# US 7,607,716 B2 · Motor vehicle door structure

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- Number: US 7,607,716 B2
- Document ID: US7607716B2
- Status: Granted
- Kind: B2
- Application number: 10/573,101
- Filed: 2004-10-07
- Published: 2007-02-22
- Granted: 2009-10-27
- Earliest claimed: 2004-10-07
- Assignees: Intier Automotive Closures Inc.
- Inventors: Christoph Buchta; Uwe Ruecker
- Web page: https://patentgrep.com/patent/US7607716B2

## CPC

- B60J 5/0429: {the elements being arranged diagonally}
- B60J 5/0416: {Assembly panels to be installed in doors as a module with components, e.g. lock or window lifter, attached thereto}
- B60J 5/045: {Panel type elements (B60J5/0455 takes precedence)}
- B60J 5/0455: {integrated in door structure or other door elements, e.g. beam-like shapes stamped in inner door panel}
- E05F 11/382: {for vehicle windows (E05F11/40 - E05F11/52 take precedence)}
- E05F 11/483: {by cables}
- E05Y 2201/684: Rails; Tracks
- E05Y 2900/55: Windows
- B60J: WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES (fastening, suspending, closing, or opening of such devices E05)
- E05F: DEVICES FOR MOVING WINGS INTO OPEN OR CLOSED POSITION; CHECKS FOR WINGS; WING FITTINGS NOT OTHERWISE PROVIDED FOR, CONCERNED WITH THE FUNCTIONING OF THE WING
- E05Y: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES E05D AND E05F, RELATING TO CONSTRUCTION ELEMENTS, ELECTRIC CONTROL, POWER SUPPLY, POWER SIGNAL OR TRANSMISSION, USER INTERFACES, MOUNTING OR COUPLING, DETAILS, ACCESSORIES, AUXILIARY OPERATIONS NOT OTHERWISE PROVIDED FOR, APPLICATION THEREOF

## Abstract

A vehicle door assembly has an inner sheet metal layer (16) which presents a substantially U-shaped structure. The inner sheet metal layer includes a latch mounting surface and at least one hinge mounting surface. An outer, substantially planar, sheet metal layer (14) is attached to the inner sheet metal layer to form a cavity. A structural reinforcement member (30) is disposed in the cavity to reinforce the inner and outer sheet metal layers, including reinforcements (44A, B and 28 A, B) for the latch and hinge mounting surfaces. A carrier assembly (60) is mounted to the structural reinforcement member, covering the U-shaped area, and a trim component (50) covers the carrier assembly. By incorporating the structural door member, the thickness of the inner and outer sheet metal layers can be reduced, for a net weight and reduced material cost savings.

## Claims

### Claim 1

A structural automotive door body, comprising:
an inner sheet metal layer, the inner sheet metal layer including a latch mounting surface and at least one hinge mounting surface;
an outer sheet metal layer; and
a structural reinforcement member disposed between the inner and outer sheet metal layers to reinforce the inner and outer sheet metal layers and providing at least one hinge reinforcement and a latch reinforcement;
wherein said inner sheet metal layer includes a pair of spaced apart end walls connected only by a bottom wall extending between said pair of spaced apart end walls thereby defining a substantially U-shaped structure having an open upper portion and said structural reinforcement member includes a top member that abuts said outer sheet metal layer and extends thereacross adjacent said open upper portion of said U-shaped structure of said inner sheet metal layer.

### Claim 2 (depends on 1)

A structural automotive door body according to claim 1, wherein said structural reinforcement member includes a side impact beam.

### Claim 3 (depends on 2)

A structural automotive door body according to claim 2, wherein said structural reinforcement member includes a bottom cross-member that abuts and supports the inner and outer sheet metal layers.

### Claim 4 (depends on 3)

A structural automotive door body according to claim 3, wherein said structural reinforcement member is welded to said inner sheet metal layer.

### Claim 5 (depends on 4)

A structural automotive door body according to claim 4, wherein said outer sheet metal layer is hemmed to said inner sheet metal layer.

### Claim 6 (depends on 1)

A structural automotive door body according to claim 1, wherein said structural reinforcement member includes a middle cross member, a bottom cross member, and continuous side peripheries, said top member reinforcing said outer panel, said middle cross member extending between said side peripheries to function as a side impact beam, said bottom cross-member abutting and reinforcing said inner and outer sheet metal layers; and wherein said side peripheries include at least one hinge reinforcement and a latch reinforcement.

### Claim 7

A structural automotive door body, comprising:
an inner sheet metal layer including a pair of spaced apart end walls connected only by a bottom wall extending between the pair of spaced apart end walls thereby defining a substantially U-shaped structure having an open upper portion;
an outer sheet metal layer;
at least one of the inner and outer sheet metal layers including a latch mounting surface and at least one hinge mounting surface;
a structural reinforcement member disposed between the inner and outer sheet metal layers, said member comprising top, middle and bottom cross-members and contiguous side peripheries, wherein:
said top member abuts and extends across said outer sheet metal layer adjacent the open upper portion of said U-shaped structure of said inner sheet metal layer;
said middle cross member extends between said side peripheries to function as a side impact beam;
said bottom cross-member abuts and supports said inner and outer sheet metal layers; and
said side peripheries include at least one hinge reinforcement and a latch reinforcement.

### Claim 8

A door assembly, comprising:
an inner sheet metal layer defining a substantially U-shaped structure, the inner sheet metal layer including a latch mounting surface and at least one hinge mounting surface;
an outer, substantially planar, sheet metal layer;
a structural reinforcement member disposed between the inner and outer sheet metal layers for reinforcing the inner and outer sheet metal layers and providing at least one hinge reinforcement and a latch reinforcement;
a carrier assembly, including a belt-line loading member connected to a non-structural hardware carrier having at least a window regulator mounted thereon, said carrier assembly being mounted to at least the structural reinforcement member and covering the U-shaped area; and
a trim component for covering said carrier assembly.

### Claim 9 (depends on 8)

A door assembly according to claim 8, wherein said hardware carrier includes a secondary trim component which provides a shelf structure for a map pocket and said trim component includes a wall for said map pocket.

### Claim 10 (depends on 8)

A door assembly according to claim 8, wherein said window regulator includes at least one rail having one end mounted to said belt-line loading member and means for adjusting the lateral and vertical position of the other end of said at least one rail.

### Claim 11

A structural automotive door body, comprising:
an inner sheet metal layer, the inner sheet metal layer including a pair of spaced apart end walls connected only by a bottom wall extending between the pair of spaced apart end walls, said inner sheet metal layer also including a latch mounting surface and at least one hinge mounting surface;
an outer sheet metal layer; and
a structural reinforcement member disposed between the inner and outer sheet metal layers, said structural reinforcement member including top, middle and bottom cross-members and continuous side peripheries, said top member reinforcing said outer panel, said middle cross member extending between said side peripheries to function as a side impact beam, said bottom cross-member abutting and reinforcing said inner and outer sheet metal layers; and wherein said side peripheries include at least one hinge reinforcement and a latch reinforcement.