Vehicle door and process for manufacturing same

A process for manufacturing a vehicle door with door casing, the process comprising the steps of:

• providing an inside door panel on a door side facing an interior space of the vehicle, said inside door panel including sheet material having a shell form;
• providing a replaceable outside door shell;
• closing said inside door panel having a shell form toward the outside of the vehicle door with said replaceable outside door shell;
• injection molding at least one plastic support part to connect the plastic support part by plastic fastening portions to said inside door panel at discrete connection points via openings defined by said inside door panel, said plastic fastening portions extending from a side through said openings with said plastic fastening portions passing through and projecting over surfaces of said openings on a reverse side, said fastening portions being injection molded integrally on said plastic support part, said plastic support part being provided on a side facing said outside door shell;
• providing fastening elements for the door components arranged in the door casing, said fastening elements being provided at said plastic support part and interior vehicle space structural elements which protrude into the interior space of the vehicle or are accessible from the interior space of the vehicle;
• fastening structural elements to said inside door panel in an area of corresponding structural element openings of said inside door panel so that no moisture can enter the interior space of the vehicle from the door casing;
• introducing said structural elements protruding into the interior space of the vehicle into said inside door panel, which is provided with said corresponding openings;
• provisionally fixing said structural elements;
• fastening said structural elements and said plastic support part, formed during the injection molding including injecting plastic into said inside door panel with a corresponding molding die to said inside door panel, wherein the injection pressure is selected to be such that the plastic composition securely seals gap openings that may be present between said corresponding openings and said structural elements.

A process for manufacturing a vehicle door with door casing having an inside door panel on a door side facing an interior space of the vehicle, said inside door panel including a sheet of material having a shell form, the process comprising the steps of:

• providing a replaceable outside door shell and closing said door panel having a shell form toward the outside of the vehicle door by said replaceable outside door shell;
• introducing said inside door panel, which is provided with corresponding openings, into an injection molding die, which comprises at least two die halves and which has, after the closing of said two die halves, die cavities;
• subsequently injecting plastic into the die cavities to form at least one plastic support part connected by plastic fastening portions to said inside door panel at discrete connection points via openings defined by said inside door panel, said plastic fastening portions extending from a side through said openings with said plastic fastening portions passing through and projecting over surfaces of said openings on a reverse side, said fastening portions being injection molded integrally on said plastic support part, said plastic support part being provided on a side facing said outside door shell;
• providing fastening elements for the door components arranged in the door casing, said fastening elements being provided at said plastic support part;
• providing interior vehicle space structural elements which protrude into the interior space of the vehicle or are accessible from the interior space of the vehicle, said structural elements being fastened to said inside door panel in an area of corresponding structural element openings of said inside door panel so that no moisture can enter the interior space of the vehicle from the door casing, said structural elements being produced and fastened to said inside door panel substantially simultaneously with the production and fastening of said plastic support part.