What is claimed is:
1. A door assembly for a motor vehicle, the door assembly comprising:
a door panel having an inner side and an outer side, the inner side being adapted to face into a passenger compartment of the motor vehicle;
a catch mounted on the outer side of the door panel and operable to detachably secure the door assembly in a closed position; and
a lock mounted on the outer side of the door panel and engaged with the catch to permit selective operation of the catch.
2. The door assembly of claim 1 further comprising an exterior handle mounted on the outer side of the door panel and adapted to operate the catch.
3. The door assembly of claim 1 wherein the lock is formed as part of a lock assembly, and the lock assembly comprises a glass edge guide.
4. The door assembly of claim 1 further comprising an inner handle mounted on the door panel and adapted to operate the catch.
5. The door assembly of claim 4 wherein the inner handle is mounted in a door handle housing formed in the door panel.
6. The door assembly of claim 4 wherein the inner handle is connected to the catch by a cable.
7. The door assembly of claim 1 further comprising a belt line reinforcement connected to the outer side of the door panel.
8. The door assembly of claim 7 wherein the belt line reinforcement comprises metal.
9. The door assembly of claim 7 wherein the belt line reinforcement comprises plastic.
10. The door assembly of claim 1 further comprising a window regulator connected to the outer side of the door panel.
11. The door assembly of claim 10 further comprising a window engaged with the window regulator.
12. The door assembly of claim 10 further comprising a motor operably connected to the window regulator.
13. The door assembly of claim 10 wherein the window regulator is adapted for movement along a generally vertically oriented member connected to the outer side of the door panel.
14. The door assembly of claim 1 further comprising means for dissipating a side impact to the door assembly.
15. The door assembly of claim 14 wherein the means for dissipating a side impact comprises foam disposed adjacent the outer side of the door panel.
16. The door assembly of claim 1 further comprising a map pocket attached to the door panel.
17. The door assembly of claim 1 wherein the door panel includes a speaker impression.
18. The door assembly of claim 1 further comprising a wiring harness connected to the outer side of the door panel.
19. The door assembly of claim 1 wherein the door panel is injection molded.
20. The door assembly of claim 1 wherein the door panel is compression molded.
21. The door assembly of claim 1 wherein the door panel comprises olephenic thermoplastic.
22. The door assembly of claim 1 wherein the door panel comprises polypropylene.
23. The door assembly of claim 1 wherein the door panel comprises acrylonitrile-butadience-styrene.
24. The door assembly of claim 1 wherein the door panel comprises a glass-reinforced composite.
25. The door assembly of claim 1 further comprising a header attached to the door panel.
26. A door assembly for a motor vehicle, the door assembly comprising:
a trim panel having an inner side and an outer side, the inner side being adapted to face into a passenger compartment of the motor vehicle;
a catch mounted on the outer side of the trim panel and operable to detachably secure the door assembly in a closed position; and
an exterior handle mounted on the outer side of the trim panel and adapted to operate the catch.
27. The door assembly of claim 26 further comprising a lock mounted on the outer side of the trim panel and engaged with the catch to permit selective operation of the catch.
28. The door assembly of claim 26 wherein the lock is formed as part of a lock assembly, and the lock assembly comprises a glass edge guide.
29. The door assembly of claim 26 further comprising an inner handle mounted on the trim panel and adapted to operate the catch.
30. The door assembly of claim 29 wherein the inner handle is mounted in a door handle housing formed in the trim panel.
31. The door assembly of claim 29 wherein the inner handle is connected to the catch by a cable.
32. The door assembly of claim 26 further comprising a belt line reinforcement connected to the outer side of the trim panel.
33. The door assembly of claim 32 wherein the belt line reinforcement comprises metal.
34. The door assembly of claim 32 wherein the belt line reinforcement comprises plastic.
35. The door assembly of claim 26 further comprising a window regulator connected to the outer side of the trim panel.
36. The door assembly of claim 35 further comprising a window engaged with the window regulator.
37. The door assembly of claim 35 further comprising a motor operably connected to the window regulator.
38. The door assembly of claim 35 wherein the window regulator is adapted for movement along a generally vertically oriented member connected to the outer side of the trim panel.
39. The door assembly of claim 26 further comprising means for dissipating a side impact to the door assembly.
40. The door assembly of claim 39 wherein the means for dissipating a side impact comprises foam disposed adjacent the outer side of the trim panel.
41. The door assembly of claim 26 further comprising a map pocket attached to the trim panel.
42. The door assembly of claim 26 wherein the trim panel includes a speaker impression.
43. The door assembly of claim 26 further comprising a wiring harness connected to the outer side of the trim panel.
44. The door assembly of claim 26 wherein the trim panel is injection molded.
45. The door assembly of claim 26 wherein the trim panel is compression molded.
46. The door assembly of claim 26 wherein the trim panel comprises olephenic thermoplastic.
47. The door assembly of claim 26 wherein the trim panel comprises polypropylene.
48. The door assembly of claim 26 wherein the trim panel comprises acrylonitrile-butadience-styrene.
49. The door assembly of claim 26 wherein the trim panel comprises a glass-reinforced composite.
50. The door assembly of claim 26 further comprising a header attached to the trim panel.
51. A structural door trim module for combining with and reinforcing an outer door panel of a motor vehicle to make a vehicle door assembly, the door trim module comprising:
an inner door panel having an inner appearance side and an outer side having a structural characteristic, the inner appearance side being adapted to face into a passenger compartment of the motor vehicle and the outer side being adapted to face the outer door panel; and
an inner door panel reinforcement mounted on the outer side of the inner door panel to provide the structural characteristic and having spaced portions adapted to interface with the outer door panel in respective spaced locations with each spaced portion being readily accessible and operable to detachably and structurally secure the inner door panel in an easy-on, easy-off combination with the outer door panel.
52. The structural door trim module of claim 51 wherein said spaced location s are on opposite sides of said inner door panel so that said spaced portions of said inner door reinforcement are more readily accessible when securing the inner door panel in combination with the outer door panel.
53. The structural door trim module of claim 51 including a lock mounted on the outer side of the inner door panel for selectively locking and unlocking the outer door panel with respect to the motor vehicle when the inner door panel is secured in combination with the outer door panel, said lock being sufficiently adjacent to one of said spaced portion of said inner door panel reinforcement that said lock is readily accessible and operable to detachably and structurally secure said lock in combination with the outer door panel in one of said spaced locations when the inner door panel is secured in combination with the outer door panel.
54. The structural door trim module of claim 53 wherein one of said spaced portions of said inner door panel reinforcement is configured substantially normal to said inner door panel adjacent said lock to cause said one of said spaced portions in one of said spaced locations to interface with a peripheral portion of the outer door panel when both the inner door panel and the lock are secured in combination with the outer door panel.
55. The structural door trim module of claim 51 including a window pane frame and a window pane regulator affixed to said inner door panel reinforcement and operable to move said window pane in and out of said window pane frame.
56. The structural door trim module of claim 51 wherein said inner door panel reinforcement is configured to resist crash loads impacting the motor vehicle.
57. The structural door trim module of claim 51 wherein said inner door panel reinforcement is configured to form a door pull support when the inner door panel is secured in combination with the outer door panel.
58. The structural door trim module of claim 51 including a lock mounted on said inner door panel reinforcement and having a handle for operating said lock, said handle adapted to extend into an exterior hand grab position through the outer door panel when said inner door panel is secured in combination with the outer door panel.
59. The structural door trim module of claim 53 including a door handle connected to said lock and an interior door handle recess on said inner door panel reinforcement between said spaced portions for receiving said door handle on said inner appearance said of said inner door panel to provide reinforcement for said door handle when said inner door panel is secured in combination with the outer door panel.
60. The structural door trim module of claim 51 including a water management system covering the outer side of said inner door panel between said inner and outer door panels when securing the inner door panel in combination with the outer door panel to inhibit the introduction of water, noise and dust into the passenger compartment.
61. The structural door trim module of claim 60 including a flange on the inner door panel reinforcement and a belt line glass seal attached to said flange as part of said water management system.
62. The structural door trim module of claim 60 including electrical devices on said outer side of said inner door panel, and wherein said water management system is a sheet configured to conformingly seal said electrical devices.
63. A vehicle door assembly for a motor vehicle comprising an outer door panel having a peripheral flange defining an opening, and a structural door trim module insertable into said opening and having a plurality of electrical components testable and adjustable before said door trim module is inserted into said opening, said door trim module having:
an inner door panel having an inner appearance side and an outer side having a structural characteristic for the vehicle door assembly, the inner appearance side being adapted to face into a passenger compartment of the motor vehicle and the outer side facing the outer door panel; and
an inner door panel reinforcement mounted on the outer side of the inner door panel to provide the structural characteristic and having spaced portions at least one of which interfaces with the peripheral flange of the outer door panel and with the peripheral flange of the outer door panel and with each spaced portion being readily accessible and operable to detachably and structurally secure the inner door panel in an easy-on, easy-off combination with the outer door panel.
64. The vehicle door assembly of claim 63 wherein said peripheral flange extends between said inner door panel and said outer door panel.
65. A method of assembling a vehicle door for a motor vehicle comprising:
providing an outer door panel with a peripheral flange having a first flange portion substantially normal to said outer door panel and a second flange portion spaced from said first portion and substantially parallel to said outer door panel,
forming a structural door trim module comprising an inner door panel having an inner appearance side and an outer side having a structural characteristic, said inner appearance side being adapted to face into a passenger compartment of the motor vehicle and said outer side being adapted to face the outer door panel;
mounting an inner door panel reinforcement on the outer side of the inner door panel to provide the structural characteristic of said inner door panel, and
forming spaced reinforcement flange portions on said inner door panel reinforcement adapted interface respectively with the first and second flange portions on the outer door panel,
positioning said structural door trim module adjacent said outer door panel so that said first reinforcement flange portion is readily accessible and interfaces with said first outer door panel flange portion and said second reinforcement flange portion is readily accessible and interfaces with said second outer door panel flange portion and,
detachably securing said structural door trim module to said outer door panel by fastening each of said reinforcement flange portions to a respective outer door panel flange portion whereby to reinforce said outer door panel with said structural door trim module.
66. The method of assembling a vehicle door of claim 65 including:
installing as a part of said structural door trim module an electrical component on the outer side of said inner door panel and sealing said outer side and said electrical component with a watershield before said structural door trim module is positioned adjacent said outer door panel whereby to shield said electrical component and the passenger compartment of the vehicle from the deleterious effects of water, noise and dust.
67. A door assembly for a motor vehicle, the door assembly comprising:
a door panel having an inner side and an outer side, the inner side being adapted to face into a passenger compartment of the motor vehicle;
a catch mounted on the outer side of the door panel and operable to detachably secure the door assembly in a closed position; and
a lock mounted on the outer side of the door panel and engaged with the catch to permit selective operation of the catch;
the door assembly being an integral removable unit.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A method of manufacturing a prefabricated dental bridge, the method comprising:
forming a unitary dental bridge framework connectable to at least two abutment teeth, each abutment tooth having a tooth occlusal surface, forming the unitary dental bridge framework including
forming a structural portion extending along an axis and having a width transverse to the axis and a length along the axis, the length being greater than the width, the structural portion having a first end and an opposite, second end, the first end being connectable to one abutment tooth and the second end being connectable to another abutment tooth, the structural portion having a first surface oriented toward the tooth occlusal surface and an opposite, second surface,
forming a truss portion integrally with the structural portion and depending from the second surface of the structural portion, the truss portion being positioned along the length of the structural portion spaced from the first end and from the second end, a first portion of the length of the structural portion being defined between the truss portion and the first end and a second portion of the length of the structural portion being defined between the truss portion and the second end,
forming a first slot in the first portion of the length, the first slot extending along the axis and from the second surface toward the first surface, the first slot having opposite side walls,
forming a second slot in the second portion of the length, the second slot extending along the axis and from the second surface toward the first surface, the second slot having opposite side walls, and
forming a plurality of openings extending through the structural portion transverse to the axis and from the first surface toward the second surface, the plurality of openings being spaced from the truss portion along the length of the structural portion, at least one of the plurality of openings being formed in the first portion of the length of the structural portion, at least another of the plurality of openings being formed in the second portion of the length of the structural portion; and
forming a pontic on the dental bridge framework.
2. The method of claim 1, wherein forming a first slot causes the at least one of the plurality of openings in the first portion of the length to be formed, and wherein forming a second slot causes the at least another of the plurality of openings in the second portion of the length to be formed.
3. The method of claim 1, wherein forming a truss portion includes forming a peripheral surface of the truss portion and a radius surface connecting the second surface of the structural portion and the peripheral surface of the truss portion.
4. The method of claim 3, wherein forming a first slot includes forming a first slot portion in a first peripheral surface portion of the truss portion adjacent to the first portion of the length of the structural portion, and wherein forming a second slot includes forming a second slot portion in a second peripheral surface portion of the truss portion adjacent to the second portion of the length of the structural portion.
5. The method of claim 1, wherein forming a truss portion includes
forming a first truss portion integrally with the structural portion, the first truss portion generally extending in a first plane substantially parallel to the axis, and
forming a second truss portion integrally with the structural portion, the second truss portion generally extending in a second plane substantially transverse to the axis and substantially transverse to the first plane.
6. The method of claim 1, wherein forming the unitary dental bridge framework further includes forming a plurality of projections integrally with the structural portion on the first surface of the structural portion, each of the projections having a projection occlusal surface spaced beyond the first surface toward the tooth occlusal surface, the projection occlusal surface providing a bridge occlusal surface for the dental bridge, the structural portion being connectable to the abutment teeth with the first surface oriented toward and positioned below the tooth occlusal surface and with the bridge occlusal surface positioned at or above the tooth occlusal surface.
7. The method of claim 6, wherein forming the plurality of projections includes removing material between adjacent ones of the projections.
8. The method of claim 7, wherein removing material between adjacent ones of the projections in the first length of the structural portion and forming a first slot causes the at least one of the plurality of openings in the first portion of the length to be formed, and wherein removing material between adjacent ones of the projections in the second length of the structural portion and forming a second slot causes the at least another of the plurality of openings in the second portion of the length to be formed.
9. A method of installing a prefabricated dental bridge, the method comprising:
prior to a dentist examining a patient, manufacturing the prefabricated dental bridge, manufacturing including
forming a unitary dental bridge framework including
forming a structural portion extending along an axis, and
forming a truss portion integrally with the structural portion, the truss portion depending from the structural portion, and
forming a tooth-shaped pontic on the dental bridge framework;
providing the prefabricated dental bridge to the dentist;
examining the patient;
preparing at least two abutment teeth of the patient;
positioning the dental bridge on the abutment teeth; and
bonding the dental bridge to the abutment teeth.
10. The method of claim 9, wherein each abutment tooth has a tooth occlusal surface, wherein forming a unitary dental bridge framework includes
forming a structural portion extending along an axis and having a width transverse to the axis and a length along the axis, the length being greater than the width, the structural portion having a first end and an opposite, second end, the first end being connectable to one abutment tooth and the second end being connectable to another abutment tooth, the structural portion having a first surface oriented toward the tooth occlusal surface and an opposite, second surface,
forming a truss portion integrally with the structural portion and depending from the second surface of the structural portion, the truss portion being positioned along the length of the structural portion spaced from the first end and from the second end, a first portion of the length of the structural portion being defined between the truss portion and the first end and a second portion of the length of the structural portion being defined between the truss portion and the second end,
forming a first slot in the first portion of the length, the first slot extending along the axis and from the second surface toward the first surface, the first slot having opposite side walls,
forming a second slot in the second portion of the length, the second slot extending along the axis and from the second surface toward the first surface, the second slot having opposite side walls, and
forming a plurality of openings extending through the structural portion transverse to the axis and from the first surface toward the second surface, the plurality of openings being spaced from the truss portion along the length of the structural portion, at least one of the plurality of openings being formed in the first portion of the length of the structural portion, at least another of the plurality of openings being formed in the second portion of the length of the structural portion; and
wherein positioning the dental bridge includes
positioning the first portion of the structural portion on one abutment tooth, and
positioning the second portion of the structural portion on another abutment tooth.
11. The method of claim 10, wherein forming a first slot causes the at least one of the plurality of openings in the first portion of the length to be formed, and wherein forming a second slot causes the at least another of the plurality of openings in the second portion of the length to be formed.
12. The method of claim 10, wherein forming the unitary dental bridge framework further includes forming a plurality of projections integrally with the structural portion on the first surface of the structural portion, each of the projections having a projection occlusal surface spaced beyond the first surface toward the tooth occlusal surface, the projection occlusal surface providing a bridge occlusal surface for the dental bridge, and wherein positioning includes positioning the structural portion on the abutment teeth with the first surface oriented toward and positioned below the tooth occlusal surface and with the bridge occlusal surface positioned at or above the tooth occlusal surface.
13. The method of claim 12, wherein forming the plurality of projections includes removing material between adjacent ones of the projections.
14. The method of claim 13, wherein removing material between adjacent ones of the projections in the first length of the structural portion and forming a first slot causes the at least one of the plurality of openings in the first portion of the length to be formed, and wherein removing material between adjacent ones of the projections in the second length of the structural portion and forming a second slot causes the at least another of the plurality of openings in the second portion of the length to be formed.
15. The method of claim 10, wherein preparing at least two abutment teeth includes forming a groove in each abutment tooth, wherein positioning the dental bridge includes positioning the first portion of the structural portion in the groove in one abutment tooth and the second portion of the structural portion in the groove in another abutment tooth, and wherein bonding the dental bridge includes applying bonding resin to the abutment teeth, the bonding resin flowing through the openings in the structural portion.
16. The method of claim 9, wherein forming a truss portion includes forming a peripheral surface of the truss portion and a radius surface connecting the second surface of the structural portion and the peripheral surface of the truss portion, and wherein positioning the dental bridge includes engaging the radius surface with at least one abutment tooth to resist twisting forces on the dental bridge after installation.
17. The method of claim 16, wherein forming a first slot includes forming a first slot portion in a first peripheral surface portion of the truss portion adjacent to the first portion of the length of the structural portion, and wherein forming a second slot includes forming a second slot portion in a second peripheral surface portion of the truss portion adjacent to the second portion of the length of the structural portion.
18. A prefabricated dental bridge comprising:
a unitary dental bridge framework connectable to at least two abutment teeth, the unitary dental bridge framework including
a structural portion extending along an axis, and
a truss portion integrally formed with the structural portion and depending from the structural portion; and
a tooth-shaped pontic formed on the dental bridge framework.
19. The dental bridge of claim 18, wherein each abutment tooth has a tooth occlusal surface, wherein the structural portion extends along an axis and has a width transverse to the axis and a length along the axis, the length being greater than the width, the structural portion having a first end and an opposite, second end, the first end being connectable to one abutment tooth and the second end being connectable to another abutment tooth, the structural portion having a first surface oriented toward the tooth occlusal surface and an opposite, second surface, wherein the truss portion depends from the second surface of the structural portion, the truss portion being positioned along the length of the structural portion spaced from the first end and from the second end, a first portion of the length of the structural portion being defined between the truss portion and the first end and a second portion of the length of the structural portion being defined between the truss portion and the second end, wherein a first slot is formed in the first portion of the length, the first slot extending along the axis and from the second surface toward the first surface, the first slot having opposite side walls, wherein a second slot is formed in the second portion of the length, the second slot extending along the axis and from the second surface toward the first surface, the second slot having opposite side walls, and wherein a plurality of openings extend through the structural portion transverse to the axis and from the first surface toward the second surface, the plurality of openings being spaced from the truss portion along the length of the structural portion, at least one of the plurality of openings being formed in the first portion of the length of the structural portion, at least another of the plurality of openings being formed in the second portion of the length of the structural portion.
20. The dental bridge of claim 19, wherein the truss portion has a peripheral surface, and wherein a radius surface connects the second surface of the structural portion and the peripheral surface of the truss portion.
21. The dental bridge of claim 20, wherein a first slot portion is formed in a first peripheral surface portion of the truss portion adjacent to the first portion of the length of the structural portion, and wherein a second slot portion is formed in a second peripheral surface portion of the truss portion adjacent to the second portion of the length of the structural portion.
22. The dental bridge of claim 19, wherein the structural portion includes a plurality of projections integrally formed on the first surface, each of the projections having a projection occlusal surface spaced beyond the first surface toward the tooth occlusal surface, the projection occlusal surface providing a bridge occlusal surface for the dental bridge, the structural portion being connectable to the abutment teeth with the first surface oriented toward and positioned below the tooth occlusal surface and with the bridge occlusal surface positioned at or above the tooth occlusal surface.
23. The dental bridge of claim 22, wherein the plurality of projections are formed by removing material between adjacent ones of the projections.
24. The dental bridge of claim 18, wherein the truss portion includes
a first truss portion formed integrally with the structural portion, the first truss portion generally extending in a first plane substantially parallel to the axis, and
a second truss portion formed integrally with the structural portion, the second truss portion generally extending in a second plane substantially transverse to the axis and substantially transverse to the first plane.