A vehicle door assembly includes a door housing configured for covering a vehicle access opening. A frame member is disposed within the door housing. A module includes an intrusion beam coupled to the frame member and removable from the door housing. The module is configured to accept attachment of a module hinge and a module latch to provide a secondary door assembly. A modular vehicle door assembly and a method of assembling a door assembly to a vehicle are also disclosed.

A main body (2) has door attaching portions respectively formed on both end sides of a long longitudinal direction thereof and a bending deformation generation portion (3) disposed between the door attaching portions, and the bending deformation generation portion (3) has a groove bottom portion (4), two edge line portions (5a, 5b), two vertical wall portions (6a, 6b), two curved portions (7a, 7b), and two flanges (8a, 8b). There is provided a bead (13) which is formed toward the longitudinal direction of the main body (2) in a part of the groove bottom portion (4) in a manner to project in a shape having a curved surface toward the outside of a cross-sectional shape of the bending deformation generation portion (3) so as to oppose an impact load acting on a door impact beam (1).

A door impact beam that is disposed across a door frame of a vehicle and a method of manufacturing the door impact beam may include a body formed in a pipe shape and concaved on a side facing an external side of the vehicle; and coupling portions integrally extending from first and second end portions of the body to be coupled to the door frame through spot welding.

A vehicle door structure includes: a door hinge member mounted on a vehicle body; a door inner panel that constitutes a side door of an automobile; a door outer panel that is mounted on an outer side of the door inner panel in a vehicle width direction, and constitutes the side door of the automobile; and a door impact beam that is disposed between the door inner panel and the door outer panel, a first end side of the door impact beam being mounted on the door inner panel through a mounting member, a second end side of the door impact beam being rotatably mounted on the door hinge member.

A door of a vehicle may include a first door module forming a door skeleton; a second door module coupled with the first door module and forming a door window; and a door frame coupled to the first door module and engaged with the second door module; wherein the second door module may include a relatively lightweight material as compared to the first door module, reducing weight and cost of the door for a vehicle.

A method includes molding an outer impact beam made of carbon fiber reinforced plastics (CFRP) and separately molding an inner impact beam made of CFRP. The outer impact beam and the inner impact beam are coupled to each other to form an impact beam and the impact beam is coupled to an inner panel of a vehicle door.

A door beam for a vehicle may include a beam portion having a rod shape which extends along a longitudinal direction of a vehicle body, a front mounting portion disposed at a front end portion of the beam portion to mount the front end portion of the beam portion to the door, and a rear mounting portion disposed at a rear end portion of the beam portion to mount the rear end portion of the beam portion to the door.

A mounting structure for mounting an interior component to a door trim body includes: a rear locking protrusion including a first portion protruding from a back surface of the interior component and a second portion extending from a distal end of the first portion toward a front of a vehicle; a rear mounting hole in a rear edge section of the door trim body and opposed to the rear locking protrusion; a locking protrusion protruding from the back surface toward the door trim body and is disposed closer to a front of the vehicle relative to the rear locking protrusion; and a mounting hole in a section of the door trim body at a position closer to the front relative to the rear mounting hole and opposed to the locking protrusion. The second portion of rear locking protrusion is locked to a hole edge of the rear mounting hole.

An impact beam structure of a CFRP door for a vehicle is disclosed. A outer impact beam and an inner impact beam are separately molded and then coupled to each other such that an impact beam is formed. The impact beam is coupled to an inner panel of the CFRP door for the vehicle.

A door beam for a vehicle may include a beam portion having a rod shape which extends along a longitudinal direction of a vehicle body, a front mounting portion disposed at a front end portion of the beam portion to mount the front end portion of the beam portion to the door, and a rear mounting portion disposed at a rear end portion of the beam portion to mount the rear end portion of the beam portion to the door.