Framework structure for a vehicle door in particular a vehicle side door

Abstract

A frame structure for a vehicle door and a method of manufacture thereof is disclosed. In particular, a vehicle side door includes at least two tubular parts which are flexurally deformed in the direction of their longitudinal extension and connected to each other to form a ring structure. The ring structure incorporated into a structural unit with the frame structure and a crash reinforcement in a vehicle door of a motor vehicle.

Claims

1. A frame structure for a vehicle door comprising: a closed ring door frame consisting of: a front unitary tubular member having an upper portion terminating at a first end, a hinge portion and a lower portion terminating at a second end; a rear unitary tubular member having an upper portion terminating at a third end, a lock portion and a lower portion terminating at a fourth end, wherein the first and third ends are connected by a upper plug connection and the second and fourth ends are connected by a lower plug connection such that the front and rear tubular members form the closed ring door frame; a reinforcement beam extending across the closed ring door frame between the hinge portion and the lock portion; and a side intrusion beam secured to an outwardly facing edge region of the closed ring door frame and extending between the front and rear tubular members.

2. The frame structure according to claim 1, wherein at least one of the first and second tubular members is an extruded part.

3. The frame structure according claim 1, wherein at least one of the first and second tubular members is a heat-formed part.

4. The frame structure according to claim 1, further comprising at least one plug-in attachment formed on one of the first and second tubular members.

5. The frame structure according claim 1, further comprises at least one connecting point configured to fasten a part to the closed ring door frame.

6. A vehicle door comprising a frame structure according to claim 1, and a paneling part connected to the frame structure by a fastener.

7. The vehicle door according to claim 6, further comprising a door outer skin and a framework structure, wherein the door outer skin is connected to the framework structure, and the framework structure is connected to the frame structure.

8. The vehicle door according to claim 7, further comprising at least one sealing element sealing the door outer skin against the framework structure.

9. The frame structure according to claim 7, further comprising: a fastening strap extending from the framework structure and terminating at a free end; and a lug formed on the free end and received in an aperture formed in the closed ring door frame.

10. The frame structure according to claim 9 further comprising a fastener extending through the fastener strap and into the closed ring door frame.

11. A motor vehicle comprising a vehicle side door according to claim 6.

12. The frame structure according to claim 1, wherein the frame structure further comprises a corrosion-resistant treatment.

13. A method for producing a frame structure for a vehicle door comprising: bending a first unitary tubular member to form an upper portion terminating at a first end, a hinge portion and a lower portion terminating at a second end; forming a first plug-in connection in the hinge portion; bending a second unitary tubular member to form an upper portion terminating at a third end, a lock portion and a lower portion terminating at a fourth end; forming a second plug-on connection in the lock portion; inserting a first end of a reinforcement beam into the first plug-in connection and a second end of the reinforcement beam into the second plug-in connection such that the reinforcement beam between the hinge portion and the lock portion; connecting the first and third ends with a third plug-in connection therebetween and the second and fourth ends with a fourth plug-in connection therebetween to form a closed ring door frame with the reinforcement beam extending across the closed ring door frame between the hinge portion and the lock portion; and securing a side intrusion beam to an outwardly-facing edge region of the closed ring door frame such that the side intrusion beam extends between the front and rear tubular members.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:

(2) FIG. 1 shows an embodiment of a frame structure tier a vehicle side door illustrated in exploded representation;

(3) FIG. 2 shows the frame structure according to FIG. 1 in the assembled state in a lateral view;

(4) FIG. 3 shows the frame structure according to FIG. 1 with a crash reinforcement and an already assembled attachment part;

(5) FIG. 4 shows another embodiment of an outer door paneling for a vehicle side door in a lateral view onto its inside;

(6) FIG. 5 shows an embodiment of a vehicle side door with the frame structure according to FIG. 1 and the door paneling according to FIG. 4 in a lateral view onto its outside;

(7) FIG. 6 shows the vehicle side door according to FIG. 5 in a lateral view onto its inside, wherein any inside paneling parts of the vehicle side door have been omitted;

(8) FIG. 7 shows an cross-section of the vehicle side door according to FIG. 6 in a sectional representation along the section line A-A according to FIG. 6;

(9) FIG. 8 shows the cross-section X according to FIG. 7 in an enlarged representation; and

(10) FIG. 9 shows the cross-section Y according to FIG. 7 in an enlarged representation.

DETAILED DESCRIPTION

(11) The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description

(12) FIG. 1 showsin a schematic exploded representation a possible embodiment of a frame structure 1 for a vehicle door, in particular a vehicle side door. FIG. 2 shows the frame structure 1 in the assembled state.

(13) As is evident from viewing FIGS. 1 and 2 together, the frame structure 1 comprises two formed parts 2 and 3, which are connected to one another subject t forming a preferentially closed ring structure 4.

(14) Preferably, the formed parts 2, 3 are designed tubular or as tube profile, which are bending formed in particular in direction of their longitudinal extension. For example, the formed parts 2 and 3 are formed in such a manner that they are each substantially C-shaped or U-shaped and at their ends the one formed part 2 is connected to the other formed part 3. For example, the formed parts 2 and 3 are formed in such a manner that in the assembled state on a vehicle and seen in travelling direction of the vehicle, the formed part 2 form a rear frame part and the formed part 3 a front frame part of the ring structure 4. In the FIGS. 1 and 2, the travelling direction of a vehicle, in particular its forward travelling direction, is marked by the arrow 520.

(15) Preferably, the connection of the formed parts 2 and 3 in each case is realized by a plug connection 5 and 6 respectively. To this end, the end portions 7 and 8 of the formed part 2 for example are formed tapered and plugged into a respective associated end 9 and 10 respectively of the other formed part 3.

(16) Preferably, the formed parts 2 and 3 are additionally connected to one another by means of a structural connection 18 and 19 respectively. The structural connection 18 and 19 respectively can be brought about by means of welding, soldering and/or gluing. It is conceivable that the formed parts 2 and 3 are connected to one another by means of CO.sub.2 welding or electromagnetic pulse welding.

(17) Preferably, the frame structure 1 additionally comprises a reinforcing structure 11, which serves for reinforcing or stiffening, in particular torsionally stiffening the frame structure 1. Preferably, the reinforcing structure 11 is connected on the one hand to the formed part 2 and on the other hand to the formed part 3. For example, the connection of the reinforcement structure 11 to the formed part 2 and likewise to the formed part 3 can be realized by means of a plug connection 12 and 13 respectively. The reinforcing structure 11 is preferably tubular formed. Preferably, the reinforcing structure 11 is arranged furthermore below the belt line of a vehicle door or vehicle side door.

(18) Preferably, the reinforcing structure 11 is additionally fastened to the formed parts 2 and 3 by means of a structural connection 20 and 21 respectively. The structural connection 20 and 21 respectively can be brought about through welding, soldering and/or gluing, for example through CO.sub.2, welding or electromagnetic pulse welding. Preferably, the structural connections 20 and 21 as well as the structural connections 18 and 19 are arranged in the overlap region of the formed parts 2 and 3 relative to one another and in the overlap region of the formed parts 2 and 3 relative to the reinforcing structure 11, provided the formed parts 2 and 3 against one another and the formed parts 2 and 3 relative to the reinforcing structure 11 are each realized through the plug connections 12, 13 and 5, 6.

(19) Preferably, the formed parts 2 and 3 and if appropriate the reinforcing structure 11 are formed from an extruded metal profile as blank, in particular an extruded light metal profile as blank. Preferably, at least the formed parts 2 and 3 and if appropriate also the reinforcing structure 11 are brought into an end form by means of heat forming. For example, the tapered end portions 7 and 8 of the formed part 2 can be created through embossing by means of heat forming. A plug-in attachment 14 and 15 respectively provided on the formed parts 2 and 3 respectively for plugging into the reinforcing structure 11 can have been formed through heat forming, in particular embossing.

(20) Preferably, the tapered end portions 7 and 8 of the formed part 2 are each formed by a plug-in attachment 16 and 17 respectively, which has been produced by means of heat forming, in particular embossing. Preferably, the formed parts 2 and 3 are designed in such a manner and the plug-in attachments 14 and 15 on the formed parts 2 and 3 aligned in such a manner that the formed parts 2 and 3 and the reinforcing structure 11 together can be joined and exactly positioned through a single translational movement according to arrow 530.

(21) Preferably, the frame structure 1 comprises multiple connecting points 22, 23, 24, 25 and 26 for fastening function parts and/or attachment parts. At least one of the connecting points 20, 23, 24, 25, 26 can be created for this purpose by means of heat forming, for example in that the at least one connecting point 22, 23, 24, 25 and 26 is formed through embossing. The connecting points 22, 23, 24, 25 and 26 can be recesses, apertures, holes, beads and/or similar forms.

(22) FIG. 3 shows the frame structure 1 according to the FIGS. 1 and 2 with a crash reinforcement 110 mounted thereon. The crash reinforcement 110 serves for reinforcing the frame structure 1 in the event of a lateral crash and of a laterally offset front impact against a vehicle door or vehicle side door, on which the frame structure 1 is mounted. Preferably, the crash reinforcement 110 is connected on the one hand to the formed part 2 and on the other hand to the formed part 3, for example glued. For this purpose, a portion of the crash reinforcement 110 acts on the connecting point 22 on the one hand and another portion of the crash reinforcement 110 on the connecting point 25 of the frame structure 1.

(23) A glued connection of the crash reinforcement 110 to the frame structure 1 is preferable to avoid contact corrosion, provided the formed parts 2 and 3 of the frame structure are formed from a light metal and the crash reinforcement 110 from steel plate.

(24) In addition, the crash reinforcement 110 can have a structural connection 120 on the formed parts 2 and 3, for example be fastened by means of rivets or screws.

(25) Preferably, the crash reinforcement 110 is arranged on the edge region of the frame structure 1 facing outward, which in the state of the frame structure 1 on a vehicle door or vehicle side door faces the outside of the same. Preferably, the crash reinforcement 110 is arranged furthermore below the reinforcement structure 11.

(26) Preferably, the frame structure 1 together with the crash reinforcement 110 are jointly treated against corrosion, in particular rust formation, tier example primed, in particular dip-primed. For example, the crash reinforcement 110 is formed from a hot-formed material, which is a high strength or super high strength material.

(27) On the frame structure 1, a hinge part 130 can be mounted for example at the connecting point 26.

(28) FIG. 4 shows paneling parts for a vehicle side door. The paneling parts can comprise plastic material or consist thereof, wherein for example glass and/or carbon fiber can be additionally provided.

(29) The paneling parts are a door outer skin 140, a framework structure 150 and a window guide unit 160. The framework structure 150 comprises at least one flange 180, to which the door outer skin 140 is connected, for example connected by means of gluing and/or welding. The window guide unit 160 is fastened to the door outer skin 140 and/or to the framework structure 150.

(30) In the door outer skin 140 an aperture 190 can be provided, on which parts of a door handle or a door handle device can be mounted.

(31) FIGS. 5 and 6 show a vehicle side door 100 in a view onto its outside (FIG. 5) and in a view onto its inside (FIG. 6), wherein in the view onto the inside any inner paneling parts of the vehicle side door 100 have been omitted. As is evident from the FIGS. 5 and 6, the vehicle side door 100 comprises the frame structure 1 according to the FIGS. 1 and 2, which are assembled with the paneling parts according to FIG. 4. Preferably, the framework structure 140 is fastened to the frame structure 1.

(32) A possible embodiment of the fastening of the framework structure 150 to the frame structure 1 is evident from FIG. 7, which shows a sectional representation along the section line A-A according to FIG. 6. There, a side wall 230 is additionally hinted, on which the door in the closed state is sealed towards the interior via a door seal which is not shown.

(33) Preferably, an engagement connection 250 is provided for fastening the framework structure 150 to the frame structure 1, with a fastening strap 200 arranged on the framework structure 150, which with a lug engages into an aperture of the formed part 3 of the frame structure 1 subject to forming the engagement connection 250, which is evident in particular in the enlarged detail representation according to FIG. 8. For forming the engagement connection 250, the formed part 3 additionally supports itself with a portion of its wall against a wall portion 280 of the framework structure 150 preferentially projecting towards the front.

(34) A sealing element 170 can be provided or connected (FIG. 8) in between the wall portion 280 of the framework structure 150, which is brought to lie against the frame structure 1 or the formed part 3. The sealing element 170 is preloaded when it is pressed between the formed part 3 and the engagement connection 250 in the direction towards the wall portion 280.

(35) Preferably, the engagement connection 250 serves for pre-fixing the framework structure 150 relative to the frame structure 1. Preferably, a screw connection is additionally provided. The screw connection can be formed by a fastening element 270, which is formed for example in the manner of a fastening screw and engages through an aperture in the fastening strap 200 and an aperture in the formed part 3 and is screwed together against an insert nut 260 inserted into one of the apertures, so that through the interaction of the fastening element 270 and the insert nut 260 the additional connection between the framework structure 150 and the frame structure 1 is formed.

(36) As is evident in particular from the FIGS. 7 and 8, the door outer skin 140 is arranged relative to the framework structure 150 at least partially spaced so that between the opposite wall portions there is a gap 240. The connection of the door outer skin 140 to the framework structure 150 can then relate to a given number of contact surfaces, for example on the flanges 180 provided for this purpose. There, fastening of the door outer skin 140 to the framework structure 150 can be realized by means of a structural connection 220. There, the structural connection can be formed for example through gluing and/or welding, in particular friction welding. As is evident in particular also from the enlarged part representation of FIG. 9.

(37) Attachment parts or function parts of the vehicle side door 100 can be fastened to the frame structure 1 and/or the framework structure 150. For example, at least one lock part 210 can be connected to the frame structure 1, as is evident in particular from FIG. 6. In addition to this, attachment parts or function parts such as for example interior covering, a door handle, at least one loudspeaker, an electric window lifter or the like can be fastened to the framework structure 150 and/or the frame structure 1.

(38) Although the invention was described by means of at least one exemplary embodiment it is to be understood that there exist a multitude of versions. It should also be noted that the exemplary embodiment or the exemplary embodiments are only examples and not intended to restrict the scope of protection, the applicability or feasibility or the construction in any way. The above description provides the person skilled in the art with a suitable guideline for implementing or carrying out at least one embodiment; it is to be understood that various changes in the function and arrangement of elements or components, which are described above in at least one exemplary embodiment, can be made without deviating from the scope of protection of the following claims and their legal equivalents.