Vehicle door frame and method for making the same

#The present application is related to our copending and commonly assigned application for a "VEHICLE DOOR", U.S. Ser. No.: 08/204,075, filed on Mar. 1, 1994, Attorney Docket No.: 2976.

#The invention relates to vehicle doors, for example passenger car doors, with a frame construction that constitutes a modular frame unit for supporting various door components, such as a window, inner and outer door cover panels, locking elements and the like. The invention further relates to a method for making a vehicle door frame.

#A supporting frame for a vehicle door having a modular frame construction includes a forward frame section as viewed in the forward travel direction of the vehicle, a rear frame section, an upper frame section, and a lower frame section, which together form a modular supporting frame. A finished vehicle door also includes various other components and accessories, such as a device for opening and closing a window and guide members for guiding the window when it is raised and lowered. Further door elements include hinges, a door lock, and respective operating components for the lock as well as the inner decorative trim or cover panel of the door. In vehicle doors of conventional frame construction it is often technically complicated, difficult and expensive to attach the various other door components to the frame module.

#In order that the invention may be clearly understood, it will now be described, by way of example, with reference to the accompanying drawings, wherein:

#FIG. 1 is a perspective view of a modular supporting frame of a vehicle door according to the invention;

#FIG. 2 is a sectional view along the line II--II in FIG. 1;

#FIG. 1 shows a vehicle door frame, especially a passenger car door frame, according to the invention. As shown, a door frame 1 forming a supporting frame module 1A includes at least a forward frame section 2, a rear frame section 3, an upper frame section 4, as well as a lower frame section 5. A diagonal bracing strut 6 is connected at one end to the forward frame section 2 and at the other end to the rear frame section 3 in order to strengthen and stiffen the frame module 1A. A substantially horizontal crossbar 7 is connected at one end to the forward frame section 2 and at the other end to the rear frame section 3 to form a horizontal strengthening brace and to define the lower edge of a window opening 8. A straight window frame member 9 is arranged at the front of the door frame 1, extending substantially parallel to the rear frame section 3.

#The vehicle door according to the invention would be completed by attaching various mechanical elements and accessories which are generally not shown in the drawings. For example, a window pane would be installed to move up and down by means of a window lifting and lowering device while being guided by the window frame member 9. Furthermore, a lock mechanism, shown generally as 10 in FIG. 2, as well as hinges and the like would be attached to the door frame 1. FIG. 2 also schematically shows an upper vehicle body member 11 and a lower vehicle body member 12 which will carry and support the door frame 1 in a manner that is not the subject of this invention. The finished vehicle door will also include an inner decorative cover panel as well as an outer skin or panel. These are not shown in detail, but the outer skin 30 is shown schematically as an example in FIGS. 2 to 6.

#The various components that complete the vehicle door, such as the lock mechanism, window lifting mechanism, inner cover panel, etc. must be securely attached to the door frame 1 in an appropriate manner, depending on the component's function. In order to achieve this, it is necessary to provide appropriate connection points on the frame and to provide sufficient space or volume within the finished door to enclose the functional components. For this purpose, the door frame 1 according to the invention comprises frame sections made of a continuous sectional member, such as an extruded section having the general cross-sectional form shown in the detailed view of FIG. 2A. FIG. 2A is a sectional view through the lower door frame section 5, which is generally representative of the frame sections according to the invention. In order to provide the necessary strength, each frame section includes a hollow or box cross-sectional part 21. In order to provide the necessary interior volume of the door, that is to say, the necessary spacing between the exterior panel and the interior panel, the frame members include laterally extending webs forming intermediate spacing members 13, 14, 15 and 31, 32, 33. In order to provide convenient attachment points for connecting the interior and exterior panels, as well as other elements and accessories for the door, the frame sections include interior connecting flanges 16, 17, 18 and exterior connecting flanges 34, 35, 36. The intermediate spacing members 13, 14, 15 and 31, 32, 33, as well as the connecting flanges 16, 17, 18 and 34, 35, 36 are each formed as an integral part of the respective frame sections 2, 3, 5 forming the door frame 1. Through such an integral construction, the manufacture of the door frame is quite economical, uncomplicated, and easy to carry out. The result is a finished door frame that is light, yet strong and resistant to torsional bending.