Abstract:
A vehicle component sub-assembly having self-aligning appropriately fitted structural members is disclosed wherein a closure member, such as a vehicle door, hood or trunk is integrated with and becomes a structural part of a vehicle body. The sub-assembly includes mating components wherein a first mating component is mounted to the vehicle body and a second mating component is mounted to the closure member in such a manner that the first and second mating components become substantially aligned and structurally engaged with one another. The first mating component includes at least one structural key member formed thereon and the second mating component has a complementary mating receptacle therein. When the first and second mating components are aligned into interlocking engagement, the structural key members and mating receptacles are thereby structurally integrating the vehicle body and the closure member. The structural key members and mating receptacles may be used with a number of vehicle component sub-assemblies such as door hinges and latches on doors; hoods, trunks, liftgates and deck lids.

Description:
FIELD OF THE INVENTION 
     The present invention relates to structurally integrating members between vehicle bodies and closures. More particularly, this invention is directed to self-aligning structural key members and mating receptacles incorporated with vehicle component sub-assemblies, such as hinges and latches, to structurally integrate vehicle closures with a vehicle body. 
     BACKGROUND OF THE INVENTION 
     While known conventional vehicle closure members, such as vehicle doors, are attached to a vehicle body, the closure members are not structurally integrated with the vehicle body. Consequently, the closure members, which are of considerable mass, are simply hanging on the vehicle body. Thus, stiffness and overall strength of the vehicle body is reduced, which results in a noticeable feeling to a vehicle occupant of shuddering and bouncy ride. Idle shake may also be experienced, along with an increase in noise and vibration, producing a poor ride and poor vehicle handling. Further, in the event of impact or collision with other vehicles, a non-integrated closure member can “pop out” from the vehicle body, or cave in, such that the closure member is separated from its attachment points. Separation of the closure member from the vehicle body causes loss of a significant amount of energy absorption that is necessary to protect the vehicle occupants from injury during a collision. 
     To address these problems, it has been previously proposed to structurally integrate a vehicle door with a vehicle body. The door and body integration technology as applied to vertically sliding doors is disclosed in the following U.S. Patents issued to John A. Townsend: U.S. Pat. No. 4,801,172 issued Jan. 31, 1989; U.S. Pat. No. 4,940,282 issued Jul. 10, 1990; U.S. Pat. No. 5,378,036 issued Jan. 3, 1995; and applied to a conventional hinged door in U.S. Pat. No. 5,806,917 issued Sep. 15, 1998. These disclosures are incorporated herein by reference. 
     In operation, when the vehicle doors of the above patents are closed, structural key members formed on the edges of the door engage with mating receptacles formed in the door jambs of the vehicle body that frame a door opening. In the engaged position, each key member and mating receptacle pair is able to transmit compressive, tensile and torsional forces between the door and the vehicle body, thereby contributing to the overall stiffness of the vehicle body. 
     However, with current technology precise manufacturing dimensional tolerances of a large closure member, such as the vehicle door, that incorporate the structural keys and receptacles are difficult to achieve such that when the vehicle door is aligned with the vehicle body by adjusting hinges and latches on the vehicle door and vehicle body, the keys and receptacles are not always properly aligned for mating engagement. To insure proper alignment of the keys and receptacles, it has been proposed to form the receptacles so as to be considerably larger than the keys. With such an arrangement, the keys could be loosely accommodated within the receptacles once the closure member had been adjusted into its correct position with respect to the vehicle body by means of the hinge and latch assemblies. Fast curing metallic epoxy resin was then applied to the inside of the receptacles and a resist compound to the keys. The closure member was then closed in its final adjustment position with reference to the vehicle body. After curing, the keys were mated precisely with the key impressions made in the resin within the receptacles. Once the keys and receptacles were properly aligned, the keys and receptacles provided an excellent structural link between the closure member and the vehicle body, due to the precise fit of the keys with the epoxy filled receptacle. 
     However, the addition of the epoxy resin to the receptacles required an additional alignment process on the production line, thereby disadvantageously increasing manufacturing time, which translates into increased costs. Further, as it is necessary to add the epoxy resin to the receptacles on the production line, the alignment of the structural keys and receptacles could not be performed by outside suppliers. 
     Another disadvantage associated with known structural keys and receptacles is that closure members and door jambs are traditionally manufactured by stamping metal of a constant gage, such that the thickness of the closure member and the door jamb are constant. Consequently, to successfully design the keys and receptacles into a closure member and vehicle body, the area around the keys and receptacles require considerable localized re-enforcing by adding additional metal of a heavier gage, thereby increasing production costs. 
     While prior art use of the closure member and vehicle body integration technology improves the structural integrity of the overall vehicle body structure, there are disadvantages with the known use of structural keys and mating receptacles. Therefore, there exists a need for improved structural integration of a vehicle closure member and vehicle body that eliminates special alignment and the reinforcing steps while introducing a new metal epoxy technology in the manufacturing process. 
     SUMMARY OF THE INVENTION 
     To achieve excellent structural integration of closure members and bodies while overcoming production difficulties, the present invention is directed to vehicle component sub-assemblies that incorporate self-aligning structural key members and mating receptacles. Hinges, latches and other vehicle components are provided with integral structural keys and receptacles such that the keys and receptacles are integrated with the hinges, latches, and strikers, as opposed to the closure member or body. 
     In accordance with one aspect of the invention, wedge-shaped structural key members and mating receptacles are manufactured as a precision fit integral with and during the same manufacturing operation as a door plate and mating body plate of a door hinge, respectively. Once formed the entire hinge sub-assembly is connected to the vehicle in a conventional manner by bolting the door plate to a closure member, such as a vehicle door, and the attached body plate to a vehicle body. The closure member and body plates are provided with traditional adjustment capability during assembly of the closure member to the vehicle body to insure their proper alignment. 
     The structural key members and mating receptacles may also be incorporated with other vehicle component sub-assemblies having mating parts such as brackets and door and hood latch sub-assemblies. For example, when the structural keys and receptacles are incorporated into latch and striker sub-assemblies, when a latch is in the correct location for mating engagement with a striker, the structural keys and receptacles formed thereon, will automatically be aligned to a precise fit. 
     The incorporation of the structural keys and receptacles with the vehicle component sub-assemblies provides important technical and manufacturing benefits over the prior art keys and receptacles. First, hinges, latches and strikers are traditionally manufactured in a heavier gage than the vehicle closure member and corresponding body structure. Therefore, the component sub-assemblies are sufficiently strong for the keys and receptacles cast therein to provided maximum structural integration of the vehicle closure member with the vehicle body without requiring any additional reinforcement. 
     Further, the manufacture of the structural keys and mating receptacles within the hinges, latches and bracket sub-assemblies is greatly simplified as compared to the prior art practice of manufacturing the structural keys and receptacles as part of the closure member and vehicle body as these component sub-assemblies are simple enough to allow for traditional tolerances that will permit the necessary precision fit of the structural keys to the mating receptacles. Because the hinges, latches and brackets sub-assemblies are usually either cast or forged, it is possible to form the structural keys and receptacles as large as may be necessary while maintaining desirable tight tolerances. Additionally, disadvantages such as warping and springback, that were previously associated with incorporating stamped keys and receptacles into large components, are eliminated, thus reduces dimensional variation. 
     Vehicle component sub-assemblies having the structural keys and mating receptacles of the present invention may also be easily incorporated to existing vehicle doors without necessitating re-design of the vehicle door or requiring a special alignment step in the manufacturing process by means of additional metal epoxy technology. Therefore, the component sub-assemblies may be manufactured at a separate facility by outside suppliers from the closure member and vehicle body, permitting “just-in-time” incorporation with the vehicle at final vehicle assembly and reducing costs associated with inventory control. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The features and inventive aspects of the present invention will become more apparent upon reading the following detailed description, claims, and drawings, of which the following is a brief description. 
     FIG. 1 is a perspective view of a vehicle door hinge sub-assembly incorporating a structural key member and a mating receptacle in accordance with the present invention. 
     FIGS. 2 and 3 are perspective views of alternative embodiments of the vehicle door hinge sub-assembly of FIG.  1 . 
     FIG. 4 is a perspective view of an alternative vehicle door hinge sub-assembly incorporating a structural key member and a mating receptacle in accordance with the present invention. 
     FIGS. 5 and 5A are perspective views of a door latch sub-assembly incorporating a structural key member that engages a mating receptacle in accordance with the present invention. 
     FIG. 6 is a perspective view of a door striker plate having a receptacle formed therein. 
     FIGS. 7-11 are perspective views of alternative embodiments of a door latch plate in accordance with the present invention. 
     FIGS. 12 and 12A are perspective views of a bracket sub-assembly incorporating structural key members that are engageable with mating receptacles in accordance with the present invention. 
     FIGS. 13-14 are perspective views of alternative embodiments of a sliding vehicle door utilizing the structural key members and mating receptacles of the present invention. 
     FIG. 15 is a perspective view of a vehicle hood latch sub-assembly incorporating the structural keys and mating receptacles in accordance with the present invention. 
     FIGS. 16 and 17 are perspective views of alternative embodiments of a hood or trunk latch plate. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The following figures depict various mating vehicle component sub-assemblies used to integrate a vehicle door to a vehicle body. The door and body integration technology serves to transmit compressive, tensile and shear forces between the vehicle door and the vehicle body with only a minimal amount of modification to an existing vehicle door. Referring to FIG. 1, a first embodiment of the present invention is shown applied to a conventional door hinge sub-assembly  10 . Door hinge  10  has a door plate  12  and a mating body plate  14 . Door plate  12  is pivotally connected to body plate  14  by a pin  16  that extends through sleeves  18  and  20 , of door and body plates  12  and  14 , respectively. 
     In accordance with the invention, the door plate  12  is provided with a structural key member  22  that extends laterally from a front surface  24  of door plate  12 . In a preferred embodiment, structural key member  22  is integral with door plate  12  and has a base portion  26  that narrows to an apex  28 , such that structural key member  22  is generally wedged-shaped. Body plate  14  is provided with a generally wedge-shaped mating receptacle  30  for complementary engagement with structural key member  22  when the door is closed such that compressive, tensile and torsional forces may be transmitted between the door and the vehicle body to provide a structurally stiffer vehicle. While the wedge shape is preferred, other shapes may be employed, as long as the shape of structural key member  22  is complimentary and appropriately fitted with receptacle  30 . Preferably, receptacle  30  is formed integral with body plate  14 . To insure proper fit between structural key member  22  and receptacle  30 , either structural key member  22 , receptacle  30  or both, may optionally be coated with an elastomeric material to provide a tight seal therebetween when the vehicle door is closed. 
     In an alternative embodiment, illustrated in FIG. 2, door plate  12  and body plate  14  are provided with a plurality of structural key members  22  and mating receptacles  30 , respectively. Further, the configurations of door plate  12  and body plate  14  may be reversed such that door plate  12  is provided with mating receptacles  30  that extend below front surface  24  and body plate  14  includes structural key members  22  that extend away from a front surface  31  of body plate  14  as seen in FIG.  3 . It is also within the scope of the invention that door plate  12  and body plate  14  have both structural key members that engage mating receptacles  30  on the other plate, respectively (not shown). 
     For structural key member  22  to precisely mate with the receptacle  30  an arc like shape is preferred to follow the mating trajectory of the closing components during opening and closing. FIGS. 2 and 3 demonstrate the curvature of the keys and receptacles to form the proper mating trajectory that facilitates a smooth and precise mating of these components in combination with the overall closure components to which they are attached. 
     To mount door hinge  10  to a vehicle door, a back surface  32  of door plate  12  is secured to a vehicle door by traditional fasteners or other suitable means. Body plate  14  is preferably secured to a vehicle body by conventional fasteners  34 , such as bolts, in a manner so as insure that body plate  14  will be substantially aligned with door plate  12 . Because structural key members  22  and mating receptacles  30  are formed on door hinge  10  components  12  and  14 , respectively, the alignment of door plate  12  and body plate  14  serve to automatically align structural key members  22  with mating receptacles  30 . 
     The depth of receptacle  30  typically exceeds the thickness of body plate  14 . Therefore, it may be necessary to provide a small cut-out on the vehicle body corresponding to the size of receptacle  30 . Generally, the cut-out will be slightly larger to permit appropriate positioning of door hinge  10  components  12  and  14  with respect to the vehicle door. Alternatively, structural key members  22  may have a reduced height and mating receptacles  30  a reduced depth such that body plate  14  may be provided with a substantially planar back surface, thereby eliminating the need for a providing a cut-out on the vehicle body. 
     In accordance with another aspect of the invention, following traditional process alignment of the vehicle door with the vehicle body, body plate  14  may be provided with elongated slots  36  for receiving bolts, whereby body plate  14  would be axially adjustable. 
     The door hinge  10  may be formed as a sheet metal stamping, such that the structural key member  22  and mating receptacle  30  may be integrally formed in the same operation as the door hinge  10 , thereby reducing manufacturing costs. Alternatively, door hinge  10  may be cast or forged with the integral structural key members  22  and mating receptacles  30  formed thereon, thereby making a stronger door hinge  10 , and thus a stronger structural connection between structural key members  22  and mating receptacles  30 . 
     Other advantages of providing door hinge  10  with structural key member  22  and mating receptacle  30  include manufacturing of door hinge  10  at a separate facility, permitting “just-in-time” incorporation with the vehicle door at the vehicle assembly line. Thus inventory control costs and costs associated with storage may be reduced. Further, as structural keys  22  and receptacles  30  are provided on door plate  12  and body plate  14 , respectively, there is no need to re-design the vehicle door or alter the body structure of the vehicle body to insure the proper strength reinforcement of structural key members  22  and mating receptacles  30 . Thus, manufacturing costs are reduced and incorporation of structural key members  22  and mating receptacles  30  on existing vehicle doors may be accomplished easily. 
     FIG. 4 depicts an alternative door hinge  100  having a door plate  112  and a body plate  114  pivotally connected together once properly aligned. Body plate  114  is L-shaped and includes a substantially planar mounting surface  116  that is configured to engage a portion of a vehicle body. Mounting surface  116  is provided with conventional oversize apertures  118  for receiving fasteners, such as bolts for fixedly securing and adjusting body plate  114  to the vehicle body. Alternatively, body plate  114  may be welded to the vehicle body or attached by other suitable means. Aligned legs  119  extend away from mounting surface  116  and include apertures  120 , to be explained in further detail below. 
     In accordance with the present invention, a front surface  121  of body plate  114  is provided with a structural key member  122  extending therefrom. Structural key member  122  is slightly angled and curved relative to body plate  114 , to be explained below, and has a rectangular cross-section. Other suitable shapes may be employed for structural key member  122 . 
     Door plate  112  includes a mounting portion  124  and a bracket portion  126 . Mounting portion  124  has a substantially planar mounting surface  128  that is configured to engage a portion of a vehicle door. Apertures  130  are provided in mounting portion  124  for receiving fasteners, such as bolts, to adjust and fixedly secure door plate  112  to a vehicle door. Bracket portion  126  is connected to mounting portion  124  by webs  132 . Bracket portion  126  includes an axially extending aperture (not shown) that corresponds an apertures  120  on body plate  114  for receiving a pin (not shown) in a conventional manner to pivotally connect door plate  112  and body plate  114 . 
     In accordance with the invention, bracket portion  126  further includes a receptacle  134  formed therein that has a size and shape that corresponds to the size and shape of structural key member  122 . Thus, when the vehicle door is closed, structural key member  122  engages receptacle  134 , similar to that of door hinge  10 , such that compressive, tensile and torsional forces may be transmitted between the door and the vehicle body, thereby providing a structurally stronger vehicle. 
     Door hinge  100  may be directly mounted to a vehicle without requiring any additional modifications to the vehicle. Unlike door hinge  10 , there is no need for the vehicle door or body to be provided with an additional cut-out as receptacle  134  is formed in the bracket portion  126 . Thus, incorporation of door hinge  100  as a “just-in-time” component to an existing vehicle door and body may be accomplished cost-efficiently with a minimum of production steps. Further, in accordance with the present invention, pre-alignment of structural key member  122  and mating receptacle  134  during manufacturing is not disturbed by virtue of the alignment of door plate  112  and body plate  114 . 
     While use of the structural key members  22 ,  122  and mating receptacles  30 ,  134  have thus far been described for use with vehicle door hinges, the inventive technology may also be utilized with other vehicle component parts, as well. Referring to FIG. 5, in an alternative embodiment a vehicle door  200  is shown having a door latch sub-assembly  202  that includes a door latch plate  204  and a mating door striker plate  206 . Door latch plate  204 , as more clearly seen in FIG. 5A, is shown mounted on a trailing edge  208  of vehicle door  200 . Door latch plate  204  has an L-shaped cross-section with a first leg  210  and a second leg  212 . First leg  212  is mounted to an outside surface  214  of trailing edge  208  and second leg  212  is mounted to an inside surface  216  of trailing edge  212 . Door latch plate  204  may be mounted by welding or conventional fasteners, such as bolts. Door latch plate  204  carries at least one conventional door latch  220 . In accordance with the invention, door latch plate  204  further includes at least one structural key member  228  formed thereon extending laterally from a front surface  229  of second leg  212 . 
     Door striker plate  206 , as more clearly seen in FIG. 6, is mounted along an inside surface  230  of a door jamb (not shown) of a vehicle body by welding or conventional fasteners so as to be aligned with door latch plate  204 . Door striker plate  206 , includes a least one bar  232  that is captured by door latch  220  in a conventional manner. In accordance with the present invention, door striker plate  206  further includes a receptacle  240  that has a size and shape that corresponds to structural key member  228 . 
     Because door latch plate  204  and door striker plate  206  are pre-aligned during manufacture and properly mated, using traditional door adjustment and assembly techniques, when vehicle door  200  is closed, bars  232  extend into and are captured by door latch  220 . Simultaneously, structural key member  228  extends into mating receptacle  240 , thereby structurally integrating the door and the vehicle body via the door latch sub-assembly  202 . The incorporation of structural key member  228  and mating receptacle  240  with door latch assembly  202  further insure that door latch  220  will remain secured to bar  232  in the event of a collision. 
     While only one structural key member  228  has been shown formed on door latch plate  204  and one mating receptacle  240  has been shown formed in door striker plate  206 , alternatively, door latch plate  204  may have multiple structural key members  228  formed thereon, as seen in FIGS. 7 and 7A. Further, door latch plate  204  may be of varying lengths to properly accommodate a predetermined number of structural key members  228  formed thereon. Similarly, door striker plate  206  may be provided with multiple receptacles  240  corresponding to the number of structural key members  228 . 
     Preferably, either door latch plate  204  or door striker plate  206  is provided with a traditional adjustability feature, similar to that described with respect to door hinge  10 . Referring to FIG. 7A, front surface of door latch plate  204  is shown having bolt slots  222  formed therein for receiving a bolt  224 , such that door latch plate  204  may be axially slidable to insure proper alignment of door latch  220  with the striker. 
     Referring to FIGS. 8-9A, structural key members  328  may optionally have alternative orientations and shapes. For example, FIG. 8 shows structural key members  328  formed so as to be laterally extending from front surface  329  of door latch plate  304  at a predetermined angle. Corresponding receptacles (not shown) would similarly angled in the door striker plate (not shown) such that structural key members  328  would interlock with the angled receptacles. FIG. 9 shows structural key members  428  formed in door latch plate  404 , wherein structural key members  428  are formed so as to be curved with a predetermined radius. Corresponding receptacles (not shown) would be formed so as to be curved such that structural key members  428  will interlock with the receptacles when door  400  is closed, thereby integrating the vehicle door with the vehicle body via the door latch assembly as described above. 
     Further, structural key member  228  and receptacles  240  may be interchanged. For example, referring to FIGS. 10 and 10A, door latch plate  504  may be provided with receptacles  540  and door striker plate  506  provided with structural key members  528 . Alternatively, door latch plate  504  and door striker plate  506  may both be provided with a structural key member and a mating receptacle (not shown). 
     Referring to FIGS. 11-11D, in another alternative embodiment, multiple door latch plates  604 , each incorporating at least one structural key member  628  and corresponding mating door striker plates  606  each incorporating at least one mating receptacle  640  therein are shown mounted on leading edge  608  of vehicle door  600  and door jam  630  of a vehicle body, respectively. In accordance with the present invention, once door latch plate  604  is properly positioned on door  600  so as to align with mating striker plate  606 ; structural key members  628  are automatically aligned with mating receptacles  640 . 
     Referring to FIGS. 12 and 12A, structural key members  728  may alternatively be provided on brackets  704  that are mounted on a trailing edge  708  of a vehicle door  700 . The use of brackets  704  is useful as an after-market product when it is desired to integrate an existing vehicle door  700  with a vehicle body. Brackets  704  may be mounted to vehicle door  700  by welding or conventional fasteners. Preferably, brackets  704  are provided with adjustment slots similar to slots  36  described in connection with door hinge such that the positioning of bracket  704  is axially adjustable to mate up with a corresponding mating bracket (not shown) mounted on the vehicle body. 
     Similar to door latch plate  204  in FIG. 5, bracket  704  preferably has an L-shaped cross section that engages both surfaces adjacent trailing edge  708  of vehicle door  700 . Integral with a first leg  712  is at least one structural key member  728 . Structural key members  728  are shown as being generally wedge-shaped, although other suitable shapes are within the scope of the invention, as discussed above. A second corresponding mating bracket (not shown) is mounted to a door jam of the vehicle body so as to be in substantial alignment with bracket  704  in a similar fashion as door striker plate  206  in FIG. 5, wherein the second bracket includes at least one receptacle that corresponds in size and shape to structural key member  728 . Thus, when vehicle door  700  is closed, structural key members  704  interlock with the corresponding receptacles to structurally integrate vehicle door  700  and the vehicle body in accordance with the present invention. 
     Referring to FIGS. 13 and 14, the present invention may also be incorporated with sliding vehicle doors  800 . In FIG. 13, vehicle door  800  is provided with a door latch plate  804  mounted along an inside trailing edge  808  and a door striker plate (not shown) mounted on the door jam of the vehicle body so as to be substantially aligned with door latch plate  804 . Door latch plate  804  carries a door latch  820  that captures an engagement member  836  of the door striker plate in a conventional manner when vehicle door  800  is closed. In accordance with the present invention, door latch plate  804  further includes at least one structural key member  828  formed thereon. Structural key members  828  are engagable with mating receptacles  840  formed on the door striker plate when vehicle door  800  is closed. Due to the path of vehicle door  800 , structural key members  828  are curved to insure proper engagement with receptacles  840 . Alternatively, referring to FIG. 14, the positions of structural key members  828  may be reversed such that structural key members  828  are connected to the vehicle body and the mating receptacles  840  are carried by vehicle door  800 . Further, structural key members  828  and receptacles  840  may optionally be integrally formed with vehicle door  800  and the door jam, respectively. 
     Referring to FIGS. 15-17, in another alternative embodiment, structural key members  928  and mating receptacles  940  are shown incorporated with hood latch assemblies  902  for a vehicle hood  900 . Referring to FIG. 15, vehicle hood  900  is provided with a hood striker plate  906  mounted thereon (as best seen in FIG.  16 ), having an engaging member  936  that generally corresponds to door striker plate  206  and engaging member  236  in FIG.  5 . The vehicle body  901  is provided with a hood latch plate  904  mounted thereon that aligns and engages with hood striker plate  906 . Hood latch plate has a latch  920  that generally corresponds to door latch plate  204  and door latch  220  in FIG.  5 . 
     In accordance with the present invention, hood latch plate  904  further includes at least one structural key member  928  formed and pre-aligned during manufacture to engage at least one mating receptacle  940  formed in hood striker plate  906 . Because hood latch plate  904  is positioned in traditional manner during assembly so as to align with hood striker plate  906 , structural key member  928  and receptacle  940  are automatically aligned in accordance with the present invention. 
     When vehicle hood  900  is closed and hood latch  920  captures bar  932  in a conventional manner and structural key member  928  engages with mating receptacle  940 , thereby structurally integrating vehicle hood  900  with vehicle body  901 . Referring to FIG. 17, hood latch plate  904  may alternatively be formed with receptacles  940   a  that engage structural key members formed in the hood striker plate. Additionally, the structural key members may be formed with a plurality of different shapes, sizes and orientations, provided that receptacles  940   a  have a corresponding shape, size and orientation. 
     Additional embodiments of the present invention include incorporating structural key members and mating receptacles with sunroofs, trunks, etc. 
     Preferred embodiments of the present invention have been disclosed. A person of ordinary skill in the art would realize, however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.