Vehicle door and method for the production thereof

Abstract

A motor vehicle door and a method for producing the motor vehicle door is disclosed having a frame plate coupled to reinforcement components and at least half of all of the reinforcement components are produced as extruded profiles which are subsequently press-formed three-dimensionally. The extruded profiles have different wall thicknesses.

Claims

1. A method for producing a motor vehicle door, comprising: providing a motor vehicle door frame plate, wherein the door frame plate is press-formed from a light metal alloy; extruding a profile from an aluminum alloy, wherein the extruded profile has different wall thicknesses in a longitudinal direction and/or in a transverse direction; cutting the extruded profile at a first length to form individual extruded profile pieces; press forming of the extruded profile piece in a three-dimensional manner to form a reinforcement component for reinforcing a region of the motor vehicle door frame plate; stamping the reinforcement component; perforating the stamped reinforcement component; and, coupling the at least one reinforcement component to the motor vehicle door frame plate.

2. The method of claim 1, further comprising annealing the extruded profile pieces.

3. The method of claim 2, further comprising quenching said extruded profile pieces.

4. The method of claim 3, wherein the quenched extruded profile pieces are artificially or naturally aged.

5. The method of claim 1, further comprising welding said at least one reinforcement component to said vehicle door frame.

6. The method of claim 1, wherein the at least one reinforcement component is riveted to the vehicle door frame plate.

7. The method of claim 1, further comprising coupling the at least one reinforcement component to the motor vehicle door frame plate at two regions and creating a hollow space between the at least one reinforcement component and the motor vehicle door frame plate.

8. The method of claim 1, further comprising providing a Y-shaped door impact support having a base portion and two bifurcating arms extending therefrom.

9. The method of claim 8, wherein each bifurcating arm includes an end, and wherein the ends are flattened.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantages, features, properties and aspects of the present invention form the subject-matter of the following description. Preferred variants are shown in the schematic drawings. These drawings serve for easy understanding of the invention. In the drawings:

(2) FIG. 1 shows a motor vehicle door according to the invention in a side view,

(3) FIG. 2 shows a beltline reinforcement according to the invention in a perspective view,

(4) FIG. 3 shows a front view of the door without the window frame,

(5) FIG. 4 shows a perspective view of a sill reinforcement profile,

(6) FIGS. 5a and 5b show a door hinge reinforcement in a sectional view from above and a perspective rear view,

(7) FIG. 6 shows a mirror reinforcement in a perspective view,

(8) FIG. 7 shows a window frame reinforcement in a perspective view,

(9) FIG. 8 shows a lock reinforcement according to the invention in a perspective view and

(10) FIG. 9 shows a door impact support according to the invention with cutting lines and cross-sectional views.

(11) The same reference numerals are used for the same or similar components in the figures, even if a repeated description is dispensed with for reasons of simplification.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(12) FIG. 1 shows a motor vehicle door 1 according to the invention which represents a frame plate 2, illustrated here with the window frame 3 in position. The frame plate 2 is in this case configured to extend in a peripheral manner and has a lower sill region 4, an upper beltline region 5 on the lower side of the window pane, not shown in more detail, a rear lock region 6 which, for example in a front door, comes to bear in the region of the B-pillar and a front hinge region 7 which, in a front door, in turn comes to bear against the A-pillar. In this case, the frame plate 2 is configured in turn as a sheet metal component made in one piece and of the same material. This may either form the window frame, by being shaped in one piece and in the same material and being coupled to the window frame reinforcement 21 shown in FIG. 7, or the window frame reinforcement 21 may also directly form the window frame. This is coupled in the known manner, not shown in more detail here, to the frame plate 2, thus to the lower door portion.

(13) The frame plate 2 has a window pane frame made in one piece and of the same material.

(14) FIG. 3 additionally shows a side view without the window frame, in which additionally an inner panel 8 and an outer panel 9 are placed on the frame plate 2. In the inner panel 8, for example, a loud speaker recess 10 is present and the outer panel 9 forms as it were the outer skin 11 of the motor vehicle.

(15) So that the frame plate 2 now fulfills sufficient requirements for rigidity and has sufficient rigidity, it is coupled to reinforcement components. Firstly in the beltline region 5 a beltline reinforcement 12 is shown in FIG. 2. The beltline reinforcement 12 in this case has different wall thicknesses w1, w4, wherein the wall thickness is able to be formed individually by producing the extruded profile. The beltline reinforcement 12, in this case relative to FIG. 1, may cover the same length L of the door or only a partial region. The beltline reinforcement 12 according to the invention is shown here as a hollow chamber profile, in particular a two-chamber hollow profile, with an additional partially open chamber protruding upwardly in the motor vehicle vertical direction.

(16) For example, a door lining and a window frame seal may be received thereby. By means of the individual chambers a high degree of rigidity with a low dead weight is in turn provided. Moreover, the beltline reinforcement has an opening 13 for coupling, for example, to the frame plate 2 by means of a riveted or screw connection or to further attached parts, for example for screwing a door lining, not shown in more detail, or a mirror, not shown in more detail, in the front region of the door. The beltline reinforcement 12 is initially produced from an extruded profile and subsequently three-dimensionally press-formed so that it follows a slight curvature extending in the longitudinal direction L of the door.

(17) Moreover, the door has a sill reinforcement 14 shown in FIG. 4. The sill reinforcement 14 in this case is in the form of a reinforcing strip which in turn has an S-shaped cross section. To this end, reinforcing beads 15 extending in the motor vehicle transverse direction are incorporated, said reinforcing beads ensuring additional reinforcement and crash protection in the motor vehicle transverse direction. Furthermore, the sill reinforcement 14 in this case has been produced as an extruded component and additionally three-dimensionally stamped, in particular by press forming, so that it is adapted to the contour of the sill region 4 of the frame plate 2 according to the invention and at the same time by means of the stamped-out portion comes to bear on the frame plate 2, forming a plurality of hollow chambers. For example, the sill reinforcement 14 may be bonded to the frame plate 2, in particular onto the inner face of the frame plate 2. The stamped portions may also be configured in the form of shaped portions. In cooperation with the frame plate 2, therefore, hollow chambers are formed, said hollow chambers significantly increasing the rigidity of the motor vehicle door 1 produced thereby.

(18) A hinge reinforcement 16 which is also coupled to an outer face 17 of the frame plate 2 is shown in FIGS. 5a and b. The hinge reinforcement 16 in this case is also produced as an extruded component which subsequently is three-dimensionally shaped and stamped and in this case for receiving a hinge, not shown in more detail. According to the invention the hinge reinforcement 16 has different wall thicknesses, in this case by way of example the wall thicknesses w1 to w4, according to which the wall thickness w1 is smaller than the wall thickness w2, smaller than the wall thickness w3 and smaller than the wall thickness w4. As a result, the required loads may be individually catered for with optimal use of the weight. Moreover, the hinge reinforcement 16 has a shaped portion 18, for example in the form of a collar which has been punched through. This applies in turn to the production of a bearing contact with the frame plate 2 and/or to the formation of different hollow chambers.

(19) Moreover, in FIG. 6 a mirror reinforcement 19 is shown, wherein the mirror reinforcement 19 also has different individual wall thicknesses. Moreover, the mirror reinforcement 19 has mounting openings 20 so that a mirror triangle or even an external mirror may be screwed thereto, and/or corresponding cable leads are able to be passed therethrough.

(20) A cross section of the window frame reinforcement 21 is also shown in FIG. 7, said window frame reinforcement being configured as a hollow chamber profile which is P-shaped in cross section. It is also possible here to produce different wall thicknesses w1, w2 by means of the extrusion method as well as an individual outer contour and or shaping by subsequent three-dimensional shaping, in particular in the form of bending or press forming.

(21) In FIG. 8, a lock reinforcement 22 is also shown, said lock reinforcement also being configured as an extruded component which is configured so as to be S-shaped in cross section. In particular, this has been stamped out so that corresponding receiver openings 23 and openings 23 and through-openings 24 are present for a corresponding door lock.

(22) Finally in FIG. 9, a door impact support 25 is shown according to the invention. The door impact support 25 in this case has a Y-shaped contour in its longitudinal direction 26. The Y-shaped contour has in this case two arms 27 for forming the Y-shaped birfurcation and from the bifurcation point of the Y-shape a base 29 extending via the central portion 28. The ends 30 of the arms 27 and the end 31 of the base 29 are in each case configured so as to be flattened in cross section, which is shown along the cutting lines D-D and E-E. The arms 27 in turn are shown in the cutting line A-A and in each case configured as a single-chamber hollow profile. In the central portion 28, the cross-sectional profile has a three-chamber hollow profile along the cutting line B-B.

(23) For producing the door impact support 25 according to the invention, initially an extruded profile is provided with three hollow chambers. This extruded profile has different wall thicknesses w1, w2. The central chamber 32 is then incised along a length 33 which corresponds to the length of the subsequent arms 27. The arms 27 are then bent apart from one another and, after being bent apart, particularly preferably the bent blank thus produced is three-dimensionally press-formed. In this case it is achieved, amongst other things, that the cross section is altered along the cutting line C-C. Furthermore, the cross section according to the cutting line C-C may already serve as an initial profile and then the cutting line B-B in cross section may be produced by corresponding three-dimensional press forming. Thus the door impact support 25 may be optimally adapted to the required contour and the curvature path of the motor vehicle door 1. The respective ends 30, 31 are then flattened and/or pressed together or obliquely cut to length and may preferably be perforated, not shown in more detail here by way of example, so that a through-opening for a screw connection is possible.

LIST OF REFERENCE NUMERALS

(24) 1Motor vehicle door 2Frame plate 3Window frame 4Sill region 5Beltline region 6Lock region 7Hinge region 8Inner panel 9Outer panel 10Recess for loudspeaker 11Outer skin 12Beltline reinforcement 13Opening 14Sill reinforcement 15Reinforcement bead of 14 16Hinge reinforcement 17Outer face of 2 18Shaped portion 19Mirror reinforcement 20Opening 21Window frame reinforcement 22Lock reinforcement 23Opening 24Through-opening 25Door impact support 26Longitudinal direction of 25 27Arm 28Central portion 29Base 30End of 27 31End of 29 32Central chamber 33Length of 27 LLength of YMotor vehicle transverse direction w1Wall thickness w2Wall thickness w3Wall thickness w4Wall thickness XMotor vehicle X-direction ZMotor vehicle Z-direction