Door cartridge module with discrete energy absorbing elements

A cartridge module for mounting between inner and outer door panels of a vehicle door assembly, said cartridge module comprising:

• a rigid frame having a pair of front and rear glass guidance rails for supporting and guiding window glass, an upper belt-line cross-member extending generally horizontally between said guidance rails, and a lower cross-member spaced from said belt-line cross-member and extending generally horizontally between said guidance rails;
• an energy-absorbing occupant protection member disposed between said guidance rails and said upper and lower cross-members and fabricated of rigid energy-absorbing foam material, said occupant protection member including a plurality of spaced-apart apertures of predetermined size;
• and
• a plurality of mounting studs formed as an integral portion of said frame and corresponding in number to the number of apertures, said mounting studs each having an insertion position extending generally normal to said frame and having a cross-sectional size corresponding substantially to the size of said apertures, said insertion portion extending into said apertures for mounting said occupant protection member on said frame, said insertion portions each including a plurality of radial projections radially larger than said apertures, said radial projections extending into said rigid foam material in response to application of a force displacing said occupant protection member toward engagement with said mounting studs to resist disengagement of said occupant protection member from said frame.