
in longitudinal-section. As shown, the side crash pad 16 installed
to the plastic mounting panel P projects from a transverse position
where the window glass W is located to atransverse position where
the trim unit T is located in a direction from the exterior to the
interior of the vehicle. The side crash pad 16 is formed with
impact absorption ribs 60 configured like cells in the interior
thereof which are arranged so as to open at their outside ends. The
side crash pad 16 thus configured receives energy due to an impact
from a side crash pad 61 secured to the outer panel D2 upon an
occurrence of a side crash. FIG. 7 is the interior door handle 30
which is exploded for the purpose of explaring a step of instaling
the interior door handle 30 to the plastic mounting panel P As
shown, the interior door handle 30 is directly secured to a base
block 62 formed as an iral part with the plastic mounting panel P
without employing separately provided parts. The interior door
handle 30 comprises a door lock knob 30a and a door release or
unlock knob 30b. These knobs 30a and 30b are put between upper and
lower brackets 63 and 64 extending from the base block 62 of the
plastic mounting panel P as depicted by a double-dotted line so as
to turn about a vertical axis in opposite directions. The door lock
knob 30a has a coupling arm 65 as an integral part therewith and
formed with a coupling hole 65a in which a bent end 31c of a cable
rod 31a (see FIG. 8) of the handle linking cable 31 is fitted.
Similarly, the door unlock knob 30b has a coupling arm 66 as an
integral part therewith and formed with a coupling hole 66a in
which a bent end 31d of a cable rod 31b (see FIG. 8) of the handle
hnking cable 31 is fitt The base block 62 is formed with an
intermediate paltaion 67 extending in parallel to and between the
upper and lower brackets 63 and 64.
[0046] As depicted in detail in FIG. 8, the handle linking cable 31
is coupled to the interior door handle 30 installed to the base
block 62 of the plastic mounting panel P. The handle linking cable
31 comprises the cable rods 31a and 31b and cable rod guide and
protect ion sheaths 31A and 31B. The cable rod 31a at its extreme
end 31c is bent at approximately a right angle and fitted in the
coupling hole 65a of the coupling arm 65. The cable rod 31b at its
extreme end 31d is bent at approximately a right angle and fitted
in the coupling hole 66ab of the coupling arm 66. In the step of
coupling the handle linking cable 31 to the interior door handle
31, namely the door lock knob 30a and the door unlock knob 30b, the
extreme bent ends 31c and 31d of the respective cable rods 31a and
31b are fitted in the coupling holes 65a and 66a of the coupling
arms 65 and 66, respectively, first Then, the interior door handle
is put and pivotally mounted between the upper bracket 63 and the
lower bracket 64 so as to locate the coupling aim 65 of the door
lock knob 30a between the upper bracket 63 and the intermediate
partition 67 and the coupling arn 66 of the door unlock knob 30b
between the intermedite partition 67 and the lower bracket 64. The
handle linkng cable coupling structure inakes the upper bracket 63
function as a stopper for preventing the cable rod 3a from slipping
off from the coupling arm 65 of the door lock knob 30a Similarly,
the handle linking cable coupling structure makes the intermediate
partition 67 finction as a stopper for preventing the cable rod 31b
from slipping off from the coupling arm 66 of the coupling arm 66
of the door unlock knob 30b. The cable rod guide and protection
sheaths 31A and 31B are fixedly supported by a bracket 67 ofthe
plastic mounting panel P.
[0047] As described above, the handle linking cable coupling
structure thus coupling the cable rod 31 to the interior door
handle 30 provides reliable power tiansrission from the door lock
knob 30a and the door unlock knob 30b to the door latch unit 33
(see FIG. 2).
[0048] FIG. 9 shows a door latch unit cover 70 by which the door
latch unit 33 is covered and protected The door latch unit cover
70, which is made of a plastic as one piece and has an outer shape
in approximately conformity with an outer shape of the door latch
unit 33, is fixed to the plastic mounting panel P through fixing
brackets 71 and 72 formed as integral parts with the plastic
mounting panel P The door latch unit cover 70 may be formed
separately from the plastic mounting panel P or may be formed as an
appendant part to the plastic mounting panel P The door latch unit
cover 70 comprises four integral sections made up as one piece.
Specifically, a cover section 73 is located at one of opposite
sides of the door latch unit cover 70 to cover a cable rod of a
handle linlkng cable 80 linking the exterior door handle 7 and a
cable rod of a cylinder inkimg cable 81 linking a key cylinder (not
shown). A cover section 74 is located at another side ofthe door
latch unit cover 70 to cover a cable rod 3la of the handle linking
cable 31 linking the door lock knob 30a A cover section 75 is
located above the cover section 74 to cover a cable rod 31b of the
handle linking cable 31 lining the door unlock knob 30b. A cover
section 76 is located at lower end of the door latch unit cover 70
to cover a motor (not shown) ofthe power-dnven door latch unit
33.
[0049] FIG. 10 shows the door latch unit 33 and its associated
parts covered by the door latch unit cover 70 in coiss-sectior The
door latch unit 33 is secured to the plastic mounting panel P from
the outer side on which the window glass W and the outer panel D2
are located. The door latch unit cover 70 protects the door latch
unit 33 from an access from the outside of the vehicle with an
intention to run away with the vehicle. The handle linking cable 31
(see FIGS. 1 and 2) extending from the interior door handle 30
along the plastic mounting panel P passes through an hole 83 formed
in rear part of the plastic mounting panel P so as to extend to the
door latch unit 33 crossing the plastic mounting panel P The hole
83 in the plastic mounting panel P is covered by the door latch
unit cover 70. Because the most part of the handle lining cable 31
lays on the inner side of the plastic mounting panel P and because
the handle linking cable 31 is linked with the door latch unit 33
withn the door latch unit cover 70, the handle linking cable 31 is
protected from an acess from the outside of the vehicle with an
intention to run away with the vehicle. As shown in FIG. 10, a
generally L-shaped reinforcernent 90 is welded, or otherwise
secured, to the inner panel D1 at a position where the door latch
unit 33 is secured by fixing bolts 84 in order to provide reliable
ftxing stiffiess of the door latch uit 33 to the inner panel
D1.
[0050] Referrng to FIG. 11 showing the 1shaped reinforcement 90 in
detail, the L-shaped reinforcement 90, which is made of a steel
plate, is formed with a generally rectangular center opening 91
through which the body striker passes across when loclkng the
vehicle door and four bolt holes 92 around the rectangular opening
91 through which bolts are inserted and fastened to the inner panel
D1 in order to fix the door latch unit 33 to the inner panel D1.
The Lshaped reinforcement 90 at its lower end is additionally
formed with a bottom rack 93. While the door latch unit 33 itself
is comparatively heavy, it is previously supported on the bottom
rack 93 of the L-shaped reinforcement 90,5s that the work of
installing the plastic mounting panel P to the door panel
sub-assembly D is made easy, as a result of which, a man-hour in
assembling the front door is considerably reduced.
[0051] FIG. 12 shows the window glass guide rail 18 of the plastic
mounting panel P in cross-section While a window glass guide rail
is conventionally provided separaely from the inner panel D1,
however, in the vehicle door of the present invention, the window
glass guide rail 18 is configured as an integral part with the
plastic mounting panel P. This integrated configion allows the
window glass guide rail 18 to be easily completed by simply fitting
a pacldng strip 18P in a groove 18a of the guide rail 18.
[0052] FIG. 13 shows the front speaker 32 attached to the speaker
mount 14 of the plastic mounting panel P in cross-section. The
speaker mount 14 projects toward the passenger compatent The front
speaker 32 is fitted in an opening reinforced by a ring 100 ofthe
speaker mount 14 and is firlly secured by, for example, fixing
bolts (not shown) to the speaker mount 14. The speaker 32 at its
back is provided with a coupler 102 to which a lead wire 101
extending the harness H is connected so as to receive audio
signals. The plastic mounting panel P is forned with a splash guard
103 extending behind and above the front speaker 32 so as to
prevent electric parts associated with the front speaker 32 from,
for example, raindrops.
[0053] FIGS. 14 and 15 show anchor strctues of the plastic mounting
panel P for anchoring the larness H and the handle linlkng cable
31. As shown in FIG. 14, the plastic mounting panel P is formed
with a harness anchor 110 as an integral part therewith for
anchoring the harness H The harness anchor 110 comprises a pair of
L-shaped anchor lugs 110a and 110b arranged oppositely in vertical
direction In order to anchor the harness H. the harness H is
positioned substantially vertically and put between the L-shaped
anchor lugs 110a and 110b. Then, the harness H at opposite parts is
bent in opposite dincons as shown by arrows so as to bring the
opposite parts into engagement with the Lshaped anchor lugs 10a and
110b, respectively. On the other hand, as shown in FIG. 15, the
plastic mounting panel P is formed with a cable anchor 111 as an
integral part therewith for anchoring the handle linking cable 31.
The cable anchor 111 comprises a generally J-shaped anchor lug
111a. In order to anchor the handle linking cable 31, the handle
linking cable 31 is inserted between the plastic mounting panel P
and the J-shaped anchor lug 111a from above and seat it on the
bottom ofthe J-shaped anchor lug 111a.
[0054] The anchor structure comprising the harness anchor 110 and
the cable anchor 111 formed as integral parts with the plastic
mounting panel P eliminates any necessity to use anchor clips which
have been conventionally prepared separately from the plastic
monting panel P Therefore, this anchor structure makes wiring work
quite simple and easy.
[0055] FIGS. 16 and 17 show the access opening covers 22 and 23
before being separated from the plastic mounting panel P,
respectively. As was previously described, the plastic mounting
panel P is prepared as one piece having the access opening covers
22 and 23. The plastic plate P isinstalled to the door panel
subassembly D with the access opening covers 22 and 23 leftjoined
to the plastic mounting panel P After having attached the plastic
mounting panel P to the door panel subassembly D, the access
opening cover 22 is separated from the plastic mounting panel P by
breaking away the joints 22a and attached to the plastic mounting
panel P in position to cover up the access opening 13 which
provides an access to the exterior door handle 7 for connecting the
handle linking cable 31 to the interior door handle 7. Similarly,
after attaching the plastic panel tot he door panel sub-assembly D,
the access opening cover 23 is sreted from the plastic mourting
panel P by breaking away the joints 23a and attached to the plastic
mounting panel P in position to cover up the access opening 12
which provides an access to the inside of the door panel
subassembly D for installing the window glass W to the window
regulator R Specifically, as shown in FIG. 16, the access opening
cover 22 is formed as an appendant partjoined to the plastic
mounting panel P by breakablejoints 20. The access cover 22 has a
shock absorbing lattice structure comprising a plurality of ribs
22a extending in opposite directions and arranged in a lattice
pattern. The access opening cover 22 is formed with a hook 22b
extending toward the inner panel Dl in conformity with the access
opening 13 so as to surround the shock absorbing lattice structure.
A rubbr packing ring 22c is seated in an annular recess formed
around the shock absorbing lattice strture before or after having
sepeeted the access opening cover 22 from the plastic mountng panel
P and before attaching it to the plastic mounting panel P to cover
up the access opening 13. As shown in FIG. 17, the access opening
cover 23 is formed as an appendant part joined to the plastic
mounting panel P by breakable joints 21. The access cover 23 is
formed with a hook 23b extending toward the inner panel Dl in
conformity with the access opening 12. A ribber packing ring 23c is
seaed in an annular recess formed around the hook 23b before or
after having separated the access opening cover 23 from the plastic
mounting panel P and before attaching it to the plastic mounting
panel P to cover up the acess opening 12.
[0056] FIGS. 18 and 19 show the access covers 22 and 23 are
attached in position to cover up the access openings 13 and 12,
respectively. As shown in FIG. 18, the access opening cover 22 is
forced toward the plastic mounting panel P so as to bend and fit
the hook 22b into the access opening 13 from the side of the
passenger compartment as mdicated by arrows A When the hook 22a
passes across the periphery 13a of the access opening 13, the hook
22a bends back and engages with the periphery 13a of the access
opening 13. In this mauner, the access opening cover 22 is easily
attached in position to the plastic mounting panel P and is
prevented from coming off from the access opening 13. Similarly, as
shown in FIG. 19, the access opening cover 23 is forced toward the
plastic mounting panel P so as to bend and fit the hook 23b into
the access openig 12 from the side of the passenger compartment as
indicated by arrows A When the hook 23a passes across the periphery
12a of the access opening 12, the hook 23a bends back and engages
with the periphery la of the access opening 12, so that the access
opening cover 23 is easily attached in position to the plastic
mounting panel P and is prevented from coming off from the access
opening 12.
[0057] As described above, the plasc mounting panel P having the
access openings 12 and 13 provides easy accesses to the exterior
door handle 7 and the window regulator R for door assembling work
and enables easily closing the access openings 12 and 13 after the
door assembling work. Further, the rubber packing rings 22c and 23c
provides reliable watertigatness of the passenger compartment In
assembling the vehicle door constucted as above, the plastic
mounting panel P having the access opening covers 22 and 23 joined
thereto by the breakable joints 20 and 21 is formed by injecting a
large amount of plastic material into a large size mold at a
stretch The plastic mounting panel P is conveyed to a door
assembling station The door panel sub-assembly D is prepared
separately from the plastic mounting panel P at another station and
conveyed to the door assembling station Because the plastic
mounting panel P is configured in the form of substantially
rectangular flat plate, it is easy to pile up a plurality of the
plastic panels P and to convey a stack of the plastic panels P
safely and reliably. At the door assembling station, the necessary
functional parts and devices such as the window regulator R, the
harness H, etc are installed to the plastic mounting panel P with
the access opening covers 22 and 23 left joined. The assembling
work of the functional parts and devices is quite easily achieved
as described previously.
[0058] Subsequently, the plastic mounting panel P with the
finctional parts and devices installed thereto is installed to the
door panel subassembly D. Specifically, after fitting the plastic
mounting panel P into the aperture 3 of the inner panel D1, the
door latch unit 33 is secured to the inner panel D1. Thereafmer,
the window glass W is inserted into the door panel subassembly D
and is coupled to the window regulator R through the access opening
12. In the next step, the handle linking cable 31 is connected to
the exterior door handle 7 through tie access opening 13.
[0059] After completing the installation of the plastic mounting
panel P, the access opening covers 22 and 23 are separated from the
plastic mounting panel P and fitted into the access openings 13 and
12, respectively, to cover up the access openings 13 and 12.
Finally, the trm unit T is installed to the door panel
semi-assembly D to cover the plastic panel, so as thereby to
complete the front door.
[0060] Because the plastic mounting panel P with the access opening
covers 22 and 23 appendant thereto by breakable joints 20 and 21,
respectively, can be formed as one piece, large molding equipment
and a great quantity of molding material can be put to effective
and efficient use and the productivity of the plastic panels is
increased.
[0061] The location of the access opening covers 22 and 23 to the
plastic mounting panel P is at the cutaway comer, the plastic
mouning panel P is so formed to have a generally rectangular flat
configuraton which is efficient This provides the injection mold
with a simple configuration Moreover, the plastic panels P are
easily and stably piled up and safely conveyed.
[0062] The access opening covers 22 and 23 are separated from the
plastic mounting panel P after having installed the plasc mounting
panel P to the door panel subassembly D and having attached the
exterior door handle 7 and the window glass W to the door panel
sub-assembly D, it is not feared that the access covers 22 and 23
are missing before assembling such as during conveyance
thereof.
[0063] Although the above embodiment has been directed to the
plastic panel formed with the access opening covers as appendant
parts to the plastic panel, the appendant pieces are not limited to
the access opening covers as long as the appendant parts are formed
as integral parts of the plastic panel and instlled to the plastic
panel after separation. It is to be understood that although the
present invention has been described with regard to a preferred
embodiment thereof, various other embodiments and variants may
occur to those skilled in the ark which are within the scope and
spirt of the invention, and such other embodiments and variants are
intended to be covered by the following claims.
* * * * *