Door assembly module and method

Abstract

This invention relates to a system and method for providing a single module which has a plurality of integrally-molded features and components which are mounted on a door of a vehicle. In a preferred embodiment, the module is used to provide a support capable of supporting a plurality of tailgate components, such as a windshield wiper motor, electric door latches and illumination system for illuminating a license plate, stop light and even a cargo area of the vehicle. The system and method provide a module platform having at least one integrally-molded handle which permits an operator to pick up the module with its various components integrally-molded in or mounted thereon and situate the module directly onto the door, thereby substantially reducing the number of assembly steps and assembly time required in the past. The module includes a plurality of molded features such as guide and aligning wedge wings which align the module on the door and which are also capable of housing and securing a plurality of wires. A latch docking station is also integrally-molded into the module to house a plurality of electronic mounting latches during transportation. The one-piece module also has an area for receiving a windshield wiper motor which drives a windshield wiper blade. The module further includes a circuit board which is mounted directly onto the module for controlling the operation of the various electrical components associated with the door. An LED illumination system for illuminating a license plate, stop light and/or even a cargo area of the vehicle is provided directly on the circuit board or is separately wired thereto. Once the components are completely assembled and mounted onto the module, an assembler may pick up the module using a module handle molded in the module at a handle area where a plurality of overturning moments associated with the module are or become substantially balanced to assist the assembler in positioning the module onto the door.