Abstract: A door module assembly for a motor vehicle door has a plate-like carrier holding a plurality of door hardware components in a pre-configured orientation, including one or more window regulator rails. The carrier seals the motor vehicle door and includes a flap that provides at least partial access to the window regulator rails. A first trim panel is pre-fixed to the carrier. A second trim panel articulates with respect to the first trim panel between an initial position generally parallel to the first trim panel and an installed position generally in-line with the first trim panel. With the carrier storing substantially all of the hardware required for the door and the trim panels covering substantially the entire surface area of the door, handling and assembly operations are minimized.

Abstract: An automotive component (10) and a method for manufacturing the same are disclosed. The component (10) comprises a core portion (14) formed of a first material and a second portion (18) integral with the core portion (14) and formed of a second material. In one illustrated embodiment, the first and second materials have different material property characteristics. For example, the first material can be made of a relatively harder plastic material than the second material made of a softtouch plastic material. The method for manufacturing the component comprises the steps of injecting the first material into a first cavity of a mold to form the core portion (14), altering the mold cavity to form a second cavity and injecting the second material into the second cavity while the first material is in a reactive state to form the second portion (18) of the component. Because the first material is in the reactive state, the second material is integrally formed with the first material.

Abstract: A door module assembly for a motor vehicle door has a plate-like carrier holding a plurality of door hardware components in a pre-configured orientation, including one or more window regulator rails. The carrier seals the motor vehicle door and includes a flap that provides at least partial access to the window regulator rails. A first trim panel is pre-fixed to the carrier. A second trim panel articulates with respect to the first trim panel between an initial position generally parallel to the first trim panel and an installed position generally in-line with the first trim panel. With the carrier storing substantially all of the hardware required for the door and the trim panels covering substantially the entire surface area of the door, handling and assembly operations are minimized.

Abstract: A method for manufacturing a vehicular door assembly (10) having a door (12), a door panel (14), a substrate (54), a plurality of systems, and a plurality of components. The method includes the steps of fastening the door panel (14) to the door (12), attaching the substrate (54) to the door panel (14), and securing the plurality of components to the substrate prior to attaching the substrate to the door panel (14) such that each of the plurality of components is operational upon the substrate being attached to the door panel (14).

Abstract: A door module assembly for a motor vehicle door has a plate-like carrier holding a plurality of door hardware components in a pre-configured orientation, including one or more window regulator rails. The carrier seals the motor vehicle door and includes a flap that provides at least partial access to the window regulator rails. A first trim panel is pre-fixed to the carrier. A second trim panel articulates with respect to the first trim panel between an initial position generally parallel to the first trim panel and an installed position generally in-line with the first trim panel. With the carrier storing substantially all of the hardware required for the door and the trim panels covering substantially the entire surface area of the door, handling and assembly operations are minimized.

Abstract: A door module assembly for a motor vehicle door has a plate-like carrier holding a plurality of door hardware components in a pre-configured orientation, including one or more window regulator rails. The carrier seals the motor vehicle door and includes a flap that provides at least partial access to the window regulator rails. A first trim panel is pre-fixed to the carrier. A second trim panel articulates with respect to the first trim panel between an initial position generally parallel to the first trim panel and an installed position generally in-line with the first trim panel. With the carrier storing substantially all of the hardware required for the door and the trim panels covering substantially the entire surface area of the door, handling and assembly operations are minimized.

Abstract: A method for assembling a motor vehicle door includes the steps of affixing a plurality of hardware components to a secondary trim component to form a door module assembly. The door module assembly is attached to the structural door body. A trim panel is secured to the structural door body overlaying the door module assembly. The secondary trim component has a map pocket wall and the trim panel has a map pocket opening. When the trim panel overlays the secondary trim component, the trim panel cooperates with the secondary trim component to define a map pocket.

Abstract: A method for manufacturing a vehicular door assembly (10) having a door (12), a door panel (14), a substrate (54), a plurality of systems, and a plurality of components. The method includes the steps of fastening the door panel (14) to the door (12), attaching the substrate (54) to the door panel (14), and securing the plurality of components to the substrate prior to attaching the substrate to the door panel (14) such that each of the plurality of components is operational upon the substrate being attached to the door panel (14).