A vehicle door beam and related methods of making door beams include a flat-rolled aluminum alloy sheet, where two edges of the sheet that are transverse to the roll direction of the sheet are brought together to form a tube. The two edges are friction stir welded together to form a butt joint along a length of the tube. The tube is arranged, along with other optional components, as a side-impact door beam in a vehicle door, such that the butt joint is facing away from an expected impact direction of the vehicle door.

A door assembly for a motor vehicle comprised of an outer door panel and an inner door panel interconnected to define a door panel structure having an internal door cavity. A collapsible carrier module is configured to be oriented in a collapsed arrangement to facilitate installation into the door cavity through an opening in the inner door panel. The collapsible carrier module can be moved from its collapsed arrangement into an expanded arrangement upon installation within the door cavity to facilitate subsequent mounting to the door panel structure. The collapsible carrier module includes a barrier configured to close off the opening in the inner panel.

A door of a vehicle may include a first door module forming a door skeleton; and a second door module coupled with the first door module and forming a door window, wherein the second door module includes a relatively lightweight material as compared to the first door module; and a reinforcement member is along an edge portion forming the door window of the second door module, reducing weight and cost of the door for the vehicle.

A door of a vehicle may include a first door module forming a door skeleton; and a second door module coupled with the first door module and forming a door window; and where the second door module is made of a relatively lightweight material as compared to the first door module and a reinforcement member is coupled along external edge portions of the first door module and the second door module, reducing weight and cost of the door of the vehicle.

A method for manufacturing a vehicular side door capable of suppressing occurrence of a residual deformation in a frame of a sash part and a panel member of a door body part in a manufacturing step including a heating step. The method for manufacturing a vehicular side door includes joining each of one end part of a front frame in the vehicle longitudinal direction and one end part of a rear frame to at least one door panel member, heating at least one door panel member, the front frame, and the rear frame joined in the first joining step, and joining the other end part of the front frame and the other end part of the rear frame to each other after the heating step.

A door beam includes an aluminum alloy extrusion body extended in a longitudinal direction and having a pair of webs and a pair of flanges to be positioned on an inner side and an outer side in a width direction of a vehicle body. The pair of webs connect the pair of flanges at joint portions of each of the pair of webs such that the pair of webs and the pair of flanges form a closed cross section in a direction perpendicular to the longitudinal direction, and the pair of webs do not have a welded portion.

A body member (1; 41) has at least one outer sheet (2), an inner sheet (3) and a reinforcing structure (10) in a cavity (6) bounded by the inner sheet (3) and the outer sheet (2). The reinforcing structure (10) has at least three ribs (11-15) that extend from the outer sheet (2) toward the inner sheet (3). An expanded structural foam connects at least one of the two outer ribs (11, 15) to the inner sheet (3).

A door of a vehicle may include a first door module forming a door skeleton and a second door module coupled with the first door module, wherein the second door module includes a door window and may include a relatively lightweight material as compared to the first door module and a hollow portion is formed along an edge portion of the second door module forming the door window, reducing weight and cost of the door.

A door of a vehicle may include a first door module forming a door skeleton; and a second door module coupled with the first door module and forming a door window; and where the second door module is made of a relatively lightweight material as compared to the first door module and a reinforcement member is coupled along external edge portions of the first door module and the second door module, reducing weight and cost of the door of the vehicle.

A door beam includes an aluminum alloy extrusion body extended in a longitudinal direction and having a pair of webs and a pair of flanges to be positioned on an inner side and an outer side in a width direction of a vehicle body. The pair of webs connect the pair of flanges at joint portions of each of the pair of webs such that the pair of webs and the pair of flanges form a closed cross section in a direction perpendicular to the longitudinal direction, and the pair of webs do not have a welded portion.