Patent ID: 9352388
Filing Date: 2016-05-31
CPC Classification: B22C,B22D,B60J

Claim Text:
1. A method for die casting an inner door panel for a vehicle side door, said method comprising: providing a die cast mold including a first mold half and a second mold half each including a cavity that combine to provide a mold cavity, said mold cavity being configured to form the inner door panel and a runner and gating system; providing a molten metal to the mold cavity so that the molten metal flows into all areas of the mold cavity; and removing a solidified molded part including the inner door panel and the runner and gating system from the die cast mold, said inner door panel including an outer frame provided substantially along a first plane, said outer frame including a top rail, a bottom rail, an inner side rail and an outer side rail defining a central opening, said inner door panel further including an impact beam having a main beam portion, a first end support portion and a second end support portion, said first end support portion being formed to the inner side rail and the second end support portion being formed to the outer side rail where the main beam portion extends across the opening, said impact beam being provided substantially along a second plane separate from the first plane, and where the inner side rail includes an upper portion, a lower portion and a vertical wall coupled thereto, said first support end of the impact beam being configured to conform to the vertical wall and the lower portion.