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 vehicle rear structure includes: an impact beam; a rocker outer rear and a rocker inner rear extending upward from a rear portion of a rocker; a rear wheel house outer including a front portion extending in the vehicle front-rear direction and placed between the rocker outer rear and the rocker inner rear; and a bulk. The bulk includes: a first wall provided between the rocker outer rear and the rocker inner rear and joined to the rocker outer rear; a second wall bending from the first wall to extend toward the rocker inner rear; and a third wall placed at a position where the third wall at least partially overlaps with the impact bean as viewed in a vehicle width direction, the third wall being bending from the second wall and joined to the front portion of the rear wheel house outer.

A vehicle door assembly includes an inner door panel, an outer door panel and an energy absorbing member. The outer door panel being configured such that at least a portion of an outer periphery thereof is fixed to an outer periphery of the inner door panel, the inner door panel and the outer door panel defining a hollow interior therebetween. The hollow interior has an upper end and a lower end. The energy absorbing member is installed within the hollow interior between the inner door panel and the outer door panel. The energy absorbing member has an outboard end surface with a first predetermined surface area and an inboard end surface having a second predetermined surface area greater than the first predetermined surface area. The energy absorbing member is spaced apart from the upper end of the hollow interior and being spaced apart from the lower end of the hollow interior.

A door beam including an aluminum alloy extrusion extended in a longitudinal direction and having a pair of webs and a pair of flanges to be positioned on an inside and an outside in a vehicle width direction. 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 each of the pair of webs has a welded portion in a vicinity of a neutral axis passing through a centroid of the closed cross section and parallel to the pair of flanges.

A door assembly, of a vehicle that includes a first pillar structure and a second pillar structure, includes a door outer panel, a door inner panel coupled to and positioned inwardly of the door outer panel, and an impact beam positioned between the door outer panel and the door inner panel. The door impact beam includes a first end and an opposite second end, the first end overlaps the first pillar structure and the second end overlaps the second pillar structure. The door assembly further includes an inner bulkhead coupled to the door inner panel and positioned between the door inner panel and the first end of the impact beam, and an outer bulkhead coupled to the door inner panel and positioned between the inner bulkhead and the first end of the impact beam, the outer bulkhead overlaps a portion of the inner bulkhead.

A side frame comprises a center pillar which includes a reinforcement provided on an outward side in a vehicle width direction and an inner panel provided on an inward side in the vehicle width direction. The reinforcement comprises upper-and-lower hinge attachment sections for attaching rear-door hinges and first-and-second recessed beads for promoting bending of the center pillar in a vehicle side collision. The hinge attachment sections are provided to be spaced apart from each other in a vertical direction. The first recessed bead is provided at a higher level than the lower hinge attachment section. The second recessed bead is provided at a lower level than the lower hinge attachment section and configured to be bent before the first recessed bead in the vehicle side collision.

An apparatus for manufacturing a bracket-integrated double-layer door impact beam is provided. The apparatus includes a lower mold having a lower cavity formed with a base material molded to have a U-shaped cross section and a predetermined length. The base material is seated on the lower cavity. A lower electrode terminal is disposed in the lower mold to contact the base material. An upper mold has an upper cavity therein and is coupled with the lower mold to pressurize both end portions of the U-shaped cross section of the base material inward to form the base material with an O-shaped cross section. An upper electrode terminal is disposed in the upper mold to contact the base material.

A vehicle side door internally includes an impact beam which extends along a longitudinal axis of a door. The impact beam is attached to a door inner panel via an outer extension. An inner extension is attached inside the outer extension. A distance along thickness of the door between the inner extension and the impact beam is shorter in a close proximity section than in a longitudinally neighboring area. Because the load received by the inner extension via the close proximity section is transferred to joint portions connecting to the outer extension, the load received by the outer extension from the impact beam is dispersed.

A door beam including an aluminum alloy extrusion extended in a longitudinal direction and having a pair of webs and a pair of flanges to be positioned on an inside and an outside in a vehicle width direction. 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 each of the pair of webs has a welded portion in a vicinity of a neutral axis passing through a centroid of the closed cross section and parallel to the pair of flanges.

A vehicle door includes an outer panel, an inner panel including an inner wall portion, a side wall portion, and a flange portion, an impact beam provided so to extend between the outer panel and the inner wall portion on a surface parallel to inner wall portion, and a bracket including a fixed portion, a joint portion, and a recessed portion. The recessed portion recesses toward an inner-panel side such that a tip end of the impact beam is distanced from the bracket. In an extending direction of the impact beam, a yield strength of a region from the fixed portion to a tip end position of the impact beam for a load applied from the outer panel-side is lower than a yield strength of a region from the tip end position of the impact beam to the joint portion for the load applied from the outer-panel side.