阅读说明：本技术 具有包括可持续承载件的承载件模块的车门 (Vehicle door with carrier module having sustainable carrier ) 是由 雷蒙德·爱德华·福廷 于 2021-03-29 设计创作，主要内容包括：提供了一种用于机动车门组件的承载件模块的承载件及其制造方法。承载件具有本体,该本体具有由外周缘界定的相反的湿侧部和干侧部,该本体构造成用于附接至机动车辆门组件的内面板。本体由可回收的、环境可持续的天然纤维材料制成。(A carrier for a carrier module of a motor vehicle door assembly and a method of manufacturing the same are provided. The carrier has a body with opposing wet and dry sides bounded by an outer periphery, the body configured for attachment to an inner panel of a motor vehicle door assembly. The body is made of a recyclable, environmentally sustainable natural fiber material.)

1. A carrier (21) for a carrier module (20) of a motor vehicle door assembly (10), the door assembly (10) having an inner panel (18) and an outer panel (16) defining a door panel structure (20), wherein the inner panel has an opening (26) to a door interior cavity (24) between the inner and outer panels, the carrier comprising:

a body (49; 49 '), said body (49; 49 ') having opposite sides (60, 62) bounded by an outer periphery (48), said body (49; 49 ') configured for attachment to said inner panel (18) to substantially close said opening (26), said body being formed of a non-synthetic material.

2. The carrier according to claim 1, wherein the body comprises at least one layer (L) of non-synthetic material.

3. The carrier of claim 2, wherein the at least one layer of non-synthetic material is coated with a thermosetting resin.

4. The carrier of claim 3, wherein the thermosetting resin comprises a non-synthetic adhesive material.

5. The carrier of claim 2, wherein the at least one layer comprises a mesh layer (80) of non-synthetic material.

6. The carrier of claim 5, wherein the at least one layer comprises a pair of pads of non-synthetic material, the mesh being disposed between the pair of pads.

7. The carrier of claim 6, wherein the mesh and the pair of pads are interconnected by a thermosetting resin.

8. The carrier of claim 7, wherein the mesh comprises a plurality of filaments having sub-filaments extending outwardly therefrom, the sub-filaments being bonded to the liner by the thermosetting resin.

9. The carrier of claim 1, wherein the at least one layer is formed from a plant-based material or a rock-based material.

10. The carrier of claim 9, wherein the plant based material is bast fibers and the rock based material is basalt fibers.

11. A method of manufacturing a carrier for a carrier module of a motor vehicle door assembly, the method comprising the steps of:

providing a body formed from at least one layer of natural fiber material; and

mounting a plurality of door hardware components to the body.

12. The method of manufacturing a carrier for a carrier module of an automotive door assembly according to claim 11 wherein the body is formed substantially free of synthetic material.

Technical Field

The present disclosure relates generally to vehicle door assemblies and, more particularly, to carrier modules for vehicle door assemblies.

Background

This section provides background information related to the present disclosure that is not necessarily prior art.

The automotive industry is continually seeking to use, where possible, lightweight, readily recyclable, and environmentally sustainable materials in components. However, in some cases, such as when the component may be exposed to high forces and/or to moisture, the component may be made of relatively heavy metal and/or plastic materials. Although plastic materials can be recyclable, inspection and sorting stations that are currently used to identify recyclable materials, such as sorting cameras by optical recycling, typically ignore plastic material parts because the plastic material parts are dark colored and in most cases black. Furthermore, plastic materials are generally not environmentally friendly or biodegradable. One such component made of metal or plastic is known as the carrier of a carrier module. While metal or plastic bearings may be used to provide the required structural and barrier functions (preventing debris and fluids from transferring from the wet side of the bearing module to the dry side of the bearing module and generally being able to resist degradation when exposed to moisture/fluids), metal or plastic bearings tend to be relatively heavy, thereby negatively impacting fuel efficiency by increasing weight, which is also receiving increased attention, such as through fuel economy regulations. Thus, metal and plastic materials tend to challenge recyclability, in addition to being undesirable from an environmental sustainability perspective.

In addition to the aforementioned disadvantages presented by known carrier modules, other disadvantages may also result during high impact forces. High impact forces on known metal and plastic carrier modules can cause the carrier modules to break into individual pieces, also known as chips, which can prove problematic. For example, one or more of the fragments may result in unwanted emissions and/or result in sharp edges, which may increase the likelihood of the fragments penetrating into the interior cabin of the vehicle and/or piercing inflation suppression devices commonly referred to as "airbags," thereby potentially reducing the efficacy of the airbags.

In view of the above, it is desirable to provide the following bearings: the carrier can be easily classified as a recyclable material by an automatic classification apparatus including an optical recycling classification camera while being environmentally friendly, environmentally sustainable and biodegradable while being capable of performing desired structural and barrier functions without becoming broken or breaking into separate parts when subjected to high impact forces, which improves economy of manufacture and assembly while reducing weight to improve fuel economy of the vehicle.

Disclosure of Invention

This section provides a general summary of the disclosure, and is not intended to be a complete or comprehensive listing of the full scope of the disclosure or all aspects, advantages, objects, and/or features of the disclosure.

It is an object of the present disclosure to provide a carrier for a carrier module of a door assembly of a motor vehicle which solves at least those problems of the known carriers described above.

According to one aspect, the present disclosure relates to a carrier for a carrier module of a door assembly of a motor vehicle, the carrier being easily recyclable and separable from non-recyclable materials, such as being separable from non-recyclable materials by an optical recycling sorting camera.

According to another aspect, the present disclosure relates to a carrier for a carrier module of a door assembly of a motor vehicle, the carrier being environmentally sustainable, environmentally friendly, easily recyclable and separable from non-recyclable materials, such as being separable from non-recyclable materials by an optical recycling sorting camera, the carrier having a high structural strength to provide a desired side impact resistance, the carrier being moisture and fluid permeable, thereby providing a desired barrier function to prevent moisture/fluid transfer from the wet side of the carrier module to the dry side of the carrier module, the carrier being degradation resistant in the presence of moisture/fluid, and the carrier reducing the weight of the carrier module relative to a metal or plastic carrier, thereby improving the fuel economy of the vehicle.

According to another aspect, the present disclosure is directed to a carrier for a carrier module of a door assembly of a motor vehicle that is resistant to crushing into multiple separate pieces when impacted in a collision scenario, thereby maintaining the carrier as a single unitary piece of material to minimize the risk of damaging adjacent components and preventing the separate piece of material from protruding outside of a door interior cavity of a door panel structure.

According to another aspect, the present disclosure relates to a door assembly for a motor vehicle, the door assembly having an outer panel, an inner panel and a carrier module, the carrier module has a carrier that is environmentally sustainable, environmentally friendly, easily recyclable, and separable from a non-recyclable material, such as a non-recyclable material that is separable from a recyclable sorting camera by optics, the carrier has high structural strength to provide the desired side impact resistance, is moisture and fluid resistant, thereby providing the required barrier function to prevent moisture/fluid transfer from the wet side of the carrier module to the dry side of the carrier module, the carrier is resistant to degradation in the presence of moisture/fluid and reduces the weight of the carrier module relative to a carrier made of metal or plastic, thereby improving the fuel economy of the vehicle.

According to another aspect of the present disclosure, a carrier for a carrier module of a motor vehicle door assembly having an inner panel and an outer panel defining a door panel structure is provided, wherein the inner panel has an opening for selectively accessing an interior cavity of a door between the inner panel and the outer panel. The carrier includes a body having opposite sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening. The opposite side of the body has a color distinguishable from the black surface to facilitate identification during recycling sorting.

According to another aspect of the present disclosure, the opposite side of the body may be provided with a non-black color different from the black surface.

According to another aspect of the disclosure, the body is formed from a mixture of natural fiber material and a binder, wherein the binder binds the natural fiber material together.

According to another aspect of the disclosure, a fluid-impermeable layer is bonded to at least one of the opposite sides of the carrier so as to prevent moisture/fluid from coming into contact with the natural fiber material.

According to another aspect of the present disclosure, the body has a plurality of fastener through openings adjacent the outer periphery, and the body further includes a metal or plastic washer secured in each of the plurality of fastener through openings to facilitate securing the carrier to the inner panel of the door panel structure without damaging the natural fiber material.

According to another aspect of the present disclosure, the body of the carrier may be formed to have a perforated structure with a plurality of through openings to reduce the weight of the carrier.

According to another aspect of the present disclosure, the perforated structure of the body may be formed as a structure having a honeycomb pattern.

According to another aspect of the disclosure, the body may include a mesh secured to the body to prevent the body from becoming broken into separate pieces when subjected to an impact force during a collision event, thereby maintaining the body as an interconnected one-piece material, wherein the pieces may be cracks within the body but remain connected to one another.

According to another aspect of the present disclosure, a carrier for a carrier module of a door assembly of a motor vehicle having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening to an interior cavity of the door between the inner panel and the outer panel, the carrier comprising a body having opposing sides bounded by outer peripheries, the body configured for attachment to the inner panel to substantially close the opening, the body being made of a non-synthetic material.

According to another aspect of the present disclosure, a carrier for a carrier module of a door assembly of a motor vehicle having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening to an interior cavity of the door between the inner panel and the outer panel, the carrier comprising a body having opposite sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening, the body formed free of thermoplastic.

According to another aspect of the present disclosure, a carrier for a carrier module of a door assembly of a motor vehicle having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening to an interior cavity of the door between the inner panel and the outer panel, the carrier comprising a body having opposing sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening, the body formed without the use of artificial chemically derived materials.

According to another aspect of the present disclosure, a carrier for a carrier module of a door assembly of a motor vehicle having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening to an interior cavity of the door between the inner panel and the outer panel, the carrier comprising a body having opposing sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening, the body formed using a renewable material. In a related aspect, the body can include at least one layer formed substantially using renewable materials. In related aspects, the layers may be at least one layer or adhered together and sealed using a resin formed from a renewable material.

According to another aspect of the present disclosure, a carrier for a carrier module of a door assembly of a motor vehicle is provided, the door assembly having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening for selectively accessing an interior cavity of the door between the inner panel and the outer panel. The carrier includes a body having opposite sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening. The body is formed to include a mesh secured to the body. The mesh may prevent the body from breaking into separate pieces of material when subjected to an impact force, thereby minimizing the risk of damage to adjacent components from the body and preventing the separate pieces from protruding outside the door interior cavity of the vehicle door panel structure.

According to another aspect of the present disclosure, a binder material may bond the web to the body.

According to another aspect of the present disclosure, the mesh may be overmolded by the material of the body.

According to another aspect of the present disclosure, a mesh may be placed between a pair of pads of a mixture of natural fiber materials, and the pair of pads may be overmolded by a binder material.

According to another aspect of the present disclosure, the mesh may be formed of natural fibers.

According to another aspect of the present disclosure, the natural fibers of the mesh may be provided as continuous, elongate multifilament yarns interwoven with one another, such as by being woven or knitted together.

According to another aspect of the present disclosure, the filaments of the mesh may be pre-coated with an adhesive material to facilitate bonding the mesh to the body upon application of sufficient heat to melt the adhesive material.

According to another aspect of the present disclosure, the filaments of the mesh may be provided with sub-filaments extending radially outward from the filaments, wherein the sub-filaments improve the adhesion of the mesh to the body.

According to another aspect of the present disclosure, the natural fibers of the mesh may be interwoven with one another at the nodes, wherein the nodes may allow the interconnected natural fibers to move relative to one another while maintaining the natural fibers in an interconnected relationship with one another at the nodes, thereby minimizing the accumulation of internal stresses within the body of the carrier during manufacture of both the carrier and the body, making the body easier to shape as desired, and at the same time easier to withstand impact forces during a crash condition, thereby further reducing the tendency to cause the body to fracture.

According to another aspect of the present disclosure, the nodes may be formed by loops during weaving or by cross-ties during weaving.

According to another aspect of the present disclosure, a carrier for a carrier module of a door assembly of a motor vehicle is provided, the door assembly having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening for selectively accessing an interior cavity of the door between the inner panel and the outer panel. The carrier includes a body having opposite sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening. The body is formed from a mesh fabric comprising filaments interconnected by a plurality of nodes, wherein the body, in a non-impact state, prevents displacement of the nodes relative to the filaments intersecting the respective nodes to maintain structural integrity of the body, and wherein the body, in an impact state, allows displacement of the nodes relative to the nodes of at least some of the filaments intersecting the respective nodes to prevent fragmentation of the load bearing member.

According to another aspect of the present disclosure, a carrier for a carrier module of a door assembly of a motor vehicle is provided, the door assembly having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening for selectively accessing an interior cavity of the door between the inner panel and the outer panel. The carrier includes a body having opposite sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening. The body is formed from a mesh fabric comprising filaments, wherein the filaments comprise a plurality of sub-filaments extending from the filaments for being surrounded by and secured to the body.

According to another aspect of the present disclosure, a method of manufacturing a carrier for a carrier module of a door panel structure of a motor vehicle for closing an opening in an inner panel of the door panel structure of the motor vehicle is provided. The method comprises the following steps: providing a recyclable natural fiber material; adding a binder material to the recyclable natural fiber material; forming a web of recyclable natural fiber material and binder material; disposing a mesh between the mold halves; and compressing the web between the mold halves to form a body having opposing sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening, wherein the opposing sides are formed with a finished profile of the carrier.

According to another aspect of the present disclosure, the method of manufacturing a carrier module may further comprise applying heat and pressure while compressing the web to bond the recyclable natural fiber material and the binder material together.

According to another aspect of the disclosure, the method of manufacturing a carrier module may further comprise bonding a fluid-impermeable layer to at least one of the opposing sides.

According to another aspect of the present disclosure, the method of manufacturing a carrier module may further include: a plurality of fastener through openings are formed adjacent the outer periphery and a metal or plastic washer is secured in each of the plurality of fastener through openings.

According to another aspect of the disclosure, the method of manufacturing a carrier module may further include forming the web and the body having a honeycomb structure.

According to another aspect of the present disclosure, there is provided a carrier for a carrier module of a door assembly of a motor vehicle, the door assembly having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening to an interior cavity of the door between the inner panel and the outer panel, the carrier comprising a body having opposite sides bounded by an outer periphery, the body being configured for attachment to the inner panel to substantially close the opening, the body being formed from a composite structure of natural fibers.

According to another aspect, a composite structure for a motor vehicle component is provided, the composite structure having a mesh core formed using a natural or vegetable based material, and at least one or more layers of a non-synthetic material connected to the mesh core.

According to another aspect of the present disclosure, there is provided a method of manufacturing a carrier of a carrier module for a door assembly of a motor vehicle, the method comprising the steps of: providing a body formed from at least one layer of natural fiber material; and mounting a plurality of door hardware components to the body. In a related aspect, the body is formed to be free or substantially free of synthetic material.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only of certain non-limiting embodiments, and are not intended to limit the scope of the present disclosure.

Drawings

The drawings described herein are for illustrative purposes only of selected non-limiting embodiments and are not intended to limit the scope of the present disclosure. In this regard, the drawings include:

FIG. 1 illustrates a motor vehicle having a door assembly constructed in accordance with one aspect of the present disclosure;

FIG. 2 is a schematic perspective view of a door assembly of the vehicle of FIG. 1 having a carrier module according to another aspect of the present disclosure;

FIG. 2A is an enlarged perspective cross-sectional view of a portion of the door assembly of FIG. 2;

FIG. 2B is an enlarged cross-sectional view illustrating the encircled area 2B of FIG. 2A;

fig. 3 illustrates a schematic plan view of the carriers of the carrier module of fig. 2;

fig. 4 is a perspective view of a mold for manufacturing a carrier according to another aspect of the present disclosure;

FIG. 4A illustrates the mold halves of the mold of FIG. 4 shown in an open position;

fig. 5 illustrates a portion of a carrier according to another aspect of the present disclosure;

fig. 5A is a plan view of a portion of the body of the carrier of fig. 5;

FIG. 6 is a cross-sectional perspective view taken through a fastener opening and washer of a portion of the carrier of FIG. 3;

fig. 7 is a flow chart illustrating a method of manufacturing a carrier according to another aspect of the present disclosure;

FIG. 8 is a flow chart illustrating a method of facilitating the ability to reclaim recyclable carriers, according to another aspect of the present disclosure;

FIG. 9 is a barrier for a carrier formed using the teachings described herein;

fig. 10 is a perspective view of a carrier made in accordance with another aspect of the present disclosure;

fig. 11 illustrates a perspective view of an alternative stage of manufacture of the carrier of fig. 10;

fig. 11A is an enlarged partial view of a web of the carrier of fig. 10;

FIG. 11B illustrates a cross-section of layers forming a composite structure of natural material, in accordance with aspects of the present invention;

fig. 12 is a schematic plan view of the carrier of fig. 10;

FIG. 12A is an enlarged partial plan view of the mesh of the load bearing member of FIG. 10 shown in a pre-crash state as manufactured;

FIG. 12B is an enlarged partial perspective view of the mesh of FIG. 12A;

FIG. 13 is a view similar to FIG. 12 showing the carrier in a post-impact condition;

fig. 13A is an enlarged partial plan view of the mesh of the carrier of fig. 10 shown in a post-impact condition;

FIG. 13B is a cross-sectional close-up view of region A showing a portion of the mesh of FIG. 12A in a pre-impact state;

FIG. 13C is a cross-sectional close-up view of region B showing a portion of the mesh of FIG. 12A in a post-impact state;

fig. 14 is an enlarged partial view of the mesh of the carrier of fig. 10 showing nodes interconnecting filaments of the mesh to one another to allow relative connecting movement between the filaments during manufacture and during a crash condition, and showing sub-filaments of the filaments for improving adhesion of the mesh of the carrier to the body;

fig. 15 is a flow chart illustrating a method of manufacturing a carrier according to another aspect of the present disclosure; and

FIG. 16 is a flow chart illustrating a series of events from a pre-impact state of a door module to a post-impact state of the door module.

Detailed Description

In general, example embodiments of a door assembly having a carrier module and a carrier module for the same constructed in accordance with the teachings of the present disclosure will now be disclosed, the carrier module of the type configured to include a window regulator and having a barrier member to be installed within a door interior cavity of a motor vehicle door assembly, the barrier member configured to separate a wet side from a dry side of the door assembly. Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known techniques have not been described in detail since those of ordinary skill in the art will readily appreciate, in view of the disclosure herein.

An example monolithic carrier module embodiment disclosed according to one aspect of the present disclosure includes a barrier member and a carrier member configured to provide a pre-bonded intrusion member arrangement, wherein a pair of window regulators are integrally attached to the carrier member, wherein the carrier allows associated window regulators and components to be supported while providing improved intrusion protection.

Another example one-piece carrier module embodiment disclosed according to one aspect of the present disclosure includes a wall bounded by an outer perimeter, the wall sized to close an opening in a door inner panel, wherein the wall is provided with a variable wall thickness to provide a relatively thick region having a first thickness and a relatively thin region having a second thickness less than the first thickness, the relatively thick region providing enhanced bearing and mounting surfaces and enhanced side impact resistance, the relatively thin region improving economy of manufacture and assembly while also reducing weight, thereby improving fuel economy of the vehicle.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Unless specifically indicated as an order of execution, the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated. It should also be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to" or "coupled to" another element or layer, it can be directly on, engaged, connected or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements (e.g., "between … …," "with" directly between … …, "" adjacent "directly adjacent," etc.) should be construed in a similar manner. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as "inner," "outer," "lower," "below," "lower," "upper," "above," "top," "bottom," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element or feature as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated angle or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Referring to fig. 1, fig. 1 shows a door assembly 10 mounted to a body 12 of a motor vehicle 14. The door assembly 10 includes an outer panel 16, an inner panel 18 (fig. 2), and a carrier assembly, hereinafter referred to as a carrier module 20, the carrier module 20 having a carrier 21 constructed in accordance with one presently preferred aspect of the present disclosure. The manufacturing, assembly, weight reduction, performance and structural impact resistance of the door assembly 10 is directly enhanced by the structure of the carrier 21. Furthermore, the material content via the carrier 21 enhances the ability to easily sort the carrier 21 into recyclable materials via an automatic sorting apparatus comprising an optical recycling sorting camera, wherein the carrier 21 is also environmentally friendly, environmentally sustainable and biodegradable. Those skilled in the art will appreciate that the carrier modules 20 and the carriers 21 of the carrier modules 20 may be incorporated into the passenger rear door assembly 11 or any other closure panel desired.

The outer panel 16 forms at least a portion of the exterior surface of the door assembly 10. The inner panel 18 provides a structural member for mounting one or more trim pieces that form the inner surface of the door assembly 10. Some of the inner panels 18 may themselves form part of the inner surface of the door assembly 10, if desired. The outer panel 16 and the inner panel 18 are joined together to provide a door panel structure 22, the door panel structure 22 forming a door interior cavity 24, the door interior cavity 24 housing various components of the door assembly 10 including the components of the carrier module 20. To facilitate assembly of the components into the cavity 24, the inner panel 18 has at least one opening 26 (FIG. 2). As is known, the opening 26 is sized to allow access to the cavity 24 as needed and desired for assembly and maintenance of the components in the cavity 24.

The outer panel 16 and the inner panel 18 may be made of any suitable material or combination of materials. For example, both the outer panel 16 and the inner panel 18 may be made of a suitable metal (e.g., a suitable steel). In another example, by way of example and not limitation, the outer panel 16 may be made of a suitable polymer or composite material (e.g., fiberglass), and the inner panel may be made of a suitable metal.

A pair of hinges 28 are connected to the door panel structure 22, and the pair of hinges 28 pivotally mount the front end of the door panel structure 22 (and the door assembly 10) to the vehicle body 12. As is known, the rear end of the door panel structure 22 mounts a door latch 30 to allow the door assembly 10 to be releasably closed against the vehicle body 12. The hinges 28 and the door latch 30 function as force transmitting members through which forces in the door assembly 10 are transmitted to the body 12. Such forces include, for example, side impact forces from another vehicle or object colliding with the vehicle 14.

The carrier 21 is shown configured for sealing mounting to the inner panel 18 and supporting a plurality of door hardware components, such as window and door latch components, including by way of example and not limitation, an electrically operated window regulator having an electric motor drive cable, pulley, and lifter plate for moving the window 34 within the glass travel channel, as will be appreciated by those of ordinary skill in the art of vehicle door assembly.

According to a non-limiting embodiment, the carrier 21 may be formed to serve as both a fluid (water and moisture) barrier and a sound barrier, and the carrier 21 may be provided as a single-piece panel configured to receive a plurality of the aforementioned electrical actuators and door hardware components in an integrally formed wave-shaped pocket. When various components, such as those discussed above, are secured in the door interior cavity 22, the carrier 21 may be adapted to be mounted in a fixed attachment to a surface of the inner panel 18 facing the passenger compartment of the vehicle 14. Further, to facilitate assembly, including ensuring that the carrier 21 is properly positioned and secured in sealed relation to the inner panel 18, the carrier 21 may be formed to include a peripherally extending sealing bead 36. By way of example and not limitation, the sealing bead 36 may be provided as any suitable continuous bead of adhesive material, such as, by way of example and not limitation, butyl elastomer, capable of maintaining a fluid-tight seal between the carrier 21 and the outer surface of the inner panel 18. A selectively removable protective layer 38, sometimes referred to as a release paper or film, and hereinafter a release member 38, may be disposed over the seal bead 36 until it is desired to expose the seal bead 36 for adhesion with the inner panel 18, thereby protecting the seal bead 36 from undesired contamination.

The carrier 21 is formed of a recyclable, environmentally sustainable (property that does not harm the environment or consume natural resources, and thereby supports long-term ecological balance), biodegradable material, such as Natural Fibers (NF) from natural fiber materials (NF'). Furthermore, the carrier 21 is formed using sustainable and renewable materials, such as plant fibers and rock fibers. The carrier 21 of the present disclosure is distinguished from known carriers formed of non-sustainable and non-renewable materials, such as petroleum-based materials that require artificial chemical processes, say, for example, chemical synthesis, to produce synthetic materials and synthetic fiber forms for forming the carrier, such as polymers and plastics, such as thermoplastics. Some highly suitable natural fiber materials (NF') include various types of Natural Fibers (NF), for example, plant-based fibers such as bast fibers, cellulose fibers, sugar cane fibers, by way of example and not limitation, bast fibers, cellulose fibers, sugar cane fibers including kenaf, hemp, flax, bamboo, and jute, by way of example and not limitation. For example, these materials may be obtained from plants or rocks. Other examples of natural fiber materials (NF') may also be rock-based materials, such as basalt fibers. Due to the content of Natural Fibers (NF), the resulting carrier 21 is a color that is distinguishable from black, and thus, may be provided in colors other than black, which is referred to as non-black, and generally tends to be tan or other generally light-colored colors, with "light" being relative to black. Therefore, the ability of the optical recovery sorting camera to recognize the carrier 21 as recyclable will be greatly enhanced. Furthermore, the carrier 21 is made entirely or substantially (almost entirely, such as between 90 to 99.9 weight percent (%/wt), and more preferably between 95%/wt to 99.9%/wt) of natural fibers, the carrier 21 is lightweight (20% lighter than a similarly sized and shaped polypropylene (PP) carrier), has high strength, and particularly, with the natural fiber material (NF') remaining dry, the carrier 21 is 100% recyclable, 100% renewable, and 100% biodegradable, the carrier 21 has a low content of Volatile Organic Compounds (VOC) and is free of formaldehyde, is excellent in sound insulation, and exhibits high thermal stability up to 220 degrees celsius (c).

According to an aspect of the present disclosure, the carrier 21 of the carrier module 20 may be manufactured to comprise at least one intruding member 40, the intruding member 40 also being referred to as a reinforcement member or an impact reinforcement member, the intruding member 40 being formed of a different material than the carrier 21, wherein the at least one intruding member 40 has a resistance to loads, such as a resistance to bending or deformation, e.g. caused by loads applied to the carrier 21, and the intruding member 40 has, e.g., a strength and/or stiffness that is greater than the material of the carrier 21. The at least one intruding member 40 is shown as a plurality of high strength elongated members, such as, by way of example and not limitation, elongated high strength metal wires/rods, hereinafter referred to as elongated rods 40, however, other materials are contemplated herein, including elongated high strength non-metallic members, such as elongated high strength non-metallic rods and unidirectional tape, to provide the carrier module 20 with enhanced impact resistance to the following impact forces: this impact force is transverse to the plane P (fig. 3) along which the carrier 21 generally extends, thereby enhancing the side impact resistance of the carrier 21 and the door assembly 10, thus providing enhanced protection for occupants within the motor vehicle 14 during side impacts, such as those side impacts experienced during an accident. Likewise or in addition, the at least one intrusive member 40 may be provided as a high stiffness member that increases the stiffness of the carrier module 20 to withstand deformation, such as deformation caused by road vibration or sound vibration generated by a speaker mounted to the carrier module 20. The enhanced side impact resistance provided by the carrier module 20 eliminates the need for separate side impact beams/members, including those that typically extend within the cavity of the door assembly, thereby freeing up space within the cavity 24, which ultimately makes assembly of the components within the cavity 24 easier. Furthermore, as will be understood by those skilled in the art, economics of manufacture and assembly are recognized by integrating the elongated bar 40 as part of the carrier module 20. The enhanced stiffness of the carrier module 20 provided by the intrusive members 40 may eliminate the development of resonant frequencies within the carrier module 20 and may improve the acoustic performance of a speaker mounted to the carrier module 20. However, it should be appreciated that the carrier 21 may be manufactured as a stand-alone carrier 21 without the need to integrate the intruding member 40 in the carrier 21, if desired for the intended application.

Where provided, intruding members (elongated metallic and/or non-metallic rods), hereinafter referred to as rods 40, may be mechanically connected and fixed with the carrier 21, for example by being inserted into mating receptacles 500 (fig. 2A and 2B) formed in the carrier 21. Retention features 505 may be provided to secure and lock the lever 40 into mechanical connection with the carrier 21, such as securing and locking the lever 40 into mechanical connection with the carrier 21 after the lever 40 has been snapped and/or engaged into mating engagement with the receptacle 500. An adhesive may also be provided to enhance the secure connection between the rod 40 and the carrier 21. The intruding member, such as rod 40, may be formed of any desired high flexural/tensile strength metal, such as steel, titanium, kevlar or other metal, and may be shaped to extend along any desired linear and/or non-linear, arcuate (non-linear) path. It should be appreciated that the bending strength and/or tensile strength of the aforementioned intruding member is set to be greater than the bending strength and/or tensile strength of the material of the carrier 21, thereby increasing the bending strength and/or tensile strength properties of the carrier 21. In the illustrated exemplary embodiment, a pair of rods 40 are shown extending in spaced relation to one another, the pair of rods 40 having generally linear portions 42 extending generally parallel to one another, and having non-linear portions 44 extending about a carrier feature, such as, by way of example and not limitation, an opening 46 provided for receiving a speaker. The rods 40 disposed in spaced relation may accommodate components that need to be positioned between the rods 40 or other adjacent components, which may otherwise be provided in an overlapping arrangement and which may be mounted to the carrier 21, for example and without limitation thereto, such as an intrusion beam provided on one of the panels 16, 18. Therefore, the cross-sectional dimension of the door assembly, for example, the width of the door assembly extending in both side directions of the vehicle can be reduced. The rod 40 is shown configured to extend from one portion of the outer periphery 48 of the carrier 21 across the width of the carrier 21 (the width direction extending from the front end to the rear end of the motor vehicle 14) to another portion of the outer periphery 48 to span the respective dimension of the opening 26 in the inner panel 18, the outer periphery 48 bounding a body 49 of the carrier 21. As such, it should be appreciated that where a rod 40 is provided, the rod 40 may extend across the entire opening 26, if desired, with the body 49 configured for attachment to the inner panel 18 to substantially close the opening 26.

The rod 40 extends longitudinally between opposite ends 50, 52, wherein at least one or both of the opposite ends 50, 52 may be configured to extend beyond the outer periphery 48 for anchored support against the inner panel 18. To facilitate anchoring the carrier assembly 20 and the post 40 to the inner panel 18, the opposing ends 50, 52 may be provided with through openings 54, the through openings 54 being configured to receive fasteners 56 through the through openings 54 to facilitate securing the carrier module 20 to the inner panel 18. In the illustrated exemplary embodiment, the through opening 54 is shown extending through a flat end region 58 of the rod 40. With the opposite ends 50, 52 of the rod 40 secured directly to the inner panel 18, the width across the carrier assembly 20 provides greatly enhanced tensile strength to the carrier assembly 20 to enhance the side impact resistance of the door assembly 10, thereby minimizing intrusion of objects and the inner panel 18 into the interior compartment 60 (fig. 1) of the motor vehicle 14 during a side impact collision scenario.

The carrier body 49 has opposite sides bounded by the outer periphery 48 including a wet side 60 and a dry side 62. As noted above, the opposing sides 60, 62 of the body 49 have a non-black color that is distinguishable from the black surface to facilitate identification during the recycling classification process. The body 49 comprises, in addition to being formed of natural fiber material (NF ') having the aforementioned Natural Fibers (NF), an adhesive additive also referred to as binder (B), wherein the binder (B) helps to bind the Natural Fibers (NF) of the natural fiber material (NF') together. Binder (B) may be provided as an additive in a web forming process, such as, by way of example and not limitation, an air laying process, and then the web may be subjected to a suitable heat treatment process to melt binder (B) and bond the Natural Fibers (NF) within the web together. In addition to applying heat to melt the binder (B), the web may also be subjected to pressure, such as in a compression molding process (fig. 4 and 4A). The compression molding process utilizes a mold assembly 64 having a male mold half 66 and a female mold half 68. The male mold half 66 includes an outwardly extending protrusion P and the female mold half 68 includes a cavity C, wherein the protrusion P and the cavity C mirror and mate with one another in a nested relationship to form a desired non-planar feature of the carrier 21. It is envisaged that a binder (B) may be provided to bind the Natural Fibres (NF) of the natural fibre material (NF') together without heating, wherein the binder (B) may be provided as a suitable binder.

According to another aspect, the body 49' may be formed to have a perforated structure with a plurality of through openings, also referred to as voids 70, the voids 70 extending through the opposing sides 60, 62. Voids 70 may form body 49 'with a honeycomb structure such as shown in fig. 5 and 5A, or otherwise form body 49' as desired. Due to the large number of voids 70, the honeycomb structure provides a substantial weight reduction while exhibiting high impact and crush strength.

A fluid impermeable sealant material or layer, also referred to as a water barrier layer 72, may be secured to at least one of the opposing sides 60, 62 of the bodies 49, 49', and preferably at least to the wet side 60, to prevent moisture or fluid on the wet side of the carrier module 20 from reaching the natural fiber material (NF ') of the bodies 49, 49 '. If desired, the layer 72 may be provided as a prefabricated solid panel of sealant material, such as a polymer or metallic material (aluminum or otherwise), with the layer 72 then being secured to the wet side 60 and optionally to the dry side 62, such as by adhesives and/or mechanical fasteners. Layer 72 may also be applied by spraying, dipping, or other coating processes before and/or after the molding operation is performed.

The body 49, 49 'may be formed with a plurality of fastener through openings 74 adjacent the outer periphery 48, and the body 49, 49' further includes a metal or plastic washer 76, the metal or plastic washer 76 being secured in each of the plurality of fastener through openings 74. The gasket 76 provides compressive structural support for receipt of the fastener 78, the fastener 78 for securing the carrier 21 to the inner panel 18, wherein the gasket 76 prevents excessive compression and tearing of the natural fiber material. As shown in fig. 7, after molding the bodies 49, 49', a washer 76 may be inserted and secured in the through opening 74.

According to another aspect, such as carrier body 49 "shown in fig. 10, wherein the following discussion also applies to bodies 49, 49' of carrier 21 discussed above, wherein the same reference numerals used above are used herein to discuss body 49", body 49 "may include mesh 80 secured to at least a portion of body 49" such that mesh 80 may be strategically positioned as desired, including throughout a portion of body 49 "or throughout body 49". As shown in fig. 11, the mesh 80 may be placed between a pair of pads, also referred to as layers (L) of natural fiber material (NF '), and then the mesh 80 is overmolded with binder material B, as discussed above with respect to the body 49, such that the mesh 80 may be encapsulated between the opposing sides 60, 62 of the body 49 "by the natural fiber material (NF') and the binder material B of the body 49"; or the mesh 80 may be laid on one side of the natural fiber material (NF') and then the mesh 80 is overmolded with the binder B of the body 49 ", wherein the mesh 80 is again encapsulated by the binder B of the body 49". The mesh 80 and the liner may be formed of natural fibers, such as plant-derived fibers or rock-derived fibers. Prior to securing mesh 80 to body 49 ", mesh 80 may be coated with an adhesive, such as material B, to further enhance the securing of mesh 80 to body 49". The mesh 80 may also be bonded or secured to one or both of the sides 60, 62 of the body 49 ", such as by a suitable adhesive or mechanical securing mechanism, e.g., adhesive, stitching, staples, rivets, or the like. Alternatively, the process for forming the body 49 "may include a first spraying or coating, or impregnating, the liner and/or web 80 with the binder material B, then subsequently laying down the liner and web 80 such that the web 80 is disposed between a pair of liners for forming a stack of layered natural fiber material (NF') as shown in fig. 11, or in other words, at least one layer of non-synthetic material forming the body 49". Next, the layered structure may be thermally cured together and formed into a hardened and rigid composite structure having layered natural fiber material (NF ') in the molded structure as shown in fig. 4 and 4A by applying heat and pressure to activate binder material B so that web 80 may be enclosed between opposing sides 60, 62 of body 49 "by natural fiber material (NF') of body 49" and binder material B. The binder material B used as a thermosetting resin may connect or adhere together the mat and any protruding natural fibers of the mat via the channels in the mesh 80 and/or may also connect or adhere the mat to the mesh 80, e.g., the sub-filaments 86 of the mesh 80 may adhere to the binder material B connected to the mat. Thus, the adhesive material B may serve both as an adhesive for the at least one layer and as a sealant for the at least one layer, which may result from a single step of treating the at least one layer prior to the step of thermally curing the at least one layer. The binder material B may be a thermosetting resin. For example, the binder material B may be a non-synthetic oil, such as castor oil or other type of vegetable-based oil (e.g., vegetable-based oil). The binder material B may be substantially a non-synthetic oil, such as a bio-based polyol, or may be a mixture of non-synthetic oil and other non-synthetic or synthetic additives, such as polyurethane. For example, binder material B may be a mixture consisting of 60% castor oil. Polyurethane or epoxy may also be used as the binder material B while still providing a body 49 "formed substantially using renewable non-man-made materials, such as plant or rock materials. The binder material B may be a plant-based polyurethane material. Fig. 11B shows a cross-section of one possible layer arrangement forming a composite structure 900 of natural material, such as layered natural fiber material (NF') for providing an eco-friendly vehicle structure, such as may be used for a load bearing member as described herein. Such structures may be used to form other vehicle structures such as interior trim panels, fenders, panels, floors, and exterior panels without limitation. The composite structure 900 is schematically illustrated as having a mesh 80 as a core, wherein the mesh is formed using a natural or plant based material. Disposed on either side of the mesh 80 is a layer L of non-synthetic material, such as renewable bast fibers 81, for example jute padding as one possible example. For example, three layers of natural padding 81 are provided, but more or fewer layers may be provided. The three-layer natural liner 81 and the mesh 80 may be thermoset after having been coated, sprayed or impregnated with a binder material such as a plant-based polyurethane, such that the plant-based polyurethane seals the layer 81 and the mesh 80, and bonds the mesh 80 and the layer 81 together after the thermoset process. Schematically, the layers of plant-based polyurethane 83 are shown as forming protective sealing layers on opposite sides of the structure 900.

The mesh 80 is flexible to allow bending, expansion and compression of the body 49 ", such as may occur in the event of a collision, wherein the mesh 80 serves to hold the body 49" together as a single piece of material, thereby preventing the body 49 "from breaking and preventing one (fragment) or more (fragments) from breaking away from the body 49" (fig. 12 and 12A show the carrier 21 and the body 49 "of the carrier 21 prior to experiencing a collision event, and fig. 13 and 13A show the carrier 21 and the body 49" of the carrier 21 after experiencing a collision event). It should be appreciated that the material, such as the natural fiber material (NF ') of the body 49 "may be broken into individual pieces of natural fiber material (NF'), and then the mesh 80 holds the individual pieces together. Alternatively, the mesh 80 may be overmolded using a thermoplastic and injection molding process for forming the body 49 ". This flexibility, expansion, and contraction of mesh 80 also facilitates construction of body 49 "by preventing the build up of internal stresses within body 49" during construction.

The mesh 80 may be formed of a non-synthetic material, such as a plant-based material or a rock-based material. The mesh 80 may be a non-metallic material. The mesh 80 may be a non-plastic material. Mesh 80 may be formed to include a plurality of filaments 82 interconnected to one another at nodes 84 (fig. 14). By way of example and not limitation, nodes 84 may be formed as loops of filaments 82, such as formed by knitting needles, to allow the plurality of filaments 82 to shift and move relative to one another, such as during construction of body 49 "as described above and when body 49" is flexed and bent during a collision condition as shown in fig. 13A, to allow the plurality of filaments 82 to shift and move relative to one another, thereby minimizing the build-up of internal stresses and providing an energy dissipation mechanism while retaining filaments 82 in an interconnected relationship to one another. The filaments 82 may be provided from any desired material including monofilament and/or natural fiber multifilament yarns, wherein the filaments 82 are braided or knitted with one another. The multifilament may be formed of inorganic or organic material as spun fibers of the yarn, also referred to as threads, wherein the plurality of fibers within the multifilament provide a textured non-smooth surface relative to the monofilament surface, which facilitates bonding of the filaments 82 to the binder material B of the body 49 ". As noted above, to further enhance the bonding of the filaments 82 to the binder material B of the body 49 ", the filaments 82 may be pre-coated with a binder material, which includes, by way of example and not limitation, the same type of binder material B used to bond the natural fiber material (NF') of the body 49". To further facilitate bonding of the filaments 82 of adhesive material B of the body 49 ", the filaments 82 may have a plurality of fingers or branches, also referred to as sub-filaments 86, the sub-filaments 86 extending radially outward to each other in a random orientation from the main branch or body of the filaments 82, wherein the sub-filaments 86 provide an increased surface area and an increased number of attachment locations of the filaments 82, thereby forming additional locations of adhesive material B for securing and anchoring the filaments 82 to the body 49".

As shown in fig. 7, a method 1000 of manufacturing a carrier 21 of a carrier module 20 for an automotive vehicle door panel structure 22 is provided, the door panel structure 22 for closing an opening 26 in an inner panel 18 of the automotive vehicle door panel structure 22 to prevent moisture and fluid from passing from a wet side of the carrier module 20 to a dry side of the carrier module 20. The method 1000 includes a step 1100 of providing at least one mat of recyclable natural fiber material (NF '), wherein, if desired, the natural fiber material (NF') can be formed having a non-porous or perforated pattern, such as a honeycomb pattern. An optional step 1150 is to provide the web 80 as described above and to place the web 80 between a pair of pads of natural fibrous material (NF ') or non-synthetic material, or to place the web 80 against one side of a pad of natural fibrous material (NF'). Then, step 1200 is performed: the binder/resin material (B) is added to the recyclable natural fiber material (NF '), such as by overmolding, spraying or otherwise, to form a blank, also referred to as a web, of recyclable natural fiber material (NF') and binder material (B). Optional step 1250 may be performed: a sealant material as described above is applied to one or both sides 60, 62 of the blank. Then, step 1300 is performed: the blank is disposed between the mold halves 66, 68 and compressed between the mold halves 66, 68 under heat and pressure to provide a blank having a desired contour along the opposing sides 60, 62 of the finished carrier 21. Then, step 1400 is performed: a washer, also referred to as a reinforcing fastener 76, is inserted into the through opening, also referred to as the attachment hole 74, and secures the washer 76 in the through opening 74. Optional step 1450 may be performed: sealant material is applied to one or both sides 60, 62 of the blank as described above to form the fluid impermeable layer 72. Then, step 1500 is performed: the carrier 21 is assembled to the inner panel 18 of the door panel structure 22 with the fluid impermeable layer 72 facing the wet side of the door panel structure 22.

In fig. 8, a method 2000 that facilitates sorting the carriers 21 of the carrier assembly 20 during a recycling process is illustrated. Method 2000 includes step 2100: the carrier 21 is provided with a non-black appearance, preferably on the wet side 60 of the carrier 21, and more preferably on both sides 60, 62 of the carrier 21. Further, as step 2200, the recyclable material of the carrier 21 is identified by distinguishing the non-black surface from the underlying black surface of the conveyor belt using an optical sorting recycling camera in the sorting process.

Fig. 9 shows a barrier for a carrier module. The barrier is formed of a water soluble material, such as a material consisting of two parts of a structure comprising a water soluble polymer (e.g. polyvinyl alcohol) and cellulose fibres (30% to 60%). Such materials may provide the following structure to the barrier: the structure is low weight, low cost, provides sound deadening properties, provides high energy absorption properties in the event of a side impact, and may have some flame retardant properties with the addition of additives to the polymer to achieve flame retardancy. This material is also 100% recyclable. The barrier can be formed into different shapes by direct extrusion dry-blending, including pellets (for injection molding), sheets (for thermoforming), filaments (for 3D printing). At the end of the product life of the barrier, if the barrier is exposed to water, the polymer melt and the cellulose fibers are completely recyclable. The carrier structure as described herein may also be formed using such materials. If it is desired to form the barrier or carrier, the carrier or semi-finished or sub-components of the barrier may be formed into different shapes and then subsequently assembled together to form the carrier or barrier using the adhesive properties of the polymer which may be activated by water exposure. Thus, even components with different densities and mechanical properties can be optimized to achieve the weight target and desired noise characteristics. In the configuration of the carrier or barrier, the energy absorbing structure may be integrated or added to the carrier or barrier. In certain areas where high energy absorption is important, the structure is positioned similar to a bird nest that will deform during impact, thereby dissipating a large amount of energy. These energy absorbing structures are made of cellulose filaments/foams covered by a polymer. This weave is welded by adding water, which melts the polymer from the surface and binds the filaments or shaped foam to each other.

As shown in fig. 15, another method 3000 of manufacturing a carrier 21 for a carrier module 20 of a motor vehicle door panel structure 22 is provided, the motor vehicle door panel structure 22 for closing an opening 26 in an inner panel 18 of the motor vehicle door panel structure 22 to prevent moisture and fluid from passing from a wet side of the carrier module 20 to a dry side of the carrier module 20. Method 3000 includes step 3100: an interconnecting structure, also referred to as a mesh or netting 80, is provided. Then, optionally, step 3200 comprises coating the web 80 with an adhesive B, such as, by way of example and not limitation, adhesive B is a trademarkBinder B is sold to provide excellent strength, flexibility and versatility, and is a water-based, formaldehyde-free acrylic binder, thereby enabling safer, simpler and more ecological handling. Additionally, optionally, step 3300 includes overmolding the mesh 80 to form the body 49 "of the carrier 21. During the overmolding step 3300, the fibers of the mesh 80 may self-adjust relative to one another to inhibit the accumulation of internal stresses within the body 49 ", thereby increasing the ability to form the carrier 21 having a desired shape, and further, to form a carrier 21 having a desired shapeThe tendency for cracking to occur within body 49 "during use and during a crash condition is reduced. Alternatively, step 3400 includes bonding the mesh 80 with one or more additional sheets, also referred to as layers or mats, such as from the natural fiber material NF described above, and molding the bonded mesh 80 and layers to form the composite carrier 21.

In fig. 16, a flow chart 4000 illustrates how the body 49 "within the carrier module 20 is used to hold the carriers 21 of the carrier module 20 as a single piece of material, regardless of whether the body 49" becomes broken in the event of a collision. As shown at 4100 in an initial normal use condition of the door module 20, the carrier 21 is in a pre-crash, as-manufactured condition. Then, at 4200, an external impact force is encountered, causing the body 49 "of the carrier 21 to become broken. However, at 4300, it is detailed how mesh 80 within body 49 "ties together the fractured components of body 49", thereby holding body 49 "as a single piece of material (without allowing any of the components to separate from body 49"). Furthermore, the interconnected configuration of the mesh 80 allows individual filaments within the mesh 80, such as those described above, to shift and move relative to one another (fig. 13A) to prevent the build-up of internal stresses within the body 49 ", thus preventing the body 49" from overstretching and preventing the mesh 80 from breaking. Thus, the mesh 80 is able to perform the intended function of the mesh 80 to hold the carrier 21 as a single component.

Fig. 13B shows a close-up cross-sectional view of a portion of body 49 "in a pre-crash state. Body 49 "is formed schematically using an overmolding process of thermoplastic material to embed filaments 82 and sub-filaments 86 in the thermoplastic upon cooling. It is understood that the filaments 82 and sub-filaments 86 may be attached to other layers or mats of natural material using an adhesive material as described hereinabove. Accordingly, filaments 82 and sub-filaments 86 are secured to body 49 "in a pre-impact state. Fig. 13C shows a close-up cross-sectional view of a portion of body 49 "in a post-impact state. As shown in fig. 13C, body 49 "has been schematically deformed, such as separation of body 49" moving to the left, such that crack 87 has formed during the impact or shock to body 49 "exposing a portion of filament 82. Separation of body 49 "may allow for a degree of extension by at least one naturally flexed or stretched filament 82 formed from a natural material, or for example, by filament 82 sliding within a cavity formed around filament 82 during overmolding. The sub-filaments 86 may also cause at least one of stretching, bending, breaking, or sliding during separation of the body 49 ". And an example of a sub-filament 86 breaking is shown as two portions 86a and 86b of the same sub-filament 86. Such stretching, buckling, snapping, or sliding allows some energy to be dissipated during an impact or collision that causes separation of body 49 ", while allowing the separate body portions of body 49" to remain connected together.

While the above description constitutes a number of embodiments of the present invention, it will be appreciated that the invention may be subject to further modification and variation without departing from the fair interpretation and intended meaning of the accompanying claims.

The foregoing description of embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The various elements or features of a particular embodiment may also be varied in a number of ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

The present disclosure may be understood with reference to the following numbered paragraphs:

1. a carrier for a carrier module of a motor vehicle door assembly having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening that opens into a door interior cavity between the inner panel and the outer panel, the carrier comprising:

a body having opposing sides defined by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening, the body formed of a non-synthetic material.

2. The carrier of paragraph 1, wherein the body comprises at least one layer of non-synthetic material.

3. The carrier of paragraph 2, wherein the at least one layer of non-synthetic material is coated with a thermosetting resin.

4. The carrier of paragraph 3, wherein the thermosetting resin comprises a non-synthetic adhesive material.

5. The carrier of paragraph 2, wherein the at least one layer comprises a mesh layer of non-synthetic material.

6. The carrier of paragraph 5, wherein the at least one layer comprises a pair of pads of non-synthetic material, the mesh being disposed between the pair of pads.

7. The carrier of paragraph 6, wherein the mesh and the pair of pads are interconnected by a thermosetting resin.

8. The carrier of paragraph 7, wherein the mesh comprises a plurality of filaments having sub-filaments extending outwardly therefrom, the sub-filaments being bonded to the liner by the thermosetting resin.

9. The carrier of paragraph 1, wherein the at least one layer is formed from natural fibrous material derived from plants or rocks.

10. The carrier of paragraph 9, wherein the plant based material is bast fibers and the rock based material is basalt fibers.

11. A carrier of a carrier module for a motor vehicle door assembly having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening for selective access to a door interior cavity between the inner panel and the outer panel, the carrier comprising:

a body having opposing sides bounded by an outer periphery, the body configured for attachment to an inner panel to substantially close the opening, the body formed to include a mesh secured to the body that prevents the body from breaking apart into separate pieces of material when subjected to an impact force.

12. The carrier of paragraph 11, wherein the body is formed as a thermoplastic overmolded with the mesh.

13. The carrier of paragraph 12, wherein the mesh is formed from a mixture of natural fibers.

14. The carrier of paragraph 11, wherein the mesh comprises a plurality of filaments interconnected to one another at nodes that allow the plurality of filaments to move relative to one another while remaining interconnected to one another and to the body.

15. The carrier of paragraph 14, wherein the plurality of filaments have sub-filaments extending radially outward from the plurality of filaments, the sub-filaments being bonded to the body.

16. The carrier of paragraph 15, wherein the plurality of filaments are formed from natural fibers.

17. A carrier of a carrier module for a motor vehicle door assembly having an inner panel and an outer panel defining a door panel structure, wherein the inner panel has an opening for allowing access to a door interior cavity between the inner panel and the outer panel, the carrier comprising:

a body having opposite sides bounded by an outer periphery, the body configured for attachment to the inner panel to substantially close the opening, the body formed from a mesh fabric comprising filaments, wherein the filaments comprise a plurality of sub-filaments extending outwardly from the filaments for being surrounded by the body.

18. The carrier of paragraph 17, wherein the filaments and the sub-filaments are formed from a natural fiber material.

19. The carrier of paragraph 17, wherein the body is formed from a mesh comprising filaments interconnected by a plurality of nodes, wherein the body prevents displacement of the nodes relative to the filaments when in a non-impact state, and wherein the body allows displacement of the nodes relative to the filaments when in an impact state.

20. The carrier of paragraph 19, wherein the body is formed from at least one liner comprising a mixture of natural fibers, the at least one liner and the web of filaments being overmolded with a binder material.