Method for assembling a door component in a vehicle door

Abstract

The invention relates to a method for assembling a door component (14) in a vehicle door (2), comprising a door shell (6) with an actuating contour (34) and a door module (12) which can be mounted on the door shell (6) and has an assembly carrier (10), wherein the door component (14) is pre-assembled on the assembly carrier (10) via a lever system (20) within an outer circumference (18) of the assembly carrier, wherein the door module (12) is mounted on the door shell (6), and the lever system (20) is driven by the actuating contour (34) in such a way that the door component (14) is moved into a final assembly position (E) which at least partially projects beyond the outer circumference (18) of the assembly carrier (10).

Description

[0001] The invention relates to a method for assembling a door component in a vehicle door, comprising a door shell and a door module with an assembly carrier that can be mounted on the door shell. The invention further relates to a door module and a door assembly.

[0002] A vehicle door for a motor vehicle typically comprises a door body or door shell as a framework or base structure. Such a door shell comprises an outer door panel forming the outer skin of the vehicle door and an inner door panel connected to the outer door panel on the vehicle interior. Between these panels, a cavity is formed as an assembly space in which functional elements or door components of the vehicle door, such as a window lifter, a door lock, an airbag, or the like, can be mounted.

[0003] The door components of the vehicle door are conventionally inserted from the inside of the door through an assembly opening arranged in the inner door panel into the cavity or assembly space between the outer door panel and the inner door panel and brought into their functional positions (final assembly positions).

[0004] To simplify the installation of door components in a vehicle door, it is possible to pre-assemble such door components on a plate-shaped assembly carrier, also called a door module carrier or carrier plate. The assembled assembly carrier is also referred to as a door module and can then be placed over the mounting opening of the vehicle door. The door module or assembly carrier covers the mounting opening and typically also provides a wet / dry compartment separation for the vehicle door.

[0005] It is possible that some door components on the door module, in the intended final assembly position, may protrude beyond the outer contours of the door module, i.e., the outer circumference of the subframe (e.g., door lock, door drive, cable interface to an A-pillar, etc.). In relation to an installation situation in a vehicle side door, the preassembled door components thus protrude, for example, in the Z direction (vehicle height direction in the vehicle coordinate system) and / or in the X direction (vehicle longitudinal direction in the vehicle coordinate system). The door components therefore protrude laterally beyond the edge of the subframe and thus also beyond the opening edge of the assembly opening in the door interior.

[0006] In the case of door components that protrude on two non-opposite sides of the assembly carrier (e.g. window lift rails in +Z and door lock in +X), it is generally still possible to install the door module using a defined turn-tilt movement. If door components protrude on at least three sides of the assembly carrier (e.g. window lift rails in +Z, door lock in +X, and door drive in -X) or on two opposite sides (e.g. door lock in +X, and door drive in -X), it is generally no longer possible to install the door module on the door shell without collision. In this case, the protruding door components (e.g. the door drive) on at least one side must be positioned and secured separately in the door shell before the module is installed. This usually results in long cycle times and a high degree of manual assembly, which leads to high costs for the original equipment manufacturer (OEM).

[0007] The invention is based on the object of providing a particularly suitable method for inserting door components in a vehicle door that, in a final assembly position, protrude from the edges of a door module or its assembly carrier. In particular, the goal is to provide the most compact packaging dimensions possible for the door module in its as-delivered state. The invention is further based on the object of providing a particularly suitable door assembly for implementing the method, as well as a particularly suitable door module.

[0008] With regard to the method, the object is achieved according to the invention with the features of claim 1, with regard to the door module with the features of claim 4, and with regard to the door assembly with the features of claim 10. Advantageous embodiments and further developments are the subject of the dependent claims (subclaims). The advantages and embodiments cited with regard to the method are also transferable mutatis mutandis to the door module and / or the door assembly, and vice versa.

[0009] The conjunction “and / or” is to be understood here and in the following in such a way that the features linked by this conjunction can be formed both together and as alternatives to one another.

[0010] The method according to the invention is intended for, and is suitable and designed for, the installation of a door component in a vehicle door. According to the method, a door shell and a door module mountable on the door shell are provided or provided. The door module has an assembly carrier, and the door shell has an actuating contour.

[0011] According to the method, the door component is pre-assembled to the assembly carrier via a lever system within the outer circumference of the assembly carrier. During subsequent assembly of the door module to the door shell, the lever system is driven by the actuating contour in such a way that the door component is moved into a final assembly position that at least partially protrudes beyond the outer circumference of the assembly carrier. This realizes a particularly suitable method for assembling the door component.

[0012] In other words, at least one door component is (pre-)positioned for assembly within the module boundaries. The door component is connected to the door module or the assembly carrier via a lever system that allows it to be moved. During assembly of the door module in or on the door shell, the lever system is "driven" by a defined actuation contour in the door shell, thus bringing the door component into the projecting final assembly position.

[0013] According to the invention, a door component pre-positioned in or on the door shell is moved or adjusted during door module assembly by interaction with the actuating contour of the door shell from a non-protruding pre-assembly or delivery position to the protruding final assembly position. In particular, the door component is moved collision-free around or over an opening edge of an assembly opening in the door shell. This advantageously reduces the number of assembly steps required on the assembly line at an original equipment manufacturer (OEM). In particular, this also enables automated assembly of the door module or door component without additional manual assembly effort.

[0014] The method according to the invention is particularly advantageous when using door modules with a number of door components that, in their final assembly positions, protrude on two opposite sides or at least three different sides of the assembly support. However, the method according to the invention is also suitable for door modules in which the door components, in their final assembly positions, protrude on two non-opposite sides or only one side of the assembly support.

[0015] The method according to the invention thus enables the assembly of door modules with no, or at least a reduced, number of assembly overhangs of the door components in the as-delivered state. This makes it possible to use the door module as a pre-tested delivery unit even for multiple door components that protrude in the final assembly position, thereby improving the flexibility and scope of delivery for such a door module. In particular, the door module can thus be designed with a particularly compact installation space in the as-delivered state, i.e., with a reduced packaging size.

[0016] The lever system movably couples the door component to the assembly support. The lever geometry between the door component and the assembly support also enables particularly secure and short-length cable routing for the door component being installed. This avoids excessive cable lengths, which would be necessary if the door component were installed separately on the door shell.

[0017] A "door component" is understood here and below to mean, in particular, an electrical and / or mechanical functional element of the vehicle door that is part of a door module or a pre-assembled door module assembly, and which, in a final assembly position in the vehicle door, protrudes beyond the door module or its assembly carrier at the edges. Thus, in the final assembly position of the door component, the door module or the assembly carrier has a component or assembly protrusion with respect to the door component.

[0018] The term “projection” or “assembly or component projection” is understood here and below to mean in particular a section or part of the door component which projects beyond the outer circumference or outer edge of the unit carrier in a lateral direction, i.e. in the plane of the unit carrier.

[0019] The following provides information regarding the spatial directions, particularly in a motor vehicle coordinate system (vehicle coordinate system), for an exemplary installation situation of the door module in a door shell of a motor vehicle side door. The abscissa axis (X-axis, X-direction) is oriented along the vehicle's longitudinal direction (direction of travel), the ordinate axis (Y-axis, Y-direction) along the vehicle's transverse direction, and the applicate axis (Z-axis, Z-direction) along the vehicle height.

[0020] In the final assembly position, the door component thus protrudes at least partially from the outer circumference of the assembly carrier in the ±X and / or ±Z direction. In other words, the assembled door module has an assembly or component projection in the ±X and / or ±Z direction. The method according to the invention also enables a pure Y-assembly of the door module on the door shell (without a window lifter rail projection).

[0021] A “final assembly position” is understood here and below in particular to mean an (installed) state in which the door component is arranged in such a way that it can essentially fulfill its specific function within the vehicle door. In the final assembly position, the door component is therefore preferably ready for regular use in the vehicle door frame, with all necessary electrical and mechanical connections to other systems being established with the door module. However, additional fixing (e.g. screwing in the door body) in the final assembly position may be necessary. In particular, this also means a “provisional” final assembly position of the door component (pre-positioning), which is moved into the final final assembly position by a concluding assembly step.For example, a bearing bracket for an exterior door handle or a door handle unit (access module) as a door component is only tightened into its final position by a screw after the door module assembly has been completed. The deviation between the "provisional" final assembly position and the final assembly position is preferably only in the order of play or tolerance.

[0022] A "lever system" is understood here and below to mean, in particular, an arrangement of one or more rigid levers that are movably coupled to the assembly carrier and / or the door component. This configuration serves to transmit and convert force during assembly on the door shell. The force during installation of the door module is transferred to the door component via the actuating contour and the lever system in such a way that the door component is adjusted, at least in sections, over the (outer) edge of the assembly carrier. The lever system also guides the door component along a guide or movement path predetermined by the lever geometry. The lever system thus ensures stable, reliable, and reproducible movement of the door component.

[0023] An "actuating contour" is understood here and below to mean, in particular, a surface or geometry on the door shell that is intended for interaction with the lever system. This contour serves, for example, as a mechanical stop for the lever system to transmit force or torque for the movement of the door component. The actuating contour can, for example, include recesses, elevations, notches, or guides that are specifically designed to interact with corresponding counterparts or counter-contours of the lever system.

[0024] In an advantageous embodiment, the door component is pre-assembled to the assembly carrier via the lever system so that it can pivot. The lever system thus couples the door component and / or the assembly carrier to one another at fixed pivot points (rotation axes), whereby the door component is pivoted about a pivot axis by the lever system during movement into the final assembly position. The pivot axis of the lever system is preferably oriented along the Z direction, particularly when the door component protrudes from the assembly carrier in the positive or negative X direction in the final assembly position. In other words, the door component is connected to the assembly carrier by a lever system mounted so that it can pivot or rotate about Z. This ensures safe and reliable movement of the door component within the door shell.The lever system or the pivoting path is designed in such a way that the door component is moved into the final assembly position without collision.

[0025] In a suitable further development, the movement of the door component in the final assembly position is held in position by the lever system and / or the actuating contour.

[0026] For example, the movement of the door component in the final assembly position is mechanically locked by the lever system and / or the actuating contour. In the final assembly position of the door component, its movement is therefore locked or blocked by the lever system itself, by the actuating contour, or by a combination thereof. In other words, the lever system and / or the actuating contour are designed in such a way that when the door module or the assembly carrier is mounted to the door shell, movement of the lever system – and thus of the door component – ​​is not possible. As a result, the door component is mechanically fixed in the final assembly position within the vehicle door when installed. This ensures that the door component is held reliably and stably in the vehicle door when installed, despite its movable connection to the assembly carrier.

[0027] Preferably, however, the door component has at least a certain amount of play or mobility in the final assembly position. This is particularly intended for applications in which the lever system moves the door component into a preliminary final assembly position, and the door component is subsequently secured to the door shell with an additional fastener. This allows for tolerance compensation between the pre-positioned door component and the door shell, ensuring consistently reliable fixation and connection of the door component to the door shell.

[0028] The door module according to the invention is intended for a vehicle door of a motor vehicle, in particular for a side door, and is suitable and configured therefor. The door module has an assembly carrier (functional carrier, carrier plate) with a lever system, wherein a door component is pre-assembled on or to the assembly carrier so as to be movable by means of the lever system. The lever system is designed such that, when the door module is mounted on a door shell of the vehicle door, it can be driven by an actuating contour of the door shell. The actuating contour enables the lever system to be actuated or driven in such a way that it moves or adjusts the door component into a final assembly position that at least partially protrudes beyond the outer circumference of the assembly carrier. This creates a particularly suitable door module for a vehicle door.

[0029] The subframe is designed, for example, as an injection-molded part and, when assembled, preferably forms a wet / dry compartment divider of the vehicle door. The lever system couples the subframe to the door component. The lever system is hinged or rotatably mounted on at least one side to the subframe or the door component. Preferably, the lever system is hinged or rotatably mounted on both the subframe and the door component.

[0030] In a preferred embodiment, the lever system pivots the door component about at least one pivot axis during assembly of the door module to the door shell. The pivot axis is oriented in particular parallel to the assembly support plane (XZ) and perpendicular to the projection direction in the final assembly position. The projection direction is oriented approximately perpendicular to the outer edge of the assembly support and essentially points along the longitudinal direction of the assembly projection.

[0031] If a component protrudes along the X-direction, the pivot axis is oriented parallel to the Z-direction, for example. In other words, the door component is pivoted in particular in the XY plane. The pivot component along the Y-direction serves in particular to pivot the door component collision-free around an opening edge of a mounting opening in the door shell, so that the opening edge is at least partially engaged behind by the projection of the door component in the final assembly position. In other words, the mounting opening is arranged in a form-fitting manner in the Y-direction between the projection and the assembly carrier in the installed state.

[0032] Accordingly, if the component protrudes along the Z-direction, the pivot axis is preferably oriented parallel to the X-direction, with the door component pivoting in the YZ plane. It is conceivable, for example, particularly if the component protrudes in the -Z-direction, that the (structural) weight of the door component actuates the lever system or at least supports its actuation.

[0033] In one conceivable embodiment, the lever system comprises at least one pivot lever, which is pivotably mounted on the unit carrier on one side and on the door component on the other. In the case of an electrical or electronic door component, the cable routing for a connecting cable of the door component is preferably via the pivot lever. In other words, the connecting cable is routed or attached to the pivot lever.

[0034] The lever system can be designed as a single-lever or multi-lever system. A multi-lever system provides a number of pivoting levers, each of which is preferably pivotably mounted on the unit carrier on one side and on the door component on the other. The multi-lever system preferably forms a coupling mechanism for adjusting the door component.

[0035] In one possible design, the lever system features two parallel and equally long pivot levers. This results in a pivoting movement of the door component, with both pivot levers pivoting synchronously. This synchronization means that the pivot levers act essentially simultaneously.

[0036] For example, the pivot levers pivot in parallel or in the same direction, moving in the same plane and at the same angle relative to each other and to the starting position (delivery position, pre-assembly position). For this purpose, the lever system is designed as a parallel crank mechanism for adjusting or moving the door component, with the pivot levers forming the cranks and the assembly carrier and the door component forming the couplings. This ensures particularly stable and reliable guidance into the final assembly position.

[0037] The lever length of the pivot levers and their pivot angle determine the assembly or pivoting movement of the door component. The pivot levers and their pivot angles can therefore be designed and dimensioned differently to accommodate the corresponding assembly movements. The pivot levers therefore do not need to be oriented or guided parallel to each other. Furthermore, the pivot levers can also be non-straight, for example, curved or bent, to avoid collisions with the door shell or other components during the pivoting movement.

[0038] An additional or further aspect of the invention provides that the lever system has an upstanding actuating extension, which, when the door module is mounted on the door shell, comes into mechanical contact with the actuating contour of the door shell. In interaction with the actuating contour, the actuating extension thus drives the lever system.

[0039] The actuating extension is, for example, integrally formed, i.e., monolithic, onto the at least one pivot lever. Alternatively, the actuating extension can also be designed as a separate component that is arranged or attached to the at least one pivot lever. During assembly, the actuating extension rests, for example, on the stationary actuating contour, with the assembly force being at least partially converted into movement of the pivot lever, so that the door component subsequently pivots into the final assembly position.

[0040] The actuating extension is arranged, for example, near a pivot or pivot point of the pivot lever, in particular in the region of the pivot point on the unit carrier side. In particular, the actuating extension is arranged such that, in the final assembly position, the door shell, in particular the actuating contour, is arranged between the actuating extension and the door component.

[0041] In a practical further development, the actuating extension limits movement of the door component or the lever system when the door component is in the final assembly position or when the door module or the assembly carrier is fastened to the door shell. The limitation preferably occurs in conjunction with the actuating contour. This holds the door component in position in the final assembly position. This includes both the case in which movement of the door component is locked or blocked, and the case in which the door component has a certain (movement) play in the final assembly position to compensate for tolerances. It is essential for this design that the mobility in the final assembly position is mechanically limited or reduced so that movement of the door component into an undesired position is avoided.

[0042] In an advantageous embodiment, the actuating extension has a guide contour that is concavely curved relative to the actuating contour. During the pivoting movement of the lever system, the guide contour slides along or off the bend or curve of the actuating contour. This ensures reliable contact between the actuating contour and the lever system or actuating extension during assembly of the door module to the door shell or during movement of the lever system. Furthermore, the curved guide contour reduces frictional resistance to the actuating contour.

[0043] The door assembly according to the invention is intended for a vehicle door and is suitable and configured therefor. The door assembly is designed in particular to carry out a method described above and has a door shell with an actuating contour and a door module as described above with an assembly carrier with a lever system, wherein a door component is pre-assembled on or to the assembly carrier so as to be movable by means of the lever system. The door component is arranged in the pre-assembly position within the module boundaries, i.e. within the outer circumference of the assembly carrier, wherein the lever system can be driven by the actuating contour when the door module is assembled to the door shell in such a way that the door component is moved or adjusted into a final assembly position that at least partially protrudes beyond the outer circumference of the assembly carrier.This results in a particularly suitable door assembly which enables easy assembly of door components with a component overhang.

[0044] Below, an example of implementation is explained in more detail using a drawing. It shows: Fig. 1 in perspective view a vehicle door with a door assembly, Fig. 2 in perspective view, a section of a door module of the door assembly with a lever system and a door component coupled to it, Fig. 3 in perspective view, section of the door assembly, Fig. 4 to 7 in successive representations an assembly of the door component on the door shell in front view (a) and top view (b), Fig. 8 shows a plan view of a second embodiment of the door module with a lever system with pivot levers of different lengths in a pre-assembly position, and Fig. 9 shows a plan view of the second embodiment of the door module in a final assembly position.

[0045] Corresponding parts and sizes are always marked with the same reference symbol in all figures.

[0046] The Fig. Figure 1 shows a partially disassembled vehicle door 2 of a motor vehicle, designed as a side door, in particular as a pivoting door. The vehicle door 2 comprises a door assembly 4 with a door shell 6 as the door body.

[0047] The door shell 6 forms a door body for accommodating functional and door components of the vehicle door 2. The door body is open on the vehicle interior through an assembly opening 8, which, in the assembled state, is closed by an assembly carrier 10 of a door module 12. In the assembled state, the assembly carrier 10 acts as a wet / dry compartment divider of the vehicle door 2.

[0048] In the schematic and simplified representation of the Fig. 1, for example, two door components 14, 16 are pre-assembled on the assembly carrier 10. In the pre-assembled state, the door components 14, 16 are positioned within the module boundaries on the assembly carrier 10, so that the door components 14, 16 do not protrude beyond the module or assembly carrier edges. In other words, the door components 14, 16 are arranged within an outer perimeter 18 of the assembly carrier 10.

[0049] In the embodiment shown, the door component 16 is, for example, an electric window lifter, which is pre-mounted rigidly or immovably on the unit carrier 10.

[0050] The door component 14 is designed, for example, as a door lock for the vehicle door 2, and is pre-assembled to the unit carrier 2 in such a way that it can be moved into a position or position in which the door component 14 at least partially projects beyond the edge of the outer circumference 18.

[0051] In the following, information regarding the spatial directions is also provided, in particular, in a coordinate system of the motor vehicle (vehicle coordinate system). The abscissa axis (X-axis, X-direction) is oriented along the vehicle's longitudinal direction (direction of travel), the ordinate axis (Y-axis, Y-direction) along the vehicle's transverse direction, and the applicate axis (Z-axis, Z-direction) along the vehicle's height. The vehicle door 2, or the opening surface of the mounting opening 8, is essentially oriented in the XZ plane.

[0052] The structure of the door assembly 4, and in particular the movable arrangement of the door component 14, is shown below with reference to Fig. 2 and Fig. 3 is explained in more detail.

[0053] As in the Fig. 2, the door component 14 is movably or pivotably connected to the unit carrier 10 by a lever system 20.

[0054] The lever system 20 is designed as a multi-lever system, in particular as a two-lever system, with two parallel and equally long pivoting levers 22. The pivoting levers 22 are each coupled at their leg ends, on the one hand, by means of a first rotary or pivot joint (pivot point) 24 to a bracket 26 arranged fixedly on the unit carrier 10, and on the other hand, by means of a second rotary or pivot joint (pivot point) 28 to a corresponding bracket 30 of the door component 14.

[0055] In an alternative embodiment not shown in detail, the leg levers 22 are of different lengths and / or are not guided parallel to one another. In particular, the pivot levers 22 can have different pivot angles during the pivoting movement. Furthermore, the pivot levers 22 can also be shaped differently. For example, it is conceivable for the pivot levers 22 to be designed with different curvatures or bends in order to realize a desired (collision-free) pivoting movement.

[0056] Each or both of the brackets 26, 30 can alternatively be designed as a single piece, i.e., a one-piece or monolithic assembly, with the assembly support 10 or the door component 14. In other words, the brackets 26, 30 can also be an integral part of the assembly support 10 or the door component 14.

[0057] The pivot levers 22 are rigid and dimensionally stable, with the distance between the pivot joints 24 on the bracket 26 and the distance between the pivot joints 28 on the bracket 30 being the same in the embodiment shown. The brackets 26, 30 are also mechanically rigid, so that the distance between the pivot joints 24 and 28 is constant. However, it is also conceivable for the distances between the pivot joints 24 and 28 to be different.

[0058] The axes of rotation of the pivot joints 24 and 28 are each oriented parallel to the Z direction, so that when the door component 14 moves, a pivoting movement occurs about a pivot axis not shown in detail.

[0059] The lever system 20 is thus essentially designed as a coupling mechanism, in particular as a parallel crank mechanism, for adjusting or moving the door component 14, with the pivot levers 22 forming the cranks and the brackets 26, 30 forming the couplings. The bracket 26 on the unit carrier side is stationary or fixed. As a result, the pivot levers 22 pivot synchronously or with the same pivoting angle during a movement in this embodiment, whereby they are moved relative to one another in the XY plane and at the same angle.

[0060] The lever system 20 further comprises an actuating extension (actuating lever, drive lever) 32 arranged upwardly in the Z direction. The actuating extension 32 is attached to the outer pivot lever 22, i.e., to the pivot lever 22 arranged closer to the outer edge 18. In particular, the actuating extension 32 is designed as a single piece, i.e., monolithic, with the outer pivot lever 22.

[0061] The actuating extension 32 is arranged in the region of the pivot joint 24 of the outer pivot lever 22 and is oriented substantially transversely or obliquely to the longitudinal direction of the pivot lever 22. The actuating extension 32 is a drive element for adjusting or pivoting the lever system 20 or the door component 14. Upon actuation or deflection of the actuating extension 32, the rigidly coupled outer pivot lever 22 is also moved, which, due to the coupling mechanism of the lever system 20, synchronously guides the inner pivot lever 22. Thus, pivoting or movement of the door component 14 can be driven by the actuating extension 32.

[0062] The lever system 20 is designed as part of an assembly unit or assembly aid for door components 14, which, in a proper final assembly position E in the vehicle door 2, have an assembly or component projection beyond the outer edge 18 of the door module 12 or assembly carrier 10. Such door components 14 would thus collide with an (opening) edge of the assembly opening 8 in an assembly direction in Y if they already had an assembly projection in the delivery or pre-assembled state.

[0063] The assembly aid further comprises an actuating contour 34 on the door shell 6, in particular on an inner door panel defining the assembly opening 12. In the illustrated embodiment, the actuating contour 34 is designed as an actuating surface of the inner door panel arranged in the XZ plane, which acts as a mechanical stop for the actuating extension 32. When the door module 12 is mounted on the door shell 6, the actuating extension 32 is pressed or pressed against the actuating contour 34, thereby pivoting the actuating extension 32 - and thus the lever system 20 and the door component 14. This is shown in the Fig. 3 is indicated schematically by arrows.

[0064] The following is a method for assembling the door component 14 in the vehicle door 2 using the Fig. 4 to 7. The Fig. 4 to 7 show, in successive illustrations, the assembly of the door component 14 using the assembly aid described above. Fig. 4a to 7a each show a front view of the XZ plane, where the Fig. 4b to 7b show the corresponding top view of the XY plane.

[0065] In the Fig. 4a, Fig. 4b, the door component 14 is in a pre-assembly position V and in the Fig. 7a, Fig. 7b, the door component 14 is shown in a final assembly position E, wherein the Fig. 5a to 6b each show the door component 14 in an intermediate position arranged therebetween and not further designated.

[0066] The door component 14 is pre-assembled to the assembly carrier 10 by means of the lever system 20 in the delivery position or pre-assembly position V, so that the door component 14 has no assembly overhang and is arranged completely within the outer circumference 18. In the pre-assembly position V, the pivot levers 22 are arranged tilted, for example. For example, the pivot levers 22 have a pivot angle of approximately 60° with respect to the X direction. The position of the pivot levers 22 in the pre-assembly position V can be stabilized, for example, by contours not shown in detail. Alternatively, the lever system 20 or the door component 14 is moved into the pre-assembly position V after delivery, e.g. manually.

[0067] The Fig. 4a and Fig. 4b show the beginning of an installation process in which the door module 12 is mounted or fixed to the door shell 6. For this purpose, the door module 12 is placed from the outside onto the mounting opening 8 essentially vertically along the Y-direction, so that the door component 14 is arranged within the mounting space formed inside the door shell 6, and the fastening extension 32 is arranged outside the inner door panel. The door component 14, designed as a door lock in the exemplary embodiment, is pre-assembled on the door module 12 such that a locking cylinder is arranged at the same height as a door lock opening 36 of the door shell 6.

[0068] As can be seen particularly in the top view of the Fig. As can be seen in Figure 4b, the actuating extension 32 has a curved or arched guide contour 38. In the XY plane, the actuating extension 32 has, for example, an approximately C-shaped or J-shaped cross-sectional shape, wherein the C- or J-curve is arranged convexly bent away from the actuating contour 34.

[0069] The Fig. 5a and Fig. 5b show an installed state in which the actuating extension 32 strikes or is brought into contact with the actuating contour 34. If the door module 12 is subsequently moved further in the Y direction toward the door shell 6, the curved or arched guide contour 38 slides or slides in the X direction along the fixed actuating contour 34, so that the actuating extension 32 is pivoted about the pivot axis oriented parallel to the Z direction ( Fig. 6a, Fig. 6b). This drives the coupling mechanism of the lever system 20 and pivots the door component 14 outward from the pre-assembly position V around the Z-axis in the direction of the door shell 6.

[0070] As shown in the front views of the Fig. 4a, Fig. 5a, Fig. 6a and Fig. 7a, the door component 14 is moved by the actuation or drive of the lever system 20 over the outer circumference 18 - and thus due to the arrangement of the door component 14 within the assembly space - over the opening edge of the assembly opening 8 in the inner door panel, so that the door component 14 engages behind the opening edge or the inner door panel in sections.

[0071] The Fig. 7a and Fig. 7b show the finished installation state, in which the door component 14 is pivoted into the final assembly position E, which at least partially protrudes beyond the outer circumference 18 in the X direction. In the final assembly position E, the pivot levers 22 have, for example, a pivot angle of approximately 145° with respect to the X direction. The actuating contour 34 is positively enclosed in the Y direction between the actuating extension 32 and the door component 14. The guide contour 38 bears against the actuating contour 34 with a straight section, so that when the assembly carrier 10 is fixed to the door shell 6, movement of the actuating extension 32 - and thus of the lever system 20 or the door component 14 - is restricted, reduced, or limited, so that the door component 14 is held in the final assembly position E. In one conceivable embodiment, the door component 14 is mechanically locked or blocked, for example, in the final assembly position E.

[0072] The Fig. 8 and in the Fig. The embodiment shown in Figure 9 shows a schematic and simplified representation of an embodiment in which the lever system 20 (or the coupling mechanism realized thereby) is designed with two pivoting levers 22 of different lengths and two holders 26, 30 of different lengths. Fig. Fig. 8 shows the pre-assembly position V and Fig. 9 the corresponding final assembly position E, whereby the door shell 6 is not shown.

[0073] In this embodiment, the distance between the pivot points 24, i.e., the length of the bracket 26, and the distance between the pivot points 28, i.e., the length of the bracket 30, are dimensioned differently. In particular, the distance between the pivot points 24 is greater than the distance between the pivot points 28. However, the distance between the pivot points 24, 28 remains constant throughout the pivoting movement of the door component 14.

[0074] Furthermore, the pivoting arm 22 supporting the actuating extension 32 is shorter than the other. The pivoting levers 22 are arranged tilted or inclined relative to each other and exhibit different pivoting angles when pivoting into the final assembly position E.

[0075] The claimed invention is not limited to the embodiment described above. Rather, other variants of the invention may be derived from it by those skilled in the art within the scope of the disclosed claims without departing from the subject matter of the claimed invention.

[0076] In particular, all individual features described in connection with the embodiment can also be combined in other ways within the scope of the disclosed claims without departing from the subject matter of the claimed invention.

[0077] Thus, the method according to the invention is not limited to the assembly of a door lock as a door component 14. Rather, the method and the assembly aid comprising the lever system 20 and the actuating contour 32 can also be applied analogously to other door components 14. Furthermore, the method and the assembly aid are not limited to door components 14 with a final assembly position E projecting in ±X, but can also be applied analogously to door components 14 with a final assembly position E projecting in ±Z. List of reference symbols 2 vehicle doors 4 Door assembly 6 Door shell 8 Mounting opening 10 aggregate carriers 12 door module 14 Door component 16 Door components 18 Outer edge 20 lever system 22 swivel levers 24 Swivel joint, swivel joint 26 Bracket 28 Swivel joint, swivel joint 30 bracket 32 Actuating process 34 Actuating contour 36 Door lock opening 38 Guide contour X Vehicle longitudinal direction Y vehicle transverse direction Z Vehicle height direction V Pre-assembly position E Final assembly position

Claims

[1] Method for assembling a door component (14) in a vehicle door (2), comprising a door shell (6) with an actuating contour (34) and a door module (12) mountable on the door shell (6) with an assembly carrier (10), - wherein the door component (14) is pre-assembled to the unit carrier (10) via a lever system (20) within an outer circumference (18), - wherein the door module (12) is mounted on the door shell (6), and the lever system (20) is driven by the actuating contour (34) in such a way that the door component (14) is moved into a final assembly position (E) which at least partially projects beyond the outer circumference (18) of the unit carrier (10). [2] Method according to claim 1, characterized bythat the door component (14) is pre-assembled to the unit carrier (10) in a pivotable manner via the lever system (20), wherein the door component (14) is pivoted about a pivot axis by the lever system (20) during the movement into the final assembly position (E). [3] Method according to claim 1 or 2, characterized by that the movement of the door component (14) in the final assembly position (E) is mechanically held in position by the lever system (20) and / or the actuating contour (34). [4] Door module (12) for a vehicle door (2), comprising an assembly carrier (10), a lever system (20), and a door component (14) pre-assembled on the assembly carrier (10) via the lever system (20) so as to be movable, wherein the lever system (20) can be driven by an actuating contour (34) of the door shell (6) when the door module (12) is mounted on a door shell (6) in such a way that it moves the door component (14) into a final assembly position (E) which at least partially projects beyond an outer circumference (18) of the assembly carrier (10). [5] Door module (12) according to claim 4, characterized by that the lever system (20) pivots the door component (14) about at least one pivot axis when the door module (12) is mounted on the door shell (6). [6] Door module (12) according to claim 4 or 5, characterized by that the lever system (20) has at least one pivoting lever (22) which is pivotably or rotatably mounted on the one hand on the unit carrier (10) and on the other hand on the door component (14). [7] Door module (12) according to one of claims 4 to 6, characterized by that the lever system (20) has an upstanding actuating extension (32) which comes into mechanical contact with the actuating contour (34) of the door shell (6) when the door module (12) is mounted on the door shell (6). [8] Door module (12) according to claim 7, characterized by that the actuating extension (32) limits a movement of the door component (14) in the final assembly position (E). [9] Door module (12) according to claim 7 or 8, characterized by that the actuating extension (32) has a guide contour (38) which is concavely curved relative to the actuating contour (34). [10] Door assembly (4) for a vehicle door (2), comprising a door shell (6) with an actuating contour (34) and a door module (12) with an assembly carrier (10) and with a lever system (20) and with a door component (14) pre-assembled on the assembly carrier 10 via the lever system (20), wherein the lever system (20) can be driven by the actuating contour (34) during assembly of the door module (12) on the door shell (6) in such a way that it moves the door component (14) into a final assembly position (E) which at least partially projects beyond an outer circumference (18) of the assembly carrier (10).

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