U.S. patent application number 10/427738 was filed with the patent office on 2004-11-04 for vehicle door.
Invention is credited to Chernoff, Adrian B., White, Tommy E..
Application Number | 20040217623 10/427738 |
Document ID | / |
Family ID | 33131498 |
Filed Date | 2004-11-04 |
United States Patent
Application |
20040217623 |
Kind Code |
A1 |
Chernoff, Adrian B. ; et
al. |
November 4, 2004 |
VEHICLE DOOR
Abstract
A vehicle door includes various features that enable a thin door
profile not achievable with the prior art. The vehicle door
includes an inner panel, an outer panel, and a reinforcement member
between the inner panel and the outer panel. Door hardware,
including at least a window regulator, is connected to the
reinforcement member such that the door hardware is outboard of a
window, thereby enabling the inner panel to be positioned in close
proximity to the window.
Inventors: |
Chernoff, Adrian B.; (Royal
Oak, MI) ; White, Tommy E.; (Rochester Hills,
MI) |
Correspondence
Address: |
KATHRYN A MARRA
General Motors Corporation
Legal Staff, Mail Code 482-C23-B21
P.O. Box 300
Detroit
MI
48265-3000
US
|
Family ID: |
33131498 |
Appl. No.: |
10/427738 |
Filed: |
April 30, 2003 |
Current U.S.
Class: |
296/146.6 |
Current CPC
Class: |
B60J 5/045 20130101 |
Class at
Publication: |
296/146.6 |
International
Class: |
B60J 005/00 |
Claims
1-7. (cancelled)
8. A vehicle door comprising: an inner panel; an outer panel
operatively connected to the inner panel such that the inner panel
and the outer panel form a cavity therebetween; a reinforcement
member operatively connected to the inner panel and the outer panel
such that the reinforcement member is at least partially located
within the cavity; a window selectively movable between an extended
position and a retracted position in which the window is at least
partially located within the cavity; and a window regulator
operatively connected to the window; wherein the outer panel is
characterized by a lower edge and an outer window sill; wherein a
first portion of the inner panel defines a hinge face and a second
portion of the inner panel defines a latch face; and wherein the
reinforcement member is operatively connected to the outer panel
substantially adjacent to the outer window sill to thereby function
as a belt reinforcement, operatively connected to the first portion
to thereby function as a hinge reinforcement, operatively connected
to the second portion to thereby function as a latch face
reinforcement and extends substantially to the lower edge; and
wherein the window regulator is mounted to the reinforcement
member.
9. The vehicle door of claim 8, wherein the window is at least
partially located between the inner panel and the reinforcement
member when the window is in the retracted position.
10. The vehicle door of claim 8, wherein the window is at least
partially located between the inner panel and the window regulator
when the window is in the retracted position.
11. The vehicle door of claim 10, wherein the reinforcement member
is one-piece.
12. The vehicle door of claim 10, wherein the window is
characterized by a contour, and wherein the inner panel
substantially follows the contour of the window when the window is
in the retracted position.
13. The vehicle door of claim 12, wherein the reinforcement member
and the outer panel substantially follow the contour of the window
when the window is in the retracted position.
14. The vehicle door of claim 8, wherein the reinforcement member
is characterized by corrugations.
15. (cancelled)
16. A vehicle door comprising: an inner panel; an outer panel
operatively connected to the inner panel such that the inner panel
and the outer panel form a cavity therebetween; a reinforcement
member operatively connected to the inner panel and the outer panel
such that the reinforcement member is at least partially located in
the cavity; a window selectively movable between a retracted
position and an extended position; and a window regulator
operatively connected to the window; wherein the window is at least
partially located between the inner panel and the window regulator
when the window is in the retracted position; wherein the window is
characterized by a contour, and wherein the inner panel
substantially follows the contour when the window is in the
retracted position; and wherein the outer panel is characterized by
a lower edge and an outer window sill; wherein a first portion of
the inner panel defines a hinge face and a second portion of the
inner panel defines a latch face; and wherein the reinforcement
member is a panel operatively connected to the outer panel
substantially adjacent to the outer window sill to thereby function
as a belt reinforcement, operatively connected to the first portion
to thereby function as a hinge reinforcement, operatively connected
to the second portion to thereby function as a latch face
reinforcement, and extends substantially to the lower edge.
17. The vehicle door of claim 16, wherein the reinforcement member
is formed using superplastic forming.
18. The vehicle door of claim 16, wherein the reinforcement member
is formed using quick plastic forming.
19. The vehicle door of claim 16, wherein the reinforcement member
is formed using sheet hydroforming.
20. The vehicle door of claim 16, wherein the inner panel is an
interior trim panel.
21. A vehicle door comprising: an inner panel; an outer panel
operatively connected to the inner panel such that the inner panel
and the outer panel form a cavity therebetween; a reinforcement
panel having at least one aperture for mounting door hardware, the
reinforcement panel being connected to the inner panel and the
outer panel such that the reinforcement panel is at least partially
located within the cavity; a window selectively movable between an
extended position and a retracted position; and a window regulator
mounted at said at least one aperture such that the window
regulator and reinforcement panel are outboard of the window when
the window is in the retracted position; wherein the outer panel is
characterized by a lower edge and an outer window sill; wherein a
first portion of the inner panel defines a hinge face and a second
portion of the inner panel defines a latch face; wherein the
reinforcement panel is operatively connected to the outer panel
substantially adjacent to the outer window sill to thereby function
as a belt reinforcement, operatively connected to the first portion
to thereby function as a hinge reinforcement, operatively connected
to the second portion to thereby function as a latch face
reinforcement, and extends substantially to the lower edge; and
wherein the reinforcement panel is characterized by
corrugations.
22. A vehicle door comprising: an inner panel; an outer panel
operatively connected to the inner panel such that the inner panel
and the outer panel form a cavity therebetween; a reinforcement
member at least partially located in the cavity; a window
selectively movable between a retracted position and an extended
position; and a window regulator operatively connected to the
window; wherein the window is at least partially located between
the inner panel and the window regulator when the window is in the
retracted position; and wherein the window is characterized by a
curvature, and wherein the inner panel is characterized by a
curvature that approximates the curvature of the window.
Description
TECHNICAL FIELD
[0001] This invention relates to vehicle doors characterized by a
reinforcement at which door hardware is mounted outboard of a
window.
BACKGROUND OF THE INVENTION
[0002] A prior art vehicle door typically includes an outer panel,
an inner panel, and numerous reinforcements such as a beltline
reinforcement, a hinge reinforcement, a latch reinforcement, and an
impact bar. Door hardware, such as a window regulator, a latch, a
window guide, etc., is mounted to the inner panel and is inboard of
a glass window when the window is in its open, i.e., retracted,
position. The inner panel is typically a structural component,
providing a substantial amount of the prior art door's structural
integrity and stiffness. An interior trim panel is mounted to the
inner panel to provide the door with an aesthetically-pleasing user
interface.
SUMMARY OF THE INVENTION
[0003] A vehicle door is provided that includes an inner panel, an
outer panel operatively connected to the inner panel such that the
inner panel and the outer panel form a cavity therebetween, and a
reinforcement member at least partially located within the cavity.
The vehicle door includes a window selectively movable between an
extended and a retracted position. When the window is in the
retracted position, it is at least partially located in the cavity
between the inner panel and the reinforcement member. Door
hardware, such as a window regulator, is preferably operatively
connected to the reinforcement member so that it is outboard of the
window when the window is in the retracted position. In the context
of the present invention, "outboard" corresponds to the direction
or orientation that would be outboard with respect to a vehicle if
the vehicle door is operatively connected thereto. In other words,
the window is between the door hardware and the inner panel.
[0004] By mounting door hardware outboard of the window, the inner
panel can be positioned in close proximity to the window, resulting
in a thinner door compared to the prior art. Furthermore, the inner
panel can follow the contour of the window to further reduce the
thickness of the door compared to the prior art.
[0005] The reinforcement member is preferably a panel that is
configured to replace the numerous reinforcements found in a
typical prior art door. The use of such a panel provides better
dimensional control and fewer tolerance stack-ups compared to the
prior art, enabling door designers to design a thinner door than is
achievable with the prior art by reducing the design clearances
between door components compared to the prior art. Furthermore, the
panel may be configured to provide the door with substantially all
its structural rigidity and stiffness so that the inner panel need
not be a structural member. Thus, the inner panel can be made
thinner than prior art inner panels, or an interior trim panel may
be employed as an inner panel, thereby eliminating a component
found in typical prior art vehicle doors. The vehicle door can
therefore reduce door thickness compared to the prior art, and
thereby increase vehicle interior space and provide increased
exterior styling options
[0006] The above features and advantages, and other features and
advantages, of the present invention are readily apparent from the
following detailed description of the best modes for carrying out
the invention when taken in connection with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an exploded schematic perspective view of a
vehicle door according to an embodiment of the invention;
[0008] FIG. 2 is a schematic sectional view of the vehicle door of
FIG. 1; and
[0009] FIG. 3 is a schematic perspective view of the vehicle door
of FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] Referring to FIG. 1, an exploded view of a vehicle door
assembly 10 is schematically depicted. The door assembly 10
includes an outer panel 12, a reinforcement panel 14, and an inner
panel 16. The outer panel 12, formed of a single sheet of material,
has a generally smooth exterior, slightly contoured in accordance
with the exterior styling of the associated vehicle. The outer
panel 12 includes an upper edge 24 forming in part an outer window
sill, a bottom edge 26, and front and rear edges 28, 30, each
including material for assembly with the inner panel, such as hem
flanges.
[0011] The inner panel 16 includes vertically and laterally
extending front and rear side portions 32, 34 longitudinally
connected by a bottom portion 36. The front portion 32 of the inner
panel defines a hinge face 33. The rear portion 34 of the inner
panel defines a latch face 37. A window sill support member 38
interconnects the upper ends of the front and rear side portions.
Outer edges of the front and rear side portions and the bottom
portion are adapted for connection with corresponding parts of the
outer panel 12. Inner panel 16 is preferably stamped and trimmed
from a single sheet of material. Alternatively, within the scope of
the claimed invention, the inner panel 16 may be a "trim panel"
formed from plastic, fabric, etc, because the reinforcement panel
14 is configured to provide the door assembly 10 with sufficient
stiffness and rigidity such that the inner panel need not be
substantially load-bearing. The trim panel would form a user
interface for the door, and would preferably include a pull handle,
an armrest, etc.
[0012] The reinforcement panel 14, like the outer panel, is formed
from a single sheet. However, its configuration in the illustrated
embodiment is considerably more complex such that it is preferably
manufactured by superplastic forming, quick plastic forming, or
sheet hydroforming. Superplastic forming is described in U.S. Pat.
No. 5,974,847, issued Nov. 2, 1999 to Saunders, et al, which is
hereby incorporated by reference in its entirety. Quick plastic
forming is described in U.S. Pat. No. 6,253,588, issued Jul. 3,
2001 to Rashid, et al, which is hereby incorporated by reference in
its entirety. The reinforcement panel, as well as the inner and
outer panels, is preferably made from a suitable aluminum alloy
material. However, other materials may also be used within the
scope of the claimed invention. For example, polymer materials,
fiber-polymer composites, metals such as steel, etc., may be
employed.
[0013] The reinforcement panel 14 is characterized by corrugations
39. The outer face 40 of the reinforcement panel is characterized
by a series of longitudinally-oriented ridges 41 which are
configured to conform to the shape or contour of the inner face 43
of the outer panel 12. The outer face 40 and the series of ridges
41 extend from near the bottom edge 26 of the outer panel to
adjacent to the upper window sill edge 24 and longitudinally along
the length of the outer panel over the distance between the front
and rear side portions 32, 34 of the inner panel. The outer face of
the reinforcement panel is provided with (or interrupted with) a
plurality of, in this case seven, longitudinally extending furrows
42. These are, optionally, each about three centimeters wide, have
a bell-shaped cross section and extend the full length of the
reinforcement panel, except for at least one which stops short of
an opening 44 for the door handle.
[0014] At the front and rear edges of the reinforcement panel 14
are vertical inwardly extending front and rear side walls 46, 48,
respectively. Four laterally extending furrows 50 are provided in
the front side wall 46 for stiffening its structure, and two
laterally extending furrows 52 are provided in the rear side wall
48 for the same purpose. The front and rear side walls 46, 48 are
fixed such as by welding to the corresponding front and rear side
portions 32, 34, respectively, of the inner panel to thereby
function as a hinge reinforcement and a latch reinforcement,
respectively.
[0015] The front side wall 46 and front portion 32 of the
reinforcement panel and inner panel define openings for the passage
of necessary wiring. The front and rear side walls 46, 48 of the
reinforcement panel add to the structural stiffness of the front
and rear door inner panel side portions 32, 34 and provide a stiff
box-like support for the reinforcement panel outer portion. If, as
shown, the reinforcement panel is not provided with an optional
lower wall, lateral strips 58 may be added for assisting in
assembly of the reinforcement panel 14 to the bottom portion of the
inner panel.
[0016] Door hardware, such as a window regulator 60, window guide
64, and latch 68, is mounted to the reinforcement panel 14 with
mechanical fasteners (not shown) at apertures (not shown) defined
by the panel 14. Door hardware may be mounted to the reinforcement
panel prior to the joining of the inner panel, outer panel, and
reinforcement panel and after the inner panel and the outer panel
have been painted. Alternatively, and within the scope of the
claimed invention, door hardware may be mounted to the
reinforcement panel after the inner panel, outer panel, and
reinforcement panel have been joined. In such a scenario, the door
hardware would be loaded through a hardware access opening 69 in
the inner panel and mounted to the reinforcement panel with, for
example, pop rivets, self-tapping screws, etc. Those skilled in the
art will recognize other door hardware components that may be
mounted to the reinforcement panel 14, such as interior and
exterior door handles, power lock switches, lock rods, etc.
[0017] Referring to FIG. 2, wherein like reference numbers refer to
like components from FIG. 1, a schematic sectional view of the door
assembly 10 is depicted. The door assembly includes the inner panel
16 operatively connected to the outer panel 12 such that the inner
panel 16 and the outer panel 12 form a cavity 76 therebetween. The
reinforcement panel 14 is operatively connected to the inner panel
16 and the outer panel 12 and is substantially entirely located
within the cavity 76. Portions of the outer face 40 of the
reinforcement panel, i.e., the ridges 41, are positioned in
abutting relation to contiguous portions of the outer panel 12 and
are preferably fixed thereto, such as by adhesive bonding. The
outer panel 12 and furrows 42 form load-bearing box sections, or
hollow load-bearing sections, which add to the stiffness of the
outer panel-reinforcement panel assembly and improve the strength
of the door assembly 10 against intrusion. Mechanical fasteners 80
for retaining the window regulator 60 extend through apertures 84
and are partially located between the reinforcement panel 14 and
the outer panel 12 within furrows. The reinforcement panel 14 is
connected to the outer panel at the upper edge 24 and the outer
window sill to function in part as a belt reinforcement.
[0018] A glass window 88 is operatively connected to the window
regulator 60. The window regulator 60 is configured to selectively
move the window 88 between a retracted position and an extended
position in which the window extends higher above the outer window
sill than when in the retracted position. The window 88 is
substantially entirely located within the cavity 76 between the
inner panel 16 and the reinforcement panel 14 when in the retracted
position, as depicted in FIG. 2. Similarly, the window 88 is
located between the inner panel 16 and the window regulator 60 when
in the retracted position so that the inner panel 16 can be in
close proximity to the window 88.
[0019] The window 88 is characterized by a contour, or curvature,
which approximates the contour of the inner panel, the
reinforcement panel, and the outer panel. Thus, the inner panel 16,
the outer panel 12, and the reinforcement panel 14 substantially
follow the contour of the window 88, i.e., have a corresponding
contour. FIG. 3 is a schematic perspective view of the door
assembly 10.
[0020] The vehicle door assembly 10 is thinner and more lightweight
than most prior art door assemblies, resulting in increased vehicle
interior space. The complexity of the reinforcement panel geometry
enables more complex door designs with more curvature and angles
than is achievable with the prior art. The vehicle door assembly 10
has fewer parts than a typical prior art door, and therefore may
reduce costs. The improved dimensional control provided by the
reinforcement panel improves door assembly reliability, and
therefore may reduce a manufacturer's warranty costs.
[0021] While the best mode for carrying out the invention has been
described in detail, those familiar with the art to which this
invention relates will recognize various alternative designs and
embodiments for practicing the invention within the scope of the
appended claims.
* * * * *