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).

An inner panel assembly of a side door of a vehicle comprises an inner panel including an inner panel portion and a reinforcement part. The inner panel portion includes a base, an outer edge and an inner edge along a length direction and partially defines a window aperture. The reinforcement part has a first end and a second end along the length direction, and is connected to the inner panel portion via a clinched herring process, and the first end and the second end of the reinforcement part are received in an outer clinched hem flange and an inner clinched hem flange of the inner panel portion formed by the outer edge and the inner edge during the clinched hem process, respectively.

Vertical frame portions provided at both side portions of a door frame are a light-metal casting, plural connecting frames, which are a light-meal hollow extrusion molding, connect the vertical frame portions, the vertical frame portions are provided with protrusion portions which engage with inward connecting frames in a longitudinal direction, plural attachment portions which attach the outward connecting frames and the vertical frame portion are provided at different points in the longitudinal direction, and an outward connecting frame is provided with an upper rib which engages with an engagement recess portion provided at an upper portion of a door outer panel formed in a non-planar shape.

A carbon fiber sheet molding compound expander system incorporating a high speed cutter and an expander. Carbon fiber tow is cut to desired length, and the carbon fiber chips are delivered to the expander to expand and randomize the chips by transvectors of the expander. The expander opens up the chips in a way that allows resin material to contact individual carbon fibers.

A side door assembly is provided for an automotive vehicle body having a side opening. The side door assembly includes a front casting for hinged connection to the vehicle body. A rear casting is also provided for latch connection of the vehicle door assembly to the vehicle. An extrusion and/or extrusions connect the front and rear castings providing a side door assembly that is extremely light, enhancing the ability of the driver to enjoy the vehicle.

A vehicle door assembly includes a door and a trim panel. The trim panel has a mount defining an aperture with a main portion and a keyway. A clip of the assembly includes a base connected to the door, a primary retainer, and a secondary retainer. The primary retainer is configured to extend through the aperture and engage with a periphery of the main portion. The secondary retainer is configured to extend through the aperture and to freely release through the aperture when the secondary retainer is disposed in the main portion allowing the clip to disconnect from the trim panel, and is configured to engage with the mount preventing release of the clip from the trim panel when the secondary retainer is disposed in the keyway.

A collapsible vehicle door is provided that can be easily installed and uninstalled on a vehicle, without modification to the vehicle. The uninstalled door can be collapsed into a compact configuration allowing for storage within the vehicle. The collapsible door includes frame pieces that can be fixed together to form a frame. The frame pieces may be shaped to match or partially match the contour of the door frame of the vehicle on which the collapsible door is to be installed. A cover piece is attached to the frame to provide protection from exterior weather conditions and prevent unauthorized access to the vehicle cabin. A hinge portion of the collapsible door is configured to connect to the hinge portion on the stock vehicle body. A latch portion of the collapsible door may be used to secure the collapsible door in the closed portion.

A door beam including an inner flange extending in a longitudinal direction, an outer flange extending in the longitudinal direction and facing the inner flange at a distance from the inner flange, and-a pair of webs connecting the inner flange and the outer flange. The inner flange has an end portion in the longitudinal direction which is made closer to an end portion of the outer flange such that the distance between the inner and outer flanges at the end portions is shorter than the distance at other portions of the inner and outer flanges.

A latch assembly for a vehicle door closure system is provided, with latch assembly having a strength module including a frame plate, a latching mechanism with components pivotably mounted by clinch nuts secured to retention apertures formed in the frame plate, and threaded fasteners in threaded engagement with the clinch nuts to mount the latch assembly to the vehicle door.

A vehicle door assembly includes a door and a trim panel. The trim panel has a mount defining an aperture with a main portion and a keyway. A clip of the assembly includes a base connected to the door, a primary retainer, and a secondary retainer. The primary retainer is configured to extend through the aperture and engage with a periphery of the main portion. The secondary retainer is configured to extend through the aperture and to freely release through the aperture when the secondary retainer is disposed in the main portion allowing the clip to disconnect from the trim panel, and is configured to engage with the mount preventing release of the clip from the trim panel when the secondary retainer is disposed in the keyway.