Abstract:
In accordance with the teachings of the present invention, a method for producing a vehicle door is disclosed. Interior door components such as a window lift mechanism, a lock assembly, and a horizontal energy absorbing member are coupled to a door substructure. A finished exterior door panel having a class-A surface is adhesively bonded to the substructure, disposing the door interior components between the finished exterior door panel and a portion of the door substructure. The assembled door is coupled to a previously painted vehicle body.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention of relates to a vehicle door and more particularly to a method of manufacturing a vehicle door which reduces assembly time and complexity.  
         BACKGROUND OF THE INVENTION  
         [0002]    Traditionally, vehicle-manufacturing techniques have required that a vehicle door must be assembled before a vehicle has been painted. In this regard, a door substructure with depending door exterior is coupled to a vehicle via a pair of hinges. While the body of a vehicle is being coated with various layers, the door is also coated. During the painting operation, the door must be opened and closed by rotation about the coupling hinge to insure proper painting of the door and vehicle body. Those skilled in the art will recognize these operations significantly increase the complexity of robotic painting systems and their associated paint paths and therefore increase manufacturing time and costs.  
           [0003]    After the door and body have been painted, mechanisms related to the functioning of an assembled door must be coupled to the door substructure and exterior surface. Traditionally the painted door is rotated about its hinges and interior door components are inserted into the door substructure through access holes within the door substructure. The time needed for incorporation of the internal door components, such as window lift mechanisms, lock mechanisms and restraint mechanisms, significantly increases manufacturing time and therefore costs. After incorporation of the internal door components, the vehicles interior trim components are then coupled to the door substructure&#39;s interior surface to cover the door substructure. At this point, the assembled door&#39;s alignment must be adjusted to insure proper fit and finish to the assembled vehicle body.  
           [0004]    What is needed then is a door assembly and associated method for producing a vehicle door which does not suffer from the above-mentioned disadvantages. This in turn, will provide a door assembly which is inexpensive and easily manufactured and increases the overall flexibility for a vehicle&#39;s design and component incorporation. It is, therefore, an object of the present invention to provide such a vehicle door and associated method for producing a vehicle door.  
         SUMMARY OF THE INVENTION  
         [0005]    In accordance with the teachings of the present invention, a method of manufacturing a vehicle door is disclosed. The method includes providing a door substructure with a finished exterior door panel. At least one interior door component is coupled to the door substructure. After the interior door components have been coupled to the door substructure, the finished exterior door panel is coupled to the door substructure disposing the interior components between finished exterior door panel and the door substructure.  
           [0006]    In other embodiment of the present invention, a method of manufacturing a door is disclosed. A plurality of interior door components are coupled to a door substructure. A finished exterior door panel having a class-A surface is adhesively bonded to the substructure, disposing the interior door components between the finished exterior door panel and the door substructure.  
           [0007]    In another embodiment of the present invention, a method for manufacturing a vehicle is disclosed. An assembled door is first produced by coupling at least one interior door component to a vehicle door substructure. A finished exterior door panel having a class-A finish is coupled to the door substructure. The assembled door is then coupled to the finished vehicle. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    Still other advantages of the present invention will become apparent to those skilled in the art after reading the following specification and by reference to the drawings in which:  
         [0009]    [0009]FIGS. 1 and 2 represent exploded views showing the door assembly process for producing doors according to the teachings of the present invention;  
         [0010]    [0010]FIGS. 3 and 4 represent perspective views of front and rear doors manufactured according to the teachings of the present invention; and  
         [0011]    [0011]FIGS. 5 and 6 represent across sectional views of doors produced according to the teachings of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0012]    [0012]FIGS. 1 and 2 represent exploded perspective views of the assembly of front and rear doors according to the teachings of the present invention. Shown is a horizontal assembly fixture  10 . Disposed upon assembly fixture jigs  12  and  14  is a vehicle door substructure  16  and mating exterior door panel  18 . The door substructure  16  has a frame portion  19  and a window frame portion  20 . Disposed within the frame portion  19  is the inner door component support structure  22 , which is incorporated onto a frame interior surface  24 . The component support structure  22  has a plurality of mounting points  26 , which can take a form of threaded fasteners (either male or female) or apertures configured to accept snap fit components such as pine-tree fasteners.  
         [0013]    The mounting points  26  are used to couple interior door components  28  to the door substructure  16 . In this regard, the interior door components  28  can be, but are not limited to, a window lift mechanism  30 , a lock assembly  32 , a horizontal energy absorbing member  34 , an exterior door panel coupling member  36 , or inflatable safety restraint (not shown). Additionally, the frame portion  19  has exteriorly positioned apertures  38 , which are used to couple a door hinges  40  and support brackets  41  to the door substructure  16 .  
         [0014]    It is envisioned that the vehicle door substructure  16  is formed either of stamped steel or is a reinforced polymer composite. As a polymer composite, the door substructure  16  can have either a reinforced thermoset or thermoformed matrix, reinforced with chopped or continuous fibers. The fibers can be formed of glass, carbon, or polyamide materials or mixtures thereof. Additionally, the vehicle door substrate can be formed of a reinforced polymer having a layer of gel coat, one layer of barrier coat and one layer of chopped fiber reinforcement. The use of a polymer door substructure  16  allows for the production of a door having a finished preformed interior trim surface. This design further allows for significant advantages with respect to inhibiting water and sound permeation into a vehicles passenger compartment. It however affords a disadvantage with respect to the repair of interior door components  28  within the door. As a result, prior to the mounting the interior door components  28  to the door substructure  16 , repair access holes  43  should be incorporated into or defined in the inner door component support structure  22 . These access holes should be covered by an interior trim panel  45  disposed on the inner surface  47  of the door substructure  16 .  
         [0015]    Additionally shown is the window  42  which is formed by first and second window sub-assemblies  44  and  46 . The first window sub-assembly  44  is a component formed of glass or a transparent polymer material that is fixably mounted into the window frame portion  20 . Additionally, the first window sub-assembly  44  is a generally U-shaped component having a generally convex surface  48  which conforms to the shape of the outside of the vehicle. The inside periphery  50  of the first window sub-assembly  44  is lined with an elastomeric seal  52 , which is used to seal the exterior periphery  54  of the second window sub-assembly  46  to the first window sub-assembly  44 .  
         [0016]    In this regard, the second window sub-assembly  46  is generally planar, so that it can be used on either the left or right side of the vehicle. The second window sub-assembly  46  is slidably coupled to the door substructure  16  using window lift mechanisms  30 . While the window lift mechanisms  30  is shown having a hand crank  56 , those skilled in the art will recognize that it is possible to utilize an electronically controlled and driven lift mechanisms.  
         [0017]    In having the door assembled on the fixture  10  as opposed to onto a door coupled to a vehicle, it is possible to quickly insert the interior door components  28  onto the component support structure  22 . While it is envisioned that the interior door components  28  will be coupled to the door substructure  16  manually, the methods disclosed herein allow for a robotic insertion system to be used to insert and couple the interior door components  28  to the component support structure  22 .  
         [0018]    After the interior door components  28  have been fastened to the door substructure  16 , the exterior door panel  18  is coupled the door substructure  16 . The exterior door panel  18  can be coupled to the door substructure  16  utilizing standard threaded fasteners, snap-in fasteners or appropriate adhesives.  
         [0019]    In this regard, the exterior door panel  18  is a finished component, which has a class-A finished surface. Because of this, the exterior door panel  18  does not need post assembly coating or surface treatments. It is preferred that the exterior door panel  18  be a reinforced polymer structure which is coated utilizing sprayed top and base coats, or in mold or vacuum applied thin film layers. The sprayed base coat can be a water based base coat or a solvent based base coat, while the sprayed top coat can be an alkyd finish, polyester finish, thermosetting acrylic finish, or thermoplastic acrylic finish.  
         [0020]    [0020]FIGS. 3 and 4 represent perspective views of front and rear doors manufactured according to the teachings of the present invention. Shown is the window  42  formed by first and second window sub-assemblies  44  and  46 . The first window sub-assembly  44  is coupled to the door assembly along window frame portion  20 . The second window sub-assembly  46  is shown disposed between the exterior door panel  18  and the door substructure  16 .  
         [0021]    [0021]FIGS. 5 and 6 represent cross-sectional views of left and right doors produced according to the teachings of the present invention. Shown is the relationship of the exterior door panel  18  to the door substructure  16 . As can be seen the exterior door panel  18  and the door substructure  16  define and interior cavity  58  which surround the interior door components  28 .  
         [0022]    The assembled vehicle door is produced by first coupling the door substructure  16  to the fixture jigs  12  and  14  of horizontal assembly fixture  10 . Interior door components  28  are coupled to the inner door component support structure  22 . These interior door components  28  can contain some or all of the components needed for the proper functioning of the door. The first window subassembly is coupled to the window frame portion  20  of the door substructure  16 , while the second window subassembly  46  is disposed within the assembled door.  
         [0023]    After the interior door components  28  are coupled to the inner door component support structure  22 , the finished exterior door panel  18  is coupled to the door substructure  16  disposing the interior components between finished exterior door panel and a portion of the door substructure  16 . The assembled door with a pre-finished exterior panel  18  is then coupled to the vehicle using the depending door hinges  40 .  
         [0024]    The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention.