Door panel for a vehicle door and method of assembling such a door panel to a door shell to obtain a vehicle door

Abstract

Door panel for a vehicle door and method of assembling such a door panel to a door shell to obtain a vehicle door The door panel (6) is of modular construction and comprises panel modules comprising a first panel module (12) and a second panel module (14) defining respective regions of the door panel (6). The first panel module (12) is provided with first panel fastening elements (26, 28) for fastening the first panel module (12) to a door shell (4) independently of the fastening of the second panel module (14) to the door shell (4).The second panel module (14) is provided with second panel fastening elements (34) for fastening the second panel module (14) to the door shell (4) independently of the fastening of the first panel module (12) to the door shell (4), the first panel fastening elements (26, 28) being different from the second panel fastening elements (34). Figure for abstract: Figure 2.

Description

Title of the invention: Door panel for a vehicle door and method of assembling such a door panel to a door shell to obtain a vehicle door

[0001] The present invention relates to a door panel for a vehicle door, in particular a vehicle door of a motor vehicle, the vehicle door comprising a door shell and a door panel attached to an inner face of the door shell.

[0002] A vehicle door of a motor vehicle generally comprises a door shell and a door panel attached to an inner face of the door shell.

[0003] The door shell includes a door frame defining the structure of the door shell and a door skin attached to an outer side of the door frame and defining the outer face of the vehicle door.

[0004] The door panel is attached to an inner side of the door frame defining the inner face of the door shell. The door panel trims the door frame. Preferably, the door trim is provided with functional members integrated into the door panel or mounted on the door panel, such as an armrest, a pocket, a door pull handle from inside the vehicle and / or controls, for example for controlling the vertical position of a window mounted on the door frame and / or for locking / unlocking the vehicle door and / or controlling the position of a rearview mirror mounted on the vehicle door.

[0005] It is possible to have a door panel of modular construction. Such a door panel comprises several distinct panel modules, for example two or three panel modules, each panel module defining a respective region of the door panel, the panel modules being assembled to the door shell to form the door panel.

[0006] Such a modularly constructed door panel comprises, for example, two panel modules comprising a lower panel module defining a lower region of the door panel and an upper panel module defining an upper region of the door panel.

[0007] A door panel of modular construction allows for customization of the door panel by changing one of the panel modules, for example based on an end user choice, and / or by sharing panel modules between different vehicle models while providing differentiated panel modules. for said vehicle models and / or by facilitating renovations of a vehicle model by changing one panel module and leaving another panel module unchanged and / or by facilitating repairs of the vehicle model by changing a damaged panel module and leaving another panel module undamaged and / or by facilitating the recyclability of the door panel.

[0008] A concern with a modularly constructed door panel is the attachment of the panel modules to the door shell as mounting tolerances must be maintained between the door panel and the door shell and also between the panel modules of the door panel.

[0009] The quality requirements must be guaranteed by the door panel manufacturer even if the panel modules of the door panel are assembled on the door shell by the automobile manufacturer, possibly at different locations on an assembly line of the automobile manufacturer.

[0010] One of the objectives of the invention is to provide a door panel of simple modular construction which is easy to mount on a corresponding door shell with satisfactory mounting tolerances.

[0011] To this end, the invention provides a door panel for a vehicle door comprising a door shell and the door panel attached to an inner face of the door shell, the door panel being of modular construction and comprising panel modules comprising a first panel module and a second panel module defining respective regions of the door panel, the first panel module being provided with first panel fastening elements for fastening the first panel module to the door shell independently of the fastening of the second panel module to the door shell and the second panel module being provided with second panel fastening elements for fastening the second panel module to the door shell independently of the fastening of the first panel module to the door shell, the first panel fastening elements being different from the second panel fastening elements.

[0012] Providing first panel fasteners for securing the first panel module to the door shell independently of securing the second panel module to the door shell and second panel fasteners for securing the second panel module independently of securing the first panel module to the door shell facilitates mounting of the first panel module and the second panel module to the door shell.

[0013] In the present context, "independently" is understood herein to mean that the secure attachment of the first panel module to the door shell with the first panel attachment elements is not subject to the secure attachment of the second panel module to the door shell and, conversely, that the secure attachment of the second panel module to the door shell with the second panel fastening elements is not subject to the secure fastening of the first panel module to the door shell.

[0014] In other words, the first panel fastening elements are designed to directly fasten the first panel module to the door shell, without the intermediary of the second panel module and, conversely, the second panel fastening elements are designed to directly fasten the second panel module to the door shell, without the intermediary of the first panel module.

[0015] The independent attachment of the first panel module and the second panel module to the door shell ensures proper positioning of the first panel module relative to the door shell and proper positioning of the second panel module relative to the door shell.

[0016] The independent attachment of the first panel module and the second panel module to the door shell allows for sequential attachment of the first panel module and the second panel module to the door shell with proper positioning of each of the first panel module and the second panel module relative to the door shell.

[0017] In some examples, the door panel includes one or more of the following optional features, taken individually or in any technically possible combination:

[0018] - the first panel fasteners are designed for a type of fastening and / or a different fixing direction than that of the second panel fixing elements;

[0019] - the first panel fasteners are designed to assemble the first panel module to the door shell in a first direction, in particular in a transverse direction;

[0020] - the second panel fastening elements are adapted to assemble the second panel module to the door shell in a second direction different from the first direction, in particular a second direction perpendicular to the first direction, for example a vertical direction;

[0021] - the first panel fastening elements comprise first elements panel fasteners designed to snap into place with corresponding first shell fasteners provided on the door shell;

[0022] - the first panel fastening elements comprise first elements panel fasteners designed to screw to corresponding first shell fasteners provided on the door shell;

[0023] - the second panel fastening elements comprise second elements panel fasteners adapted to engage with corresponding second shell fasteners provided on the door shell;

[0024] - the door panel includes connecting assemblies designed to secure securely connecting the first panel module to the second panel module, each connecting assembly comprising a first connecting element provided on the first panel module and a second connecting element provided on the second panel module for cooperating with said first connecting element;

[0025] - the connecting assemblies comprise:

[0026] - one or more hook connection assemblies each designed for hooking of the two corresponding connecting elements, and / or

[0027] - one or more snap-fit ​​connection assemblies each designed to the snap-fitting of the two corresponding connecting elements, and / or

[0028] - one or more snap hook connection assemblies each designed to the attachment and snap-fitting of the two corresponding connecting elements, and / or

[0029] - one or more screw connection assemblies each designed for screwing of connecting element provided as screw in the corresponding connecting element provided as nut, and / or

[0030] - one or more clip-on connecting assemblies each designed for snap-fastening of a connecting element in the corresponding connecting element provided as a clip attached to the corresponding panel module, and / or

[0031] - one or more clip nut connecting assemblies each designed for the screwing one connecting element provided as a screw into the other connecting element provided as a clip nut attached to the corresponding panel module.

[0032] - the connecting assemblies comprise:

[0033] - one or more connecting assemblies for securely fixing a formed armrest in the second door panel module to a wall of a pocket formed in the first panel module; and / or

[0034] - one or more connecting assemblies for securely fixing a formed handle in the second panel module to a wall of a pocket formed in the first panel module; and / or

[0035] - one or more connecting assemblies for securely fixing a rim of the first panel module at an edge of the second panel module;

[0036] - at least one of the first connecting elements is in proximity to one of the first panel fastening elements of the first panel module, in particular a first panel fastening element defining a screw fastening assembly with a corresponding first shell fastening element, and / or at least one of the second connecting elements is proximate to one of the second panel fastening elements of the second panel module.

[0037] The invention also relates to a vehicle door comprising a door shell and a door panel as defined above, the door panel being securely attached to the inner face of the door shell, the first panel module being securely attached to the door shell via the first panel attachment elements and the second panel module being securely attached to the door shell via the second attachment elements.

[0038] The invention also relates to a method of assembling a door panel as defined above on a door shell, comprising:

[0039] - assembling the first panel module to the door shell in a first direction, with engagement of the first panel fasteners with corresponding first shell fasteners provided on the door shell in the first direction;

[0040] - assembling the second panel module to the door shell in a second direction different from the first direction, with engagement of the second panel fasteners with corresponding second shell fasteners provided on the door shell in the second direction.

[0041] In some examples, the assembly method comprises one or more of the following optional features, taken individually or in any technically possible combination:

[0042] - the assembly of the second panel to the door shell comprises the engagement first connecting elements provided on the first panel module with corresponding second connecting elements provided on the second panel module;

[0043] - first connecting elements and corresponding second connecting elements are adapted to securely attach the second panel module to the first panel module in at least one direction perpendicular to the second direction, for example in the first direction and / or in a direction perpendicular to the first direction and the second direction.

[0044] The invention and its advantages will be better understood on reading the description which follows, given solely as a non-limiting example and made with reference to the appended drawings in which:

[0045] - [Fig.l] [Fig.l] is an assembled perspective view of a vehicle door;

[0046] - [Fig.2] [Fig.2] is an exploded perspective view of the vehicle door illustrating a door shell and a door panel consisting of two panel modules;

[0047] - [Fig.3] [Fig.3] is a rear view of the panel modules of the panel of door illustrating the position of the fixing elements and the connecting elements of the panel modules;

[0048] - [Fig.4][Fig.5][Fig.6] Figures 4 to 6 illustrate fixing elements for fixing the panel modules to the door shell;

[0049] - [Fig.7][Fig.8][Fig.9][Fig.lO][Fig.ll][Fig.l2] Figures 7 to 12 illustrate connecting assemblies to securely fix the panel modules together.

[0050] The vehicle door 2 illustrated in Figures 1 and 2 is designed to be mounted in a door opening of the body of a vehicle (not shown), in particular a motor vehicle. The vehicle door 2 is for example a side door designed to be mounted in a side door opening of the vehicle body.

[0051] In the following, the terms "horizontal", "vertical", "longitudinal", "transverse", "front", "rear", "right", "left", "upper" and "lower" refer to a vehicle door mounted on a side door opening of a vehicle body, the vehicle door being closed, and to the usual orthogonal frame of motor vehicles illustrated in Figures 1 to 12 and comprising a longitudinal axis X extending horizontally from rear to front, a transverse axis Y extending horizontally from right to left and a vertical axis Z extending from bottom to top.

[0052] The vehicle door 2 generally extends parallel to a vertical extension plane and parallel to the longitudinal axis X and the vertical axis Z when the door is mounted on the vehicle body and closed.

[0053] The vehicle door has a lower edge 2A, an upper edge 2B, a rear edge 2C and a front edge 2D.

[0054] The vehicle door 2 comprises a door shell 4 ([Fig.2]) and a door panel 6 (Figures 1 and 2) attached to the door shell 4.

[0055] The door shell 4 has an inner face 4A and an outer face 4B. The inner face 4A faces toward the inside of the vehicle when the vehicle door 2 is closed. The outer face 4B faces toward the outside of the vehicle when the vehicle door 2 is closed.

[0056] The door shell 4 generally comprises a door frame 8 and a door covering (not visible). The door frame 8 defines the structure of the door shell 4. The door covering covers the door frame 8 on the side of the external face 4B. The door covering defines the external face 4B of the vehicle door 2.

[0057] The door panel 6 lines the inner face 4A of the door shell 4. The door panel 6 is attached to the inner face 4A of the door shell 4. The door panel 6 covers the inner face 4A of the door shell 4, preferably entirely.

[0058] The door panel 6 is of modular construction. The door panel 6 comprises several distinct panel modules assembled to the door shell 4 so as to collectively form the door panel 6.

[0059] Each panel module defines a respective region or portion of the door panel 6. The panel modules complement each other to cover the inner face 4A of the door shell 4, preferably entirely. Adjacent panel modules are preferably contiguous.

[0060] In some examples, the door panel 6 comprises a first panel module 12 and a second panel module 14. The first panel module 12 and the second panel module 14 are contiguous along a join line.

[0061] The first panel module 12 and the second panel module 14 form for example respectively a lower part and an upper part of the door panel 6. The first panel module 12 extends between the lower edge 2A of the vehicle door 2 and the second panel module 14. The second panel module 14 extends between the first panel module 12 and the upper edge 2B of the vehicle door 2.

[0062] In some examples, the door panel 6 consists of exactly two panel modules, i.e., the first panel module 12 and the second panel module 14. The first panel module 12 and the second panel module 14 form, for example, respectively a lowest part and an uppermost part of the door panel 6.

[0063] In some examples, the door panel 6 comprises functional members, each functional member being formed in one of the panel modules.

[0064] The door panel 6 comprises for example an internal pocket 16 designed to store objects in the door panel 6. The internal pocket 16 opens via a pocket opening 18. The internal pocket 16 is for example formed in the first panel module 12.

[0065] The door panel 6 comprises for example an armrest 20 having an upper surface 22. The upper surface 22 of the armrest 20 is adapted so that a passenger can rest his arm or forearm. The armrest 20 is for example formed in the second panel module 14.

[0066] The door panel 6 comprises for example a handle 24. The handle 24 is designed so that a user can grasp the handle 24 from inside the vehicle to pull the vehicle door 2 into the closed position. The handle 24 is for example formed by a cavity provided in the armrest 20, in particular in the upper surface 22 of the armrest 20.

[0067] As illustrated in Figures 2 and 3, the first panel module 12 is provided with first panel fastening elements 26, 28 ([Fig. 3]) adapted to secure the first panel module 12 to the door shell 4. The door shell 4 comprises corresponding first shell fastening elements 30, 32 ([Fig. 2]) adapted to cooperate with the first panel fastening elements 26, 28.

[0068] The second panel module 14 is provided with second panel fastening elements 34 ([Fig.3]) adapted to secure the second panel module 14 to the door shell 4. The door shell 4 comprises corresponding second shell fastening elements 36 ([Fig.2]) adapted to cooperate with the second panel fastening elements 34.

[0069] Advantageously, the first panel fastening elements 26, 28 are designed to fix the first panel module 12 to the door shell 4 independently of the second panel module 14. The first panel fastening elements 26, 28 are designed to cooperate with the first shell fastening elements 30, 32 without being subject to the second panel module 14 or the second fastening elements 34.

[0070] Advantageously, the second panel fixing elements 34 are designed to fix the second panel module 14 on the door shell 4 independently of the first panel module 12. The second panel fixing elements 34 are designed to cooperate with the second shell fixing elements 36 without being subject to the second panel module 14 or the first panel fixing elements 26, 28.

[0071] Preferably, the first panel fastening elements 26, 28 are designed to fasten the first panel module 12 to the door shell 4 in a first direction F1 and the second fastening elements 34 are designed to fasten the second panel module 14 to the door shell 4 in a second direction F2 different from the first direction F1.

[0072] The first direction F1 and the second direction F2 are non-parallel. The first direction F1 and the second direction F2 define a non-zero angle between them. The second direction F2 is preferably perpendicular to the first direction FL.

[0073] In certain examples, the first direction F1 is parallel to the transverse axis Y (and perpendicular to the extension plane P) and the second direction F2 is perpendicular to the transverse axis Y, and in particular parallel to the vertical axis Z.

[0074] Each panel fastener (first panel fasteners 26, 28 and second panel fasteners 34) defines a panel fastener assembly with the corresponding shell fastener (first shell fasteners 30, 32 and second shell fasteners 36).

[0075] In particular, each first panel fastening element 26, 28 defines a first panel fastening assembly with the first panel fastening element corresponding shell 30, 32 and each second panel fastener 34 defines a second panel fastener assembly with corresponding second shell fasteners 36.

[0076] The panel fastening elements of the first panel module 12 and the second panel module 14 may define panel fastening assemblies of different types with the corresponding shell fastening elements.

[0077] Possible types of fastening assemblies include, for example, hook fastening assemblies designed to hook the two corresponding fastening elements together, snap fastening assemblies designed to snap the two corresponding fastening elements into each other, and screw fastening assemblies designed to screw the two corresponding fastening elements into each other.

[0078] The first panel fasteners 26, 28 comprise for example a first set of first panel fasteners 26 defining panel fastener assemblies of a first type with a first set of first shell fasteners 30 and a second fastener assembly of first fasteners 28 defining panel fastener assemblies of a second type with a second set of first shell fasteners 32, the first type being different from the second type.

[0079] As illustrated in [Fig.4], each panel fixing assembly of the first type is for example a snap-on fixing assembly.

[0080] One of the first panel fastener 26 and the corresponding first shell fastener 30 of each panel fastener assembly of the first type is for example a dowel and the other is a hole, the dowel being adapted to snap into the hole upon insertion of the dowel into the hole in the first direction FL

[0081] In a particular example, the first panel fastener 26 is a peg and the corresponding first shell fastener 30 is a hole, the first panel fastener 26 being configured to snap into the first shell fastener 30 upon insertion of the first panel fastener 26 into the corresponding first shell fastener 30 in the first direction FL

[0082] As illustrated in [Fig.3], the first panel fixing elements 26 are for example distributed along a rear edge, a lower edge and / or a front edge of the first panel module 12.

[0083] As illustrated in [Fig.5], each fixing assembly of the panel of the second type is for example a screw fixing assembly.

[0084] One of the first panel fastening element 28 and the corresponding first shell fastening element 32 of each panel fastening assembly of the second type is for example a screw and the other is a nut, the screw being adapted to be screwed into the nut, preferably in the first direction F1.

[0085] In a particular example, the first panel fastener 28 is a screw and the corresponding first shell fastener 32 is a nut, the first panel fastener 28 being adapted to screw into the first shell fastener 32, preferably in the first direction F1.

[0086] As illustrated in [Fig.3], the first panel fasteners 28 are distributed along an edge of the first panel module 12 which is proximate to the second panel module 14 when the first panel module 12 and the second panel module 14 are mounted on the door shell 6.

[0087] Advantageously, the first panel module 12 is provided with a removable portion 38 which is removable to provide access to the first panel fastening elements 28 of the second set of panel fastening elements 28 for screwing them to the corresponding first hull fastening elements 32 of the second set of hull fastening elements 32.

[0088] The removable part 38 is for example located in an upper zone of the pocket 16 which is preferably located below the armrest 20 when the door panel 6 is mounted on the door shell 4.

[0089] The provision of the panel fastening assemblies of two different types makes it possible to facilitate the mounting of the first panel module 12 on the door shell 4 and to firmly fix the first panel module 12 to the door shell 4, in particular when using a first set of panel fastening elements 26 adapted to snap-fit ​​with the corresponding first shell fastening elements 30 in the first direction F1 and / or a second set of panel fastening elements 28 adapted to screw-fit with the corresponding first shell fastening elements 32.

[0090] The first panel fasteners 26 of the first set are easily engaged with the corresponding first shell fasteners 30 in the first direction F1 and hold the first panel module 12 on the door shell 4 when the first panel fasteners 28 of the second set are engaged with the corresponding first shell fasteners 32.

[0091] As illustrated in [Fig.6], the second panel fastening elements 34 define, for example, hook fastening assemblies with the corresponding second shell fastening elements 36.

[0092] The second panel fastening elements 34 are adapted to be engaged with the second shell fastening elements 36 in the second direction F2, and in particular to engage with the second shell fastening elements 36 in the second direction F2.

[0093] Preferably, one or more second panel fastening elements 34 and the corresponding second shell fastening elements 36 are adapted to locate the second panel fastening elements 34 and the second shell fastening elements 36 relative to each other in at least one direction perpendicular to the second direction F2, in particular in the direction of the longitudinal axis X and / or in the direction of the transverse axis Y.

[0094] Such a location is achieved for example by complementary guide elements and / or complementary inclined surfaces provided on the second panel fastening elements 34 and the corresponding second shell fastening elements 36 which cooperate to locate the second panel fastening elements 34 and the corresponding second shell fastening elements 36 relative to each other when engaging them together in the second direction F2.

[0095] The first panel module 12 and the second panel module 14 comprise a plurality of connecting assemblies 40, 50, 60, 70, 80 configured to securely attach the first panel module 12 to the second panel module 14, each connecting assembly 40, 50, 60, 70, 80 comprising a first connecting element 42, 52, 62, 72, 82 provided on the first panel module 12 and a corresponding second connecting element 44, 54, 64, 74, 84 provided on the second panel module 14 for cooperating with said first connecting element 42, 52, 62, 72, 82.

[0096] Preferably, the plurality of connecting assemblies comprises connecting assemblies of different types.

[0097] Possible types of connecting assemblies include for example:

[0098] - one or more hook connection assemblies designed for hooking the two corresponding connecting elements, and / or

[0099] - one or more snap-fit ​​connection assemblies designed for a snap-fitting of the two corresponding connecting elements, and / or

[0100] - one or more snap hook connection assemblies designed for the hooking and snapping of the two corresponding connecting elements, and / or

[0101] - one or more screw connection assemblies designed for screwing elements connecting element provided as a screw in the corresponding connecting element provided as a nut, and / or

[0102] - one or more clip-on connecting assemblies designed to snap-on a connecting element in the corresponding connecting element provided as a clip attached to the corresponding panel module, and / or

[0103] - one or more clip nut connection assemblies for screwing a connecting element provided as a screw in a clip nut attached to the corresponding panel module.

[0104] The connecting assemblies 40, 50, 60, 70, 80 may comprise:

[0105] - one or more connecting assemblies for securely fixing a formed armrest in the second door panel module 14 to a wall of the pocket 16 formed in the first panel module 12, in particular an upper wall of the pocket 16, and / or

[0106] - one or more connecting assemblies for securely fixing the formed handle 24 in the second panel module 14 to a wall of the pocket 16 formed in the first panel module 12, in particular an upper wall of the pocket 16, and / or

[0107] - one or more connecting assemblies for each securely fixing an edge of the first panel module 12 to an edge of the second panel module 14.

[0108] As illustrated in [Fig.7], in some examples, the connecting assemblies comprise one or more hook connecting assemblies 40, each comprising a first connecting member 42 and a second connecting member 44 configured to hook onto each other in an engagement direction, which is preferably the second direction F2.

[0109] Preferably, at least one hook connection assembly 40 is configured such that the first connection element 42 and the second connection element 44 cooperate to position the first panel module 12 and the second panel module 14 relative to each other in at least one positioning direction different from the engagement direction, in particular in at least one positioning direction perpendicular to the engagement direction, more particularly in two positioning directions perpendicular to the engagement direction and to each other.

[0110] In some examples, the hook connection assembly 40 is configured such that the first connection member 42 and the second connection member 44 engage each other in the second direction F2 (engagement direction) and cooperate to position the first panel module 12 and the second panel module 14 relative to each other in the first direction F1 and / or in the direction perpendicular to the first direction F1 and the second direction F2.

[0111] For such positioning, the first connecting element 42 and the second connecting element 44 are for example provided with respective homologous contact surfaces 42A, 44A which come into contact with each other when the first connecting element 42 and the second connecting element 44 are engaged together, said surfaces homologous contact pins 42A, 44A being inclined relative to the engagement direction and the positioning direction.

[0112] Alternatively or optionally, the first connecting element 42 and the second connecting element 44 are provided with positioning features adapted to engage each other so as to position the first connecting element 42 and the second connecting element 44 relative to each other in one positioning direction or two positioning directions.

[0113] As illustrated in [Fig.7], the second connecting element 44 is for example provided with a positioning feature which is a positioning notch 46 adapted to receive a portion of the first connecting element 42 for positioning the first panel module 12 and the second panel module 14 relative to each other in the first direction F1.

[0114] Alternatively or optionally, as illustrated in [Fig.8], the first connecting element 42 is for example provided with a position feature which comprises at least one guide surface 48, in particular two guide surfaces 48, arranged to guide the second connecting element 44 along a positioning direction perpendicular to the first direction F1 and to the second direction F2 (i.e., here the longitudinal axis direction X) upon engagement of the second connecting element 44 with the first connecting element 42.

[0115] As illustrated in [Fig.9], the second connecting element 54 of a hook connection assembly 50 is for example provided with a positioning notch 56 adapted to receive a portion of the first connecting element 52 for relative positioning of the first connecting element 52 and the second connecting element 54 in the first direction F1 (i.e., here the direction of the transverse axis Y).

[0116] A hook connection assembly 50 as illustrated in [Fig.9] is for example provided on one side of the handle 24 of the first panel module 12. In a particular example, such a connection assembly 50 is provided on each side of the handle 24.

[0117] As illustrated in [Fig. 10], in some examples, the connecting assemblies comprise one or more snap hook connecting assemblies 60, each comprising a first connecting element 62 and a second connecting element 64 configured to hook onto each other in an engagement direction, particularly the second direction F2 with snap-fastening with each other.

[0118] The first connecting element 62 and the second connecting element 64 are adapted to engage each other in the engagement direction, which is for example the second direction F2.

[0119] For the purpose of snap-fastening, one of the first connecting element 62 and a second connecting element 64 comprises, for example, a tooth 66 designed to snap-fasten in a corresponding depression 68 provided on the other of the first connecting member 62 and the second connecting member 64, upon engagement of the first connecting member 62 and a second connecting member 64 with each other in the engagement direction.

[0120] In some examples, the first connecting element 62 is provided with the depression 68 and the second connecting element 64 is provided with the tooth 66.

[0121] The snap-fastening between the first connecting element 62 and the second connecting element 64 allows the movement of the first connecting element 62 and the second connecting element 64 closer to each other in the engagement direction and once a snap-fastening device opposes the movement of the first connecting element 62 and the second connecting element 64 away from each other in the engagement direction.

[0122] In some examples, a snap hook connection assembly 60 is provided between flanges of the first panel module 12 and the second panel module 14 provided on a front edge of the door panel 6 and / or a snap connection assembly 60 is provided between flanges of the first panel module 12 and the second panel module 14 provided on a rear edge of the door panel 6.

[0123] Advantageously, each such snap-on hook connection assembly 60 provided on flanges of the first panel module 12 and the second panel module 14 is designed to position the first panel module 12 and the second panel module 14 relative to each other in the first direction F1 and / or in a positioning direction perpendicular to the first direction F1 and to the second direction F2 (i.e., here the longitudinal direction X).

[0124] This is achieved for example by providing positioning features and / or inclined homologous contact surfaces similarly to what has been indicated above in relation to the hook connection assemblies 40, 50.

[0125] As illustrated in [Fig.l 1], in some examples, the connecting assemblies comprise one or more clip connecting assemblies 70, each comprising one of the first connecting member 72 and the second connecting member 74 is a tab having a base and a free end and the other is a clip inserted into an opening 75 of the other of the first panel module 12 and the second panel module 14 with a snap fit on edges 76 of the opening 75, the tab being configured to snap into the clip upon insertion of the tab into the opening 75 in an engagement direction, thereby subsequently preventing movement of the first panel module 12 and the second panel module 14 from each other in said engagement direction.

[0126] As illustrated in [Fig.l 1], a clip connection assembly 70 comprises for example a first connection element 72 provided as a separate clip from the first panel module 12 and attached to the first panel module 12 by being stapled into an opening 75 of the first panel module 12 and a second connecting element 74 provided in the form of a tab adapted to snap into the staple upon insertion of the tab into the staple in an engagement direction, thereby subsequently preventing movement of the first panel module 12 and the second panel module 14 from each other in said engagement direction.

[0127] The first connecting element 72 comprises for example two branches delimiting between them a space for receiving the second connecting element 74, on or each branch being provided with a locking feature 77, for example a flexible tab cut into the branch, designed to engage with the second connecting element 74 so as to allow the insertion of the second connecting element 74 between the branches and subsequently prevent the extraction of the second connecting element 74 from between the branches.

[0128] Each branch is for example provided with locking surfaces 78 arranged to allow the insertion of the first connecting element 72 provided as a staple between opposite edges 76 of the opening 75 with elastic deformation of the branches and the return of the branches to the initial state such that the locking surfaces 78 interfere with said opposite edges 76 to prevent removal of the first connecting element 72 from the opening 75.

[0129] This engagement direction is for example the second direction F2.

[0130] The first connecting element 72 is for example made of metal.

[0131] A staple bonding assembly 70 can provide a very strong bond preventing thereby reliably causing the first panel module 12 and the second panel module 14 to move away from each other in the direction of engagement of the clip connection assembly 70.

[0132] The clip connection assembly 70, comprising a clip attached to one of the first panel module 12 and the second panel module 14, may particularly be created with greater separation force than a snap connection assembly having a first fastener and a second fastener formed as a single piece of material with the first panel module 12 and the second panel module 14 respectively.

[0133] As illustrated in [Fig. 12], in some examples, the connecting assemblies comprise one or more screw connecting assemblies 80 each comprising a first connecting element 82 and a second connecting element 84 adapted to screw into each other along a screw axis, which is for example parallel to the second direction F2.

[0134] One of the first connecting element 82 and a second connecting element 84 is a nut having a threaded hole and the other is a screw for screwing into the nut.

[0135] Preferably, as illustrated in [Fig.12], the nut is a clip nut comprising a nut body 86 having the threaded hole 87 therein and a clip 88 for attaching the clip nut to one of the first panel module 12 and the second panel module 14.

[0136] In some examples, as illustrated in [Fig. 12], the first connecting element 82 is a screw provided in the first panel module 12, for example on an upper wall of the pocket 16, and the second connecting element 84 is a nut, in particular a clip nut, attached to the second panel module 14, in particular to a wall of the handle.

[0137] A screw connection assembly 80 can very reliably connect the first panel module 12 and the second panel module 14 thereby ensuring that the first panel module 12 and the second panel module 14 cannot be moved apart from each other even under a significant force such as might be generated during a side impact on the vehicle door 2.

[0138] Advantageously, at least one of the first connecting elements 42, 52, 62, 72, 82 is in proximity to one of the first panel fastening elements 26, 28 of the first panel module 12, in particular a first panel fastening element 28 defining a screw fastening assembly with a corresponding first shell fastening element 32, and / or at least one of the second connecting elements 44, 54, 64, 74, 84 is in proximity to one of the second panel fastening elements 34 of the second panel module 14.

[0139] The panel fastening elements (first panel fastening elements 26, 28 or second panel fastening elements 34) are attached to corresponding hull fastening elements (first hull fastening elements 30, 32 or second hull fastening elements 36).

[0140] A connecting element provided on a panel module proximate a panel fastening element allows precise positioning of the connecting element relative to the door shell and thus improves the positioning of the panel modules relative to the door shell, particularly if the panel fastening element defines a screw fastening assembly with a corresponding shell fastening element, in which case the positioning of the panel fastening element relative to the door shell is very precise.

[0141] As illustrated in [Fig.2], a method of assembling the door panel 6 to the door shell 4 comprises:

[0142] - the assembly of the first panel module 12 to the door shell 4 in a first direction Fl, with the engagement of the first panel fastening elements 26, 28 with corresponding first shell fastening elements 30, 32 provided on the door shell 4 in the first direction Fl; then

[0143] - the assembly of the second panel module 14 to the door shell 4 in a second direction F2 different from the first direction F1, with the engagement of the second panel fastening elements 34 with the corresponding second shell fastening elements 36 provided on the door shell 4 in the second direction F2.

[0144] Advantageously, the assembly of the first panel module 12 to the door shell 4 comprises for example the engagement of the first panel fixing elements 26 with corresponding first shell fixing elements 30 together defining snap-fastening assemblies snapped in the first direction F1, then the engagement of the first panel fixing elements 28 with corresponding first shell fixing elements 32 together defining screw fixing assemblies.

[0145] Preferably, the assembly of the second panel on the door shell 4 comprises the engagement of each first connecting element 42, 52, 62, 72, 82 provided on the first panel module 12 with the corresponding second connecting element 44, 54, 64, 74, 84 provided on the second panel module 14.

[0146] Advantageously, as explained above, first connecting elements 42, 52, 62, 72, 82 and corresponding second connecting elements 44, 54, 64, 74, 84 are designed to securely fix the second panel module 14 to the first panel module 12 in at least one direction perpendicular to the second direction F2, for example in the first direction F1 and / or in a direction perpendicular to the first direction F1 and to the second direction F2.

[0147] By virtue of the invention, the provision of the first panel fastening elements 26, 28 for fastening the first panel module 12 to the door shell 4 independently forms the fastening of the second panel module 14 on the door shell 4 and the second panel fastening elements 34 for fastening the second panel module 14 for fastening the second panel module 14 to the door shell 4 independently of the fastening of the first panel module 12 to the door shell 4 facilitates the mounting of the first panel module 12 and the second panel module 14 on the door shell 4.

[0148] The independent attachment of the first panel module 12 and the second panel module 14 to the door shell 4 ensures the proper positioning of the first panel module 12 relative to the door shell 4 and the proper positioning of the second panel module 14 relative to the door shell 4.

[0149] The independent attachment of the first panel module 12 and the second panel module 14 to the door shell 4 allows for sequential attachment of the first panel module 12 and the second panel module 14 to the door shell 4 with appropriate positioning of each of the first panel module 12 and the second panel module 14 relative to the door shell 4.

[0150] The provision of first fastening elements 26, 28 different from the second fastening elements 34 facilitates the sequential mounting of the first panel module 12 and the second panel module 14 with good positioning.

[0151] The first panel module 12 may be rigidly mounted to the door shell 4, for example with first fastening elements 28 defining screw fastening assemblies with corresponding first shell fastening elements 32.

[0152] The second panel module 14 can be mounted on the door shell 4 precisely relative to the door shell 4 while still taking into account the presence of the first panel module 12 and ensuring good relative positioning of the first panel module 12 and the second panel module 14.

[0153] The connecting assemblies for securely attaching the first panel module 12 and the second panel module 14 together allow precise relative positioning of the first panel module 12 and the second panel module 14.

[0154] The invention is not limited to the examples described above and illustrated in the drawings. Other examples may be envisaged.

[0155] For example, in some embodiments, the door panel 6 comprises more than two panel modules, for example three panel modules.

[0156] As illustrated in [Fig.l], the door panel 6 comprises for example the first panel module 12 defining a lower region of the door panel 6, the second panel module 14 defining an intermediate region of the door panel 6, and a third panel module 90 defining an upper region of the door panel 6.

[0157] Furthermore, other combinations and positioning of the fixing assemblies and the connecting assemblies can be envisaged, for example depending on the presence of functional members on the door panel 6 (armrest 20, handle 24, pocket 16) and / or depending on said functional members.

Claims

Claims

1. A door panel for a vehicle door comprising a door shell (4) and the door panel (6) attached to an inner face of the door shell (4), the door panel (6) being of modular construction and comprising panel modules comprising a first panel module (12) and a second panel module (14) defining respective regions of the door panel (6), the first panel module (12) being provided with first panel fastening elements (26, 28) for fastening the first panel module (12) to the door shell (4) independently of the fastening of the second panel module (14) to the door shell (4) and the second panel module (14) being provided with second panel fastening elements (34) for fastening the second panel module (14) to the door shell (4) independently of the fastening of the first panel module (12) to the door shell (4),the first panel fastening elements (26, 28) being different from the second panel fastening elements (34).,

2. A door panel according to claim 1, wherein the first panel fastening elements (26, 28) are adapted for a different fastening type and / or fastening direction than the second panel fastening elements (34).

3. Door panel according to claim 1 or claim 2, wherein the first panel fastening elements (26, 28) are adapted to assemble the first panel module (12) to the door shell (4) in a first direction (F1), in particular in a transverse direction.

4. Door panel according to claim 3, wherein the second panel fastening elements (34) are adapted to assemble the second panel module (14) to the door shell (4) in a second direction (F2) different from the first direction (F1), in particular a second direction (F2) perpendicular to the first direction (F1), for example a vertical direction.

5. A door panel according to any preceding claim, wherein the first panel fasteners (26, 28) comprise first panel fasteners (26) adapted to snap-engage with first panel fasteners (26, 28). corresponding shell fixings (30) provided on the door shell (4).

6. A door panel according to any preceding claim, wherein the first panel fasteners (26) comprise first panel fasteners (26) adapted to be screwed with corresponding first shell fasteners (32) provided on the door shell (4).

7. A door panel according to any preceding claim, wherein the second panel fasteners (34) comprise second panel fasteners (34) adapted to engage with corresponding second shell fasteners (36) provided on the door shell (4).

8. A door panel according to any preceding claim, comprising connecting assemblies (40, 50, 60, 70, 80) adapted to securely attach the first panel module (12) to the second panel module (14), each connecting assembly comprising a first connecting element (42, 52, 62, 72, 82) provided on the first panel module (12) and a second connecting element (44, 54, 64, 74, 84) provided on the second panel module (14) for cooperating with said first connecting element (42, 52, 62, 72, 82).

9. Door panel according to claim 8, wherein the connecting assemblies (40, 50, 60, 70, 80) comprise: - one or more hook connecting assemblies each adapted for hooking the two corresponding connecting elements, and / or - one or more snap connecting assemblies each adapted for snapping the two corresponding connecting elements, and / or - one or more hook snap connecting assemblies each adapted for hooking and snapping the two corresponding connecting elements, and / or - one or more screw connecting assemblies each adapted for screwing a connecting element provided as a screw into the corresponding connecting element provided as a nut, and / or - one or more clip connecting assemblies each adapted for snapping a connecting element into the connecting element corresponding provided as a clip attached to the corresponding panel module, and / or - one or more clip nut connecting assemblies each designed for screwing one connecting element provided as a screw into the other connecting element provided as a clip nut attached to the corresponding panel module.

10. A door panel according to claim 8 or 9, wherein the connecting assemblies comprise: - one or more connecting assemblies for securely attaching an armrest formed in the second door panel module (14) to a wall of a pocket formed in the first panel module (12); and / or - one or more connecting assemblies for securely attaching a handle formed in the second panel module (14) to a wall of a pocket formed in the first panel module (12); and / or - one or more connecting assemblies for securely attaching a rim of the first panel module (12) to a rim of the second panel module (14).

11. A door panel according to any one of claims 8 to 10, at least one of the first connecting elements (42, 52, 62, 72, 82) is in proximity to one of the first panel fastening elements (26, 28) of the first panel module (12), in particular a first panel fastening element (28) defining a screw fastening connection with a corresponding first shell fastening element (32), and / or at least one of the second connecting elements (44, 54, 64, 74, 84) is in proximity to one of the second panel fastening elements (34) of the second panel module (14).

12. A vehicle door comprising a door shell (4) and a door panel (6) according to any preceding claim, the door panel (6) being securely attached to the inner face of the door shell (4), the first panel module (12) being securely attached to the door shell (4) via the first panel fastening elements (26, 28) and the second panel module (14) being securely attached to the door shell (4) via the second fastening elements (34).

13. A method of assembling a door panel (6) according to any one of claims 1 to 11 on a door shell (4), comprising: - assembling the first panel module (12) to the door shell (4) in a first direction (F1), with engagement of the first panel fastening elements (26, 28) with corresponding first shell fastening elements (30, 32) provided on the door shell (4) in the first direction (F1); - assembling the second panel module (14) to the door shell (4) in a second direction (F2) different from the first direction (F1), with engagement of the second panel fastening elements (34) with the corresponding second shell fastening elements (36) provided on the door shell (4) in the second direction (F2).

14. The assembly method of claim 13, wherein assembling the second panel to the door shell (4) comprises engaging first connecting members (42, 52, 62, 72, 82) provided on the first panel module (12) with corresponding second connecting members (44, 54, 64, 74, 84) provided on the second panel module (14).

15. An assembly method according to claim 14, wherein first connecting elements (42, 52, 62, 72, 82) and corresponding second connecting elements (44, 54, 64, 74, 84) are adapted to securely attach the second panel module (14) to the first panel module (12) in at least one direction perpendicular to the second direction (F2), for example in the first direction (F1) and / or in a direction perpendicular to the first direction (F1) and to the second direction (F2).

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