Note: Descriptions are shown in the official language in which they were submitted.
1332~20
AUTOMOBILE DOOR MODULAR ASSEMBLY
Field
This invention relates to an automobile door. In
particular, it relates to an automobile door having modular
components adapted to permit pre-assembly and pre-testing of
major sub-assemblies.
Background of the Invention
In recent years there has been an accelerating trend
toward more automation in the manufacture and assembly of
automobiles. Accordingly, the engineering of automobile
components is becoming increasingly directed by design for
assembly (DFA) principles which predicate the development of
modular components which can be pre-tested and pre-assembled
before installation in a car.
It is an object of the present invention to provide a
design for a vehicle door which can be used on a complete range
of vehicles from passenger cars to trucks and, in particular,
will permit modern features such as flush-mounted window glass
and other current styling treatments.
It is also an object of this invention to provide a
door design which will reduce end-unit assembly cost without
compromising quality.
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It is an object of this invention to provide a hardware
module which will provide functionality and structural
performance similar to that available with other conventional
designs.
It is also an object of this invention to provide a
door which provides easy access to the interior of the door for
installation of window seals, glass and other hardware.
It is an object of this invention to provide an
exterior door handle which can be installed from the interior of
the car door.
It is also an object of this invention to provide a
door hardware module which permits pre-assembly of major door
installation aggregates and pre-testing of same.
It is an object of this invention to provide cable
actuated exterior door release and snap in lock cylinder
assembly.
It is an object tojprovide a door hardware module which
has a plug-in wire harness to provide electricity for the powered
hardware components.
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1332620
It is an object of this invention to provide an
improved sealing means to segregate "wet" and "dry" components in
the hardware module.
The Invention
(a) General Description
The present invention is an automobile door comprising
a door shell having an outer belt reinforcement member; an outer
panel; and an inner panel including a hinge member and a latch
member; a module adapted to contain all door hardware including
an inner belt reinforcement member, an exterior door release, an
interior release, a latch mechanism, a window and window
regulator mechanism and wire harness; and a trim panel including
bezels.
The module of this invention is adapted to be
installed, from the inside, into the door shell and to be
fastened therein to locate all the hardware components in the
door. It is preferred that the module have a core comprising two
overlapping metal plates adapted with receptacles to receive the
hardware components, each such plate having a partial box section
inverted and opposed to the other to form the inner belt
reinforcement member.
4 1332620
The module has two embodiments of the exterior door
release. The first embodiment is an exterior door release
separate from the core of the module which is adapted to be
installed from inside the door shell and to be connected by
actuating cables to a latch mechanism mounted on the module core.
The second embodiment is an integrally mounted exterior door
release also adapted to be installed from inside the door shell
and connected by actuating means to a latch mechanism mounted on
the module. The actuating means for the integrally mounted door
release can be either rods or cables.
The outer panel has an opening adapted to receive the
exterior release and is reinforced about the opening by a flange
extending from the door shell. The flange provides a base upon
which the exterior release can be fastened. The exterior release
can be contained in a housing having a first portion adapted to
be inserted under a first portion of the flange and having a
second portion adapted to be fastened to the flange to secure the
exterior release in the opening. In one embodiment the housing
has an upward extension adapted to be inserted under a depending
lip of the flange and an inward extension adapted to be fastened
onto~ an inward extending ledge of the flange to secure the
exterior release in the opening. In a preferred embodiment the
housing is adapted to be fastened by a downwardly biased ratchet
cam rotatably mounted on the housing. The cam is adapted to
~ 5 1332~20
rotate into and to connect with an opening in the inward
extending ledge of the flange to secure the exterior release in
the opening~
(b) The Outer Belt Reinforcement Member
It will be appreciated that the flange supporting the
exterior release can extend about the opening from virtually any
structural member of the door sheil. It is preferred, however,
in the present invention, that the outer belt reinforcement
member be provided as a separate inner panel section which can be
installed into the remainder of the door shell during assembly
prior to the installation of the module. The outer belt
reinforcement section can have a depending cantilever flange-
adapted to be bonded to the outer panel inside and about the
opening for the exterior release. In one embodiment, the frame
of the inner panel is driven outward at the belt line and back
parallel to the outer panel to form the end portions adapted to
receive the outer belt reinforcement section. In another
embodiment, the inner panel continues parallel to the outer panel
to form the end portions, but the outer belt reinforcement
section bends back up on itself to be spot welded to the outside
surfaces of the end portions. This latter embodiment provides
for more space along the inner door panel perimeter for attaching
other things like the vapour seal and the trim panel.
6 1332~20
(c) The Hardware Module
In order to effect easy assembly of the hardware
components on the production line of an automobile factory, it is
desirable to have access to the inside of the door through the
inner panel of the door. For example, in the 1987-1988 BMW 700
series cars, a large cut out is provided in the inner panel below
the conventional inner and outer belt reinforcement sections to
permit installation of the hardware. However, notwithstanding
the large cut out provided, it lS still necessary to fish the
window glass through the slot between the inner and outer panels,
thereby complicating the assembly process. The design for
assembly approach is facilitated in this invention by
incorporating the inner belt reinforcement in the removable
hardware module which contains the window and window regulator
and other components as described above.
The hardware module core can be made from preferably
two metal plates which are welded together and appropriately
stamped and fitted to receive the components of the module. It
will be appreciated that the module could be fabricated from one
stamping or more than two, depending on the structural
requirements. The core panel is designed to extend down from the
~elt line. An inner belt reinforcement member can be fabricated
onto the core panel, for example by spot welding inverted and
opposite box sections onto the panel. Both parts of the inner
7 1332~20
belt reinforcement member can be stamped from sheet steel, box
sectioned and attached along the inner belt line to provide a
light weight, yet stiff structure which has the required
stiffness to pass crush tests.
Mechanical fasteners can be used to attach the hardware
module to the door shell. The module provides the additional
structure required to give integrity to the construction of the
door.
The hardware module of this invention incorporates
virtually all the door hardware components. The exterior handle
is presented in two embodiments, one in which it is incorporated
with the hardware module, the other in which it is a separate but
an attached part. In both embodiments, hardware components such
as a window regulator and interior release handle are
incorporated directly into the module, thus eliminating the
duplication of materials and reducing the overall costs of the
door. Components such as the speaker, latch, wiring harness and
latch power actuator are bolted or clipped to the module.
It is a novel feature of this invention that the
exterior door release is mounted from the interior of the door.
In one embodiment, the door release mechanism is integral to the
hardware module and installed from the interior of the door. In
8 1332~2~
a second embodiment, a complete exterior release and handle is
attached to the hardware module by actuating cables and the
complete unit is installed from the interior side of the door.
It will be appreciated by those skilled in the art that
this novel installation will provide many advantages in the line
assembly operations. Most exterior releases in use today are
installed from outside the vehicle. Exterior installation
requires rods to be added between the exterior release/lock
cylinder and latch. Since most doors have a substantial inner
panel perforated with cut outs, attachment of these rods tends to
be somewhat awkward. The present invention simplifies
installation of the exterior handle substantially. It will also
be appreciated that a cosmetic door handle can be affixed to the
release mechanism from the exterior of the door to obtain colour
coordination or other effects while still enjoying the benefits
of this invention. Moreover, by incorporating the release
mechanism in the hardware module the entire latch function can be
adjusted and tested before it reaches the assembly line for
installation in the door.
The opening for the exterior release can be provided
with an inward facing stiffening lip which is bent into the
exterior sheet metal about the periphery of the hole in the
panel. This feature improves the accuracy of the cut out as well
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13326tt~
as providing a location position for the handle. A rubber gasket
is fitted about the stiffening lip to seal the handle insert and
to reduce vibration noise. The handle insert can be preferably a
die cast or plastic housing. The rubber gasket lies about the
lip between the sheet metal and the housing. A groove in the
gasket is adapted to be deep enough to accept variances in the
lip depth. The housing extends upwardly and downwardly past the
rubber gasket. A depending cantilevered flange can extend from
the outer belt reinforcement box section behind and about the
hole in the exterior panel and can be fixed to the inside of the
outer panel by suitable fastening means such as an adhesive. The
upper projecting portion of the handle housing is adapted to fit
under the upper portion of the depending cantilevered flange in a
spring fit which presses the upper portion of the housing
towards the outer panel onto the rubber gasket. The lower end of
the housing can be fastened by a bolt or other suitable fastening
means to the lower portion of the depending cantilevered flange
to secure the housing in place.
The window regulator hardware can be any of a number of
conventional systems but preferably is an X-arm type which can be
riveted directly to the hardware module. Because the window
regulator is integral with the hardware module, the guidance slot
that typically is an extra piece can be stamped from the hardware
module itself. The roller that moves within the guide can be
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pre-installed onto the X-arm and inserted through an enlarged end
of the slot at the time of assembly. The window regulator
mechanism can be a power or manual type without departing from
the scope of this invention.
A pocket stamped into the sheet metal of the module
accommodates the window regulator motor, keeping the overall
height of the hardware module to a minimum. The pocket in the
sheet metal also provides support for the motor during door
closing and opening as well as providing protection against
water.
It is possible to hang the body of the motor outside
the confines of the sheet metal, however, this reduces packaging
efficiency for an application where hardware modules are
supplied, assembled and pre-tested directly to the manufacturer.
The hardware module can accept most conventional latch
designs. The latch can be attached to the hardware module by a
single rivet, but when the hardware module is installed into a
door it can be fastened to the door mounting by means of
mechanical fasteners. A power door lock actuator can be integral
with the latch, or separate and attached to the hardware module
inner belt portion. In the latter case, a rod can be used to
connect the latch to the lock actuator button. The entire latch
ll 1332620
system can be fully tested prior to shipment of the hardware
module to the final assembly facility.
The interior release can be installed onto the hardware
module utilizing pivot points stamped directly from the hardware
module sheet metal, thus eliminating additional components.
Tension rods can be used in conjunction with the interior release
and can be easily installed onto the hardware module before the
module is installed in a door, thus eliminating the major
drawback of fishing odd-shaped rods through blind holes as the
door is moved down the line during assembly. It will be apparent
to those skilled in the art, that depending on manufacturing
requirements, the "push to release" (compression) rods or "pull
to release" cables can be used.
The interior release handle can be a modified "hockey
stick" type to provide easy installation through an opening in
the trim bezel.
A stamped recess in the hardware module carrier plate
accommodates currently available speakers. By adding this
speaker to the hardware m,odule rather than the trim panel,
installation of the wiring harness is simplified. The steel of ;
the hardware module also provides a secure, protecting mounting
surface and protection against water. The speaker is most easily
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12 1332~20
installed prior to the installation of the trim panel. However,
it remains accessible with the trim panel installed and the bezel
removed.
Rather than incorporating a courtesy lamp within the
trim panel, necessitating an electrical connection to the trim
panel from the wiring harness, the design of this invention
places only the lens and the reflector in the trim panel. The
bulb and the bulb holder are separately mounted to the hardware
module. This design provides an opportunity to test the entire
wiring harness and the lamp prior to shipment of the hardware
module to the vehicle assembly facility.
Any reasonable dimensional differences between the
hardware module and the trim panel can be accommodated by using
an oversized hole in the back of the reflector through which the
bulb fits. A foam pad with a silver reflective material on the
bulb side acts as an anti-rattle padding and dust and moisture
seal between the lamp socket and the reflector and lens.
A lens and reflector for the courtesy lamp are supplied
to the assembly plant installed into the trim panel. Access to
change a defective bulb remains simple, however, as the lens and
reflector can easily be snapped out of the trim panel.
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1332620
The wiring harness necessary to provide power to the
components of the hardware module is provided on the hardware
module as well. It is adapted to extend from the module through
the perimeter of the door on the hinge member to be plugged into
a socket in the car body. This feature of consolidating the
complete wire harness onto the hardware module eliminates the
cost of additional connectors, facilitates checking and testing
of components prior to assembly. Reduction of connectors reduces
costs and the likelihood of electrical failure due to corrosion
of same.
The conduit for the wiring harness is provided with a
sealing means where it crosses the perimeter of the door and
penetrates the seal line.
The hardware module is also provided with a area
adapted to contain the "dry" components of the hardware such as
the interior door handle, the speaker and electrical switches for
power window regulator and door locks. The perimeter of this
area is adapted to attach a sealing membrane. In one embodiment,
conventional polyethylene sheeting is attached about the dry area
perimeter and to the perimeter of the inner door panel to effect
the sealing of "wet" from "dry" zones. In another embodiment,
the vapour seal is provided by the trim panel itself. In this
embodiment, a sealing bead, lip or other suitable sealing means
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1332620
is provided about the dry area perimeter and about the surface of
the inner panel upon which the trim panel and its concomitant
bezel rest to obtain the required vapour seal when the trim panel
is attached. This embodiment obviates the need for the vapour
barrier sheeting and the cumbersome step of handling the sheeting
and adhesive on the assembly line. It also permits the door to
be opened up for repair and re-closed with a proper seal without
having to reseal it with vapour barrier.
In providing a hardware module which contains an
exterior release there is the problem that each car will receive
at least two such modules which both must lock and unlock with
the same key. The problem of producing two matched modules and
keeping them mat`ched until installation in one car is an onerous
one, particularly if pre-testing is contemplated.
The present invention avoids that problem by having ~-
snap in lock cylinders which are installed in the car on the
assembly line after the modules have been installed in the cars.
In this way, the modules can be installed without concern as to
matching locks and keys. This matching can be done after the car
is built. ~ ~
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The hardware module has a receptacle adapted to receive
the lock cylinder in snap fit connection. A spring clip retainer
1~32~2~
is provided within the lock receptacle adapted to snap fit about
a retainer cap which fits over and secures the lock cylinder.
The Preferred Embodiments
In the figures which describe the preferred embodiments
of this invention:
Figure 1 is an exploded view of a preferred embodiment
of the automobile door of this invention.
Figure 2 is a detail of the rear outer belt
reinforcement fastening ledge.
Figure 3 is a detail of the front outer belt
reinforcement fastening ledge.
Figure 4 is an illustration of a complete hardware
module of this invention.
Figure 5 is an illustration from an inside point of
view of the core plate and box section of the hardware module.
Figure 6 is an illustration of the cable attached
exterior door release installed in a door.
Figure 7 is a side view of the ratchet embodiment of
the exterior door release installation.
Figure 8 is a perspective of the ratchet embodiment of
Figure 7.
Figure 9 is a drawing of a module adapted to receive
with an integral exterior handle.
' 16
13~262~
Figure 10 is a sketch of a vertical flip-out handle
mechanism integral to the module.
Figure 11 is an exploded view of the lock cylinder
mechanism.
Figure 12 is a cut-away view of the assembled lock
cylinder.
Figure 13 illustrates details of a dry well in the
module with various sectional views of components.
Figure 14 is an illustration of the courtesy lamp of
this invention.
In the Figures, like numerals indicate like elements.
~:,
In Figure 1, the general configuration of a preferred
embodiment of this invention is illustrated in an exploded view
of a front door. The outer panel (10) is a conventional one
piece stamped steel outer panel hemmed and spot welded to a two
piece inner panel comprising the perimeter section ~20) and outer
reinforcement section (21). Glass run (30) is adapted to be
attached in a conventional manner. A water shield (40) is shown
rolled up before assembly. After assembly, it is unrolled to
provide a vapour barrier for the door. The hardware module (50)
of this invention is shown to contain the hardware components of
the door and includes an inner belt line reinforcement section
-
(51). The wiring harness (52) is shown extending out of the
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17 1 3 32 6~ o
hardware module t50) and is adapted with an extendable cord to
extend through slot (22) in the perimeter inner panel section
(20) and to plug into a socket (not shown) in the car body. The
trim panel (11) is adapted to be fastened over the hardware
module (50) and the water shield (40).
In Figure 2, one embodiment of the outer belt
reinforcement section (21) is illustrated spot welded in place to
the inner panel perimeter section (20~. Outer belt reinforcement
section (21) has depending from it a flange (23) which is adapted
to surround the exterior release opening (12) in the outer panel .:~
(10). Flange (23) is adapted to reinforce the outer panel (10)
about the exterior release opening and to provide a support for
the exterior release mechanism of the hardware module (50). .
It will be appreciated that a similar flange could be
extended from the intrusion beam (80) or from the perimeter inner
panel section (20j to provide the support required around the
exterior release opening (12) in the outer panel (10).
In an embodiment of the outer belt reinforcement
section (21) shown in Figure 2, the inner panel perimeter section
(20) continues in the same plane to form the fastening ledge
(25). The outer belt reinforcement section (21) is bent back
upon itself at its ends and spot welded to the outside of the
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18 13~62~
ledges (25). The enlarged inner panel flange (27) found in this
embodiment provides greater area for attachment of vapour barrier
and trim panel detail (not shown in Figure 2).
At the front of the door, shown in Figure 3, the inner
panel perimeter section (20) is driven outwardly below the window
opening at position (24) and then bent back parallel to the plane
of the outer panel (10) to form a fastening ledge (25) upon which
the outer belt reinforcement section (21) is attached.
One embodiment of a hardware module (50) of this
invention is shown in Figure 4 having an exterior release
mechanism (53) attached to the module (50) by cables (54) which
transmit the loads from the handle (55) and the lock cylinder
(56) to the latch mechanism (57). The window regulator mechanism
(58) is a conventional X-type mechanism. The wiring harness (52)
extends from the module through a soft rubber or plastic grommet
(59) which is adapted to seal and protect the harness at the door
perimeter where it passes through slot (22). The harness (52)
terminates in a plug (60) adapted to be plugged into an
electrical socket in the car body. Alternately, conventional
wiring harness means may be,employed in this combination.
The hardware module (50) is made of two parts as shown
in Figure 5, a core panel (62) and a inner belt line
19
1 3~262~
reinforcement member (61) which is spot welded to it. Both parts
can be stamped from sheet steel. The inner belt reinforcement
member (61) is box-sectioned to provide a lightweight but stiff
structure along the inner belt line su~ficient to pass
appropriate crash tests. The core plate (62) is stamped to
receive the hardware components in predetermined locations and
appropriate fastening receptacles are provided. Without,
attempting to be exhaustive in this regard, for such methods are
within the scope of the art, a slot (42) is provided as a guide
for an X-arm of the window regulator (58), an interior release -:h
bracket (63) is provided for the interior release handle and
associated mechanisms, a well (64) is provided to house a speaker
for a radio or tape deck. A latch bracket (65) is provided to
contain and support the latch mechanism (57) (not shown).
It can be seen, therefore, that the hardware module can
be adapted to contain virtually all the door hardware. The door
module can be pre-assembled and pre-tested before shipment to a
manufacturer for installation.
The embodiment of the invention having an exterior door
release (53) attached to the hardware module (50) by means of
cables (54) can be installed from the interior of the door. This
novel feature permits the complete assembly of the module (50)
before shipment and installation in a car door without any pre-
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1332620
assembly of components on the assembly line. Moreover, theinstallation can be done at once from one side of the door and
the fishing of rods and other components through panel holes and
adjustment and calibration is eliminated or substantially reduced
on the assembly line.
The installation of the exterior door release (53) is
shown in Figures 6, 7 and 8. It will be recalled that the outer
belt reinforcement section (21) has a depending flange (23) which
surrounds opening (12) in the outer panel (10). The flange (23)
is bonded to the inside of outer panel (10) by a suitable bonding
material (66) which preferably does not penetrate the outer
panel, for example, an adhesive. Above opening (12), the flange
(23) bends inwardly and downwardly to form a spring lip (67).
Below the opening (12), the flange (23) bends inwardly to produce
- ~ :
a ledge (68). About the edge of opening (12), the outer panel
~10) is bent inwardly to form a stiffening lip (69). A rubber
gasket (70) is adapted to fit over the stiffening lip (69) and to
lie between the outer panel (10) and the housing (71) of the
exterior release (53). The rubber gasket (70) has a groove which
fits about the stiffening lip (69) and has sufficient depth to
accommodate any reasonable tolerances in the dimensions of the
stiffening lip (69). The rubber gasket (70) is also adapted to
accommodate reasonable tolerances in the dimensions of the
opening (12) and the housing (71) that fits into it. The housing
133262~
(71) has a first projection (72) which spring fits under lip (67)
of flange (23). The bottom of the housing (71) has a second
projection (73) adapted to locate a fastener such as a bolt (74)
(in Figure 6) or a ratchet (75) (in Figures 7 and 8) biased by a
spring (76).
. . . . ~
In Figures 6, therefore, the exterior release is fitted
under lip (67) of flange (23) and then bolted to ledge (68) of
flange (23). In Figures 7 and 8, the exterior release is first
fitted under lip (67) and then pushed over ledge (68) until
ratchet (75) drops into an opening in ledge (68). The ratchet
embodiment is very easy to install and easy to release for
repair. Moreover, in use, vibration in the door will tend to
seat the ratchet (75) under the force of biasing spring (76) and
pulling on the exterior release (53) will also tend to seat the
ratchet. Therefore, security of the fastening is improved with
use.
In another embodiment of the exterior release, shown in
Figures 9 and 10, the exterior release (53) is integral to the
module (50). As shown in Figure 9 in this embodiment the module
(50)/ is further adapted with a handle carrier (77) adjacent to
the latch bracket (65). As shown in Figure 10, the handle
carrier (77) supports the handle mechanism (78) which can be
connected to the latch mechanism (57) by rod (79). In this
.
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22
133262~
embodiment, the handle mechanism (78) can be installed with the
hardware module (50). Following installation to the module (50),
in one embodiment, a handle plate (81) can be installed from the
outside after assembly of the door. In this mode, handle plates
can be coordinated to the colour of the outer panel (10).
Adjustments for tolerances can be made by installation of the
handle plate (81) with bolts (80) that fit into oversized holes -~
in the handle (81) and into holes in brackets in the handle
mechanism (78). The handle plate (81) can be adjusted to be
flush to the outer panel (10) and then bolted in place.
It will be appreciated by those skilled in the art that
the means of this invention can be adapted to a variety of
handles including flip-up, flip-out, suitcase and other
conventional types. ;~
It will also be appreciated that the lock cylinder
receptacle would be installed with the exterior release
mechanism. For example, in Figure 4, the lock cylinder
receptacle (56) is shown as part of the exterior release (53).
One of the cables (54) is dedicated to the lock while the other
is for the release mechanism. What is new about the lock
mechanism of this invention is the fact that the lock cylinder
can be installed after assembly of the door. As explained
earlier, this avoids the necessity of ensuring that during line
~- .
23 133262
assembly of the door modules, each module in each car has a
matching lock cylinder. This substantially reduces the shipping
and handling concerns associated with the modules. The matching
lock cylinders can be dealt with as a separate item.
The means for installing the locks after assembly is
illustrated in Figure 11 the lock cylinder receptacle (56), an
illumination bulb (82), a molded plastic arm (83) and a spring
clip retainer (84) are shown. These elements would be pre-
assembled in the receptacle (56) as part of the module (50). The
lock cylinder (85), the illuminator ring (86) and the retainer
cap (87) would be installed after the module (50) is assembled
into the door. The retainer cap (87) would snap into the
illuminator ring (86). The lock cylinder (85) would be pushed
into the receptacle (56) and the retainer cap and illuminator
ring assembly pushed in, over and about the lock cylinder (85).
Spring clip retainer (89) is located in groove (88) and would
snap fit into grooves (89) and (90) in the illuminator ring (86)
and retainer cap (87) respectively. The assembled unit is
displayed in Figure 12.
In some embodiments of this invention, it has been
desirable to provide separate "wet" and "dry" areas in the
hardware module to segregate the components that do not tolerate
water vapour from those that do. For example, electrical
24 1 332~20
controls for power windows and door locks, the speaker for the
radio and the interior door latch are items that have been
identified as being components that should be inside the vapour
barrier. To achieve this objective, a dry area is provided in
the module similar to the speaker well (64) shown in Figure 5,
however this dry area is expanded to include other components and
is fitted with means adapted to provide a vapour seal.
In Figure 13, a dry area (100) is illustrated which
contains the interior release (101). (See sections A-A and C-C),
the electrical controls (102) (See section D-D) and a speaker
(103) (See section E-E). The window regulator crank (104) or
electrical motor (105) is left outside the dry area (100). (See
section B-B).
Dry area (100) is surrounded by a sealing surface (106)
which is adapted to receive either conventional polyethylene
vapour barrier material (such as water shield (40)) or sealing
means (107) located on the bezel (111). In either mode, the dry
area (100) provides a vapour barrier and it is isolated from the
other parts of the module (50) by sealing means (107). It is
preferred that the sealing means (107) be located on the bezel
(111), but it will be apparent that the sealing means could be
located on the module (50) to seat on the bezel (111). The
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. 25 1332620
sealing means (107) might also be located on another portion of
the trim panel.
The wiring harness (52) passes through a sealing
grommet (not shown) as it exits the dry area (100).
In the preferred embodiment of the courtesy lamp of
this invention, shown in Figure 14, only the lens (150) and the
reflector (151) are located in the trim panel (11). The bulb
(152) and the socket (153) are separately mounted to the hardware
module by a clip (154). To accommodate reasonable dimensional
tolerances of the hardware module and the trim panel an oversized
hole (155) is made in the back of the reflector through which the
bulb (152) fits. A foam pad (156) with silver reflective
material t157) on the bulb side is attached over the socket (153)
to act as an anti-rattle padding and a dust and moisture seal
between the socket (153) and the reflector (151) and lens (150).
