Vehicle door

#This invention relates to vehicle doors characterized by a reinforcement at which door hardware is mounted outboard of a window.

#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.

#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.

#FIG. 1 is an exploded schematic perspective view of a vehicle door according to an embodiment of the invention;

#FIG. 2 is a schematic sectional view of the vehicle door of FIG. 1; and

#FIG. 3 is a schematic perspective view of the vehicle door of FIGS. 1 and 2.

#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.

#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.

#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.