The present invention relates to a reinforced door frame construction for a vehicle and a method of manufacturing the same.
Structural reinforcements are commonly provided with a vehicle door frame assembly in order to increase the rigidity or stiffness of the door. Such reinforcements are typically rolled sections or extrusions and are joined to the door frame to provide rigidity to the stamped door frame. The joining technology for these types of reinforcements to the door frame is generally done by welding, and in particular, fusion welding. The welding process can be slow and cumbersome. In addition, high heat input from the welding process can cause distortion or even weakness in the regions surrounding the weld joint. Consequently, the welding process may create function and appearance problems with the finished parts. All of these problems contribute to poor quality door frames and increased cost, due to scrap and grinding or re-work of assembled door frames in order to have acceptable function and appearance of the weld joints and finished doors.
Whereas conventional door frames provided with reinforcing members must be welded, the present invention provides a product and manufacturing process free from the need of welding. The reinforced door panel assembly of a vehicle wherein the assembly increases the rigidity or stiffness of the door is provided wherein the door corresponds to an opening in the vehicle.
Conventionally, a motor vehicle 10 may have an A-pillar 13, a B-pillar 14, and as well as a roof 19. The A-pillar 13 supports the windshield 21 on either side of the vehicle 10, and the A-pillar 13 may be the area where a front side door assembly would be hingedly secured. The B-pillar 14 in a four-door vehicle, as illustrated in
Conventionally, the door panel assembly may be made by stamping a sheet of metal to define a shape that corresponds to a vehicle's contours and the shape of a door opening 11. The door panel assembly 30 could also be formed with alternate processes, such as injection molding or formed with composite material, for example. The door panel assembly 30 pictured here is that of a side door assembly 15, although the door panel assembly 30 could be configured to a rear door assembly 20 or another vehicle door assembly not shown. The door panel assembly 30 may be configured to attach an interior trim panel 17 along the inner surface of door panel assembly 30. The door panel assembly 30 may also have an outer body panel 18 disposed on the outer surface of the door panel assembly 30.
The door panel assembly 30 may include at least one reinforcing member 34 to increase the structural rigidity of the door frame 31. Whereas the reinforcing member 34 is pictured along the periphery of the window opening 33, the reinforcing member may be alternatively located anywhere on the door panel assembly where increased structural rigidity is desired. As such, it is also contemplated that the reinforcing member may be located on an the interior region of the door panel assembly 30. The reinforcing member 34 may be oriented vertical, or may be transverse to the door panel, such as an side intrusion beam to provide impact resistance in addition to structural rigidity.
The reinforcing member 34 may be extruded to form a shape adapted to cooperate and engage with the receiving portion 40. Conventionally, the reinforcing member may be extruded metal and have a tubular cross-section. However, the reinforcing member 34 may be formed from any material, or by any process which is suitable to form a receiving member 34 with a shape adapted to cooperate and mate with the cross-section of the receiving portion 40. The longitudinal shape of the reinforcing member may be formed engage with the longitudinal shape of a corresponding receiving portion 40, or may be at least partially engaged with a receiving portion 40. The reinforcing member 34 may be of a single piece which may be secured to both the lower frame panel 35 and the upper frame panel 32 or there may be more than one reinforcing members 34 disposed at different locations on the door frame 31.
Since the claimed invention eliminates the need for the welding process, it is also contemplated that the door frame 31 and the reinforcing member 34 could be dissimilar materials. In the case that the door frame 31 may be, for example, injection molded, and the receiving portion 40 may be integrally molded or formed in the door frame 31.
Additionally, while the receiving portion 40 illustrated in
The corresponding shape and dimensions of the receiving portion 40 may vary along different areas of the door frame 31. For example,
Conversely, a shallower receiving portion 40, as show section A-A in
Alternative cross-section geometry of the reinforcing members 34 may be employed to cooperate with a different geometry of receiving portions 40 and locating features 60. The reinforcing member 34 may be formed by extrusion or roll formed in order to create a shape adapted to engage with the receiving portion 40 and the door frame 31. The reinforcing member 34 may also have a shoulder feature 41 which cooperates with an edge of the receiving portion 40. In cooperating with the receiving portion 40 the shoulder feature 41 may be designed to allow the correct amount of engagement of the reinforcing member 34 with the retaining member 40.
In order to secure the reinforcing member 34, an adhesive 43 may be used to attach the reinforcing member 34 to the receiving portion 40 or to the door frame 31. Adhesive may be a two-part epoxy with a short cure time or that cures under ambient conditions. Alternatively, a single part adhesive could be used where the adhesive curing is achieved in a subsequent paint process, or any additional curing or thermosetting process. Additionally, any adhesive compatible with the base materials in association with the applicable curing processes could be used.
The door frame 31 may also include retaining features for holding the reinforcing member 34 into the receiving portion 40 until the adhesive 43 is completely cured. One method, as illustrated in
In step 72 of the process, a receiving portion is provided on the door. The receiving portion may be a channel formed on the inner surface of the door panel. Alternatively, the receiving portion may be a separate component which is attached to the door frame. The receiving portion may be formed on the door panel by roller clinching, roll forming, or integrally molded or any other process suitable for forming a channel of the desired geometry.
In step 74 of the process, the reinforcing member is assembled with the retaining member. The reinforcing member may be pressed into the receiving portion, or slidably assembled with the receiving portion, or assembled in a process suitable for mating the reinforcing member with the receiving portion. The reinforcing member may be only assembled with a portion of the receiving portion, or the door panel may have multiple retaining portions in which a reinforcing member or multiple reinforcing members cooperate.
In step 76 of the process, the reinforcing member is secured to a door frame. The reinforcing member may be secured and retained solely by the engagement of the reinforcing member with the receiving portion. Or the door frame may be provided with a locating feature which deforms to cooperate with and restrain the reinforcing member. Additionally, the reinforcing member may be secured to the door frame with a fastener such as a screw, rivet, self-piercing fastener, or other mechanical fastener. The reinforcing member may also be secured to the door frame or receiving portion with an adhesive.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.