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A door assembly includes a carrier panel attachable to a vehicle door outer structure such that the carrier panel substantially covers an opening of the door outer structure. The carrier panel is configured to function as a water shield between the door outer structure and a vehicle occupant compart

A door assembly includes a carrier panel attachable to a vehicle door outer structure such that the carrier panel substantially covers an opening of the door outer structure. The carrier panel is configured to function as a water shield between the door outer structure and a vehicle occupant compartment. The carrier panel also includes an upper portion and a lower portion, and the lower portion defines a lower appearance surface. The assembly further includes a hardware component mounted to and supported by the carrier panel, and an upper trim panel arrangement that is attachable to the carrier panel after the carrier panel has been attached to the door outer structure. The upper trim panel arrangement is configured to substantially cover the upper portion of the carrier panel and defines an upper appearance surface.

대표청구항 ▼

1. A door assembly for use with a motor vehicle having a door outer structure and an interior occupant compartment, wherein the door outer structure has an opening for receiving the door assembly, the assembly comprising:a carrier panel adapted to be attached to the door outer structure such that th

1. A door assembly for use with a motor vehicle having a door outer structure and an interior occupant compartment, wherein the door outer structure has an opening for receiving the door assembly, the assembly comprising:a carrier panel adapted to be attached to the door outer structure such that the carrier panel substantially covers the opening, the carrier panel having a first side adapted to face toward the occupant compartment and a second side adapted to face the door outer structure, the carrier panel being configured to function as a water shield between the door outer structure and the occupant compartment for inhibiting water from passing from the second side to the first side, the carrier panel further including an upper portion and a lower portion, the lower portion defining a lower, finished appearance surface that is adapted to face the occupant compartment; a vehicle door hardware component mounted to and supported by the carrier panel; and an upper trim panel arrangement that is attachable to the carrier panel after the carrier panel has been attached to the door outer structure, the upper trim panel arrangement being configured to substantially cover the upper portion of the carrier panel and having an upper, finished appearance surface that is adapted to face the occupant compartment. 2. The door assembly of claim 1 wherein the carrier panel includes a carrier panel body and a cover material attached to the carrier panel body, the cover material defining the lower, finished appearance surface.3. The door assembly of claim 1 wherein the opening has a height and a width, and the carrier panel includes a carrier panel body that is adapted to span the height and the width of the opening.4. The door assembly of claim 3 wherein the carrier panel body defines the lower, finished appearance surface.5. The door assembly of claim 3 wherein the carrier panel body comprises plastic.6. The door assembly of claim 3 wherein the carrier panel body comprises polypropylene.7. The door assembly of claim 3 wherein the carrier panel body comprises foamed plastic material.8. The door assembly of claim 3 wherein the carrier panel body comprises thermoplastic material reinforced with fiberglass.9. The door assembly of claim 3 wherein the carrier panel body includes an access slot configured to receive a positioning tool that is used to position the vehicle door hardware component relative to the carrier panel body after the carrier panel has been attached to the door outer structure.10. The door assembly of claim 9 wherein the carrier panel includes a sealer patch that is attachable to the carrier panel body for covering the access slot after the vehicle door hardware component has been positioned.11. The door assembly of claim 3 wherein the carrier panel body includes a main portion and a back portion attached to the main portion, wherein the main portion and the back portion cooperate to define a map pocket.12. The door assembly of claim 1 further comprising multiple vehicle door hardware components mounted to and supported by the carrier panel, the components including a door latch mechanism and a window regulator mechanism, the door latch mechanism including an inner door handle mounted on the first side of the carrier member, and a latch assembly connected to the door handle and mounted on the second side of the carrier member, the window regulator mechanism including a motor mounted on the first side of the carrier member, and a window regulator arm mounted on the second side of the carrier member.13. The door assembly of claim 1 wherein the vehicle door hardware component is a window regulator mechanism that includes a pair of window regulator arms fixedly attached to and fully supported by the carrier panel, such that the window regulator arms are not directly attachable to the door outer structure.14. A method for making a vehicle door for use with a vehicle having an interior occupant compartment, the method comprising:positioning a carrier module proximate a vehicle door outer structure having an opening, the carrier module including a carrier panel and a vehicle door hardware component attached to the carrier panel, the carrier panel including first and second sides and upper and lower portions, the lower portion having a lower, finished appearance surface for facing the occupant compartment; attaching the carrier panel to the door outer structure such that the carrier panel substantially covers the opening; and securing an upper trim panel arrangement against the carrier panel after the carrier panel has been attached to the door outer structure such that the upper trim panel arrangement substantially covers the first side of the upper portion, the upper trim panel arrangement having an upper, finished appearance surface for facing the occupant compartment; wherein the carrier panel is configured to function as a water shield for inhibiting water from passing from the second side to the first side of the carrier panel. 15. The method of claim 14 wherein the carrier panel includes a carrier panel body having an access aperture, and wherein the method further comprises inserting a tool through the access aperture, after the carrier panel has been attached to the door outer structure, and positioning the vehicle door hardware component relative to the carrier panel using the tool.16. The method of claim 15 further comprising attaching an access patch to the carrier panel body, after the vehicle door hardware component has been positioned, so as to cover the access aperture.17. The method of claim 14 wherein the vehicle door hardware component is a window regulator mechanism that includes two window regulator arms fixedly attached to the carrier panel such that each regulator arm is in a use position with respect to the carrier panel prior to the positioning step, and wherein the step of attaching the carrier panel to the door outer structure is performed such that the window regulator arms remain in the use positions.18. A method for making a vehicle door for use with a vehicle having an interior occupant compartment, the method comprising:forming a carrier panel body from plastic material, the carrier panel body having first and second sides and upper and lower portions, the upper portion having an access aperture extending therethrough, the lower portion having a lower, finished appearance surface for facing the occupant compartment; mounting a window regulator arm to the carrier panel body; attaching the carrier panel body to a vehicle door outer structure having an opening such that the carrier panel body substantially covers the opening, inserting a tool through the access aperture after the carrier panel body has been attached to the door outer structure; rotating the window regulator arm with respect to the carrier panel body using the tool; securing the window regulator arm to the door outer structure; attaching a sealing patch to the carrier panel body so as to cover the access aperture; and securing an upper trim panel arrangement against the carrier panel after the window lift guide has been attached to the door outer structure such that the upper trim panel arrangement substantially covers the first side of the upper portion, the upper trim panel arrangement having an upper, finished appearance surface for facing the occupant compartment; wherein the carrier panel body is configured to function as a water shield for inhibiting water from passing from the second side to the first side of the carrier panel body.