Method of manufacturing a lightweight composite automotive door beam

Abstract

A lightweight, composite beam for reinforcing a vehicle door is provided. The reinforcing beam comprises an open channel-shaped metal member having a longitudinal cavity which is filled with a reinforcing polymeric material which in one aspect is a thermoset or thermoplastic resin-based material. The composite beam includes end pieces which are adapted to be mounted to a vehicle door panel in a door cavity by spot-welds or the like. The horizontally mounted beam provides substantially increased resistance to side impacts to the vehicle door in the event of a collision. In one embodiment, the beam is mounted between the window glass space and the inner door panel for flush-glass vehicle doors. In another configuration, one surface of the beam is sculptured to mate with a concise outer door panel. A method of making the reinforcing beam of the present invention is also provided which in one aspect includes cutting a sheet metal blank which is then bent to form a channel-shaped member having a longitudinal cavity. End mounting pieces integral with the beam are formed as the longitudinal cavity is filled with reinforcing material.

Dependencies are inferred from the claim text.