VEHICLE SIDE DOOR STRUCTURE

In a state where a glass run channel that sandwiches an end portion of a door glass sandwiches a flange portion formed at an outer side of a door frame in a vehicle width direction, the glass run channel is attached to the door frame. A bracket is connected to a portion (outer wall upper portion) of the door frame, which is different from the flange portion. Therefore, it is possible to ensure continuity in the cross-sectional shape of the glass run channel. Thus, even when the glass run channel is attached to the door frame so as to sandwich the flange portion, it is possible to inhibit a deformation of a design surface of the glass run channel due to thermal effect, or the like.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a vehicle side door structure.

2. Description of Related Art

For example, Japanese Utility Model Application Publication No. 04-23519 (JP 04-23519 U) describes a technique for fixing a division bar to a door frame by pressing the distal end of a bracket against a flat portion of the door frame in a state where the bracket is fixed to the upper end of the division bar (pillar frame) and fastening the bracket to the door frame with a screw. In addition, Japanese Patent Application Publication No. 2012-106715 (JP 2012-106715 A) describes a technique for attaching a resin glass run channel (glass run channel) to a door frame in a state where a flange portion is provided at the door frame and the flange portion is sandwiched by the resin glass run channel in order to make it difficult for the resin glass run channel to fall off from the door frame.

Therefore, if the invention described in JP 2012-106715 A is applied to the invention described in JP 04-23519 U and the resin glass run channel is attached so as to sandwich the flat portion of the door frame, a shaft portion of the screw becomes an obstacle because the shaft portion projects from the lower side of the frame flat portion. Therefore, it is required to avoid interference with the shaft portion by forming a cutout portion in part of the resin glass run channel. However, if the resin glass run channel has the cutout portion, a design surface of the resin glass run channel may have a warp due to thermal effect, or the like.

SUMMARY OF THE INVENTION

The invention provides a vehicle side door structure that is able to suppress a deformation of a design surface of a glass run channel due to thermal effect, or the like, even when the glass run channel is attached to a door frame so as to sandwich a flange portion of the door frame.

An aspect of the invention provides a vehicle side door structure. The vehicle side door structure includes: a door frame having a flange portion extending outward in a vehicle width direction, a glass run channel being attached to the flange portion so as to sandwich the flange portion, the door frame supporting an end portion of a door glass; a bracket connected to a portion of the door frame, the portion being different from the flange portion; and a pillar frame mounted on the bracket so as to extend in a vehicle up-and-down direction on an inner side of the door frame, the pillar frame supporting an end portion of the door glass together with the door frame.

In the vehicle side door structure according to the above aspect, in the door frame that supports the end portion of the door glass, the flange portion extends outward in the vehicle width direction, and the glass run channel is attached to the door frame so as to sandwich the flange portion. The bracket is connected to the portion of the door frame, which is different from the flange portion. The pillar frame is mounted on the door frame via the bracket so as to extend in the vehicle up-and-down direction on the inner side of the door frame, and the end portion of the door glass is supported by the pillar frame together with the door frame.

For example, it is assumed that a fastener is fastened (connected) to a bracket at the flange portion of the door frame. In this case, the glass run channel that is attached so as to sandwich the flange portion needs to change its cross-sectional shape by, for example, forming a cutout portion (forming a cross-section sudden change portion) in order to avoid interference with the fastener.

However; in the aspect of the invention, because the bracket is connected to the portion of the door frame, which is different from the flange portion, it is possible to ensure continuity in the cross-sectional shape of the glass run channel attached so as to sandwich the flange portion. That is, in the cross-sectional shape of the glass run channel, there is no cross-section sudden change portion that can be formed by connecting the bracket. With the vehicle side door structure according to the above aspect, even when the glass run channel is attached to the door frame so as to sandwich the flange portion of the door frame, it is possible to inhibit a deformation of the design surface of the glass run channel due to thermal effect, or the like.

In the vehicle side door structure according to the above aspect, the bracket may have a long plate shape, and may include a first connecting portion extending in a vehicle longitudinal direction at an upper portion of the bracket and connected to the door frame and a second connecting portion extending in a vehicle width direction on a lower side of the first connecting portion and to which the pillar frame is connected.

In the vehicle side door structure according to the above aspect, the bracket has a long plate shape, and includes the first connecting portion and the second connecting portion. The first connecting portion extends in the vehicle longitudinal direction at the upper portion of the bracket, and is connected to the door frame. On the other hand, the second connecting portion extends in the vehicle width direction on the lower side of the first connecting portion, and the pillar frame is connected to the second connecting portion. The bracket is connected to the door frame at the first connecting portion, and the pillar frame is connected to the bracket at the second connecting portion. Thus, the pillar frame is connected to the door frame via the bracket. With the vehicle side door structure according to the above aspect, it is possible to change the shape of the bracket in accordance with the shape and connecting method of the door frame and the pillar frame, so general versatility is high.

In the vehicle side door structure according to the above aspect, the second connecting portion may be fastened to the pillar frame with a fastener, and the pillar frame may have a recessed seat portion in which a head portion of the fastener is accommodated.

In the vehicle side door structure according to the above aspect, the second connecting portion of the bracket is fastened to the pillar frame with the fastener, and the pillar frame has the recessed seat portion in which the head portion of the fastener is accommodated. Thus, it is possible for the head portion of the fastening portion not to protrude from the surface of the pillar frame. With the vehicle side door structure according to the above aspect, at the time when the glass run channel is attached to the pillar frame, it is possible to avoid interference between the head portion of the fastener and the glass run channel.

In the vehicle side door structure according to the above aspect, the second connecting portion may have a relief portion that avoids interference with the seat portion.

In the vehicle side door structure according to the above aspect, the second connecting portion of the bracket has the relief portion that avoids interference with the seat portion formed in the pillar frame, so it is possible to overlappingly arrange the pillar frame and the bracket at least at a portion other than the second connecting portion. With the vehicle side door structure according to the above aspect, it is possible to improve the stiffness of the pillar frame.

In the vehicle side door structure according to the above aspect, the door frame may be formed of a light metal material by extrusion molding.

In the vehicle side door structure according to the above aspect, when the door frame is formed of a light metal material by extrusion molding, it is possible to increase the thickness of the door frame in comparison with the case where the door frame is formed by roll forming. Thus, it is possible to tap a screw thread for fastening a screw at the connecting portion with the bracket. With the vehicle side door structure according to the above aspect, it is possible to reduce weight and cost.

DETAILED DESCRIPTION OF EMBODIMENTS

Hereinafter, a vehicle side door structure according to an embodiment of the invention will be described with reference to the accompanying drawings. In these drawings, the arrow FR indicates a vehicle front side, the arrow UP indicates a vehicle upper side, and the arrow OUT indicates an outer side in a vehicle width direction.

Configuration of Vehicle Side Door Structure

As shown inFIG. 5, in a rear side door10, a door outer panel12is arranged at the outer side in the vehicle width direction, and a door inner panel (not shown) is arranged on the inner side of the door outer panel12in the vehicle width direction. The door outer panel12and the door inner panel are connected to each other so as to form a closed section, and a window regulator (not shown) is provided between the door outer panel12and the door inner panel. With the window regulator, a door glass16is movable up and down between the door outer panel12and the door inner panel.

A door, frame18is provided at the upper portion of the rear side door10. The door frame18has an inverted U shape that is open downward in a vehicle up-and-down direction (vehicle lower side). The door frame18is connected to the door inner panel via a bracket (not shown). An opening portion20is formed between the door frame18and the upper end portion (so-called belt line L) of the door inner panel. The opening portion20is opened or closed by moving the door glass16up and down.

The door frame18will be described first. As shown inFIG. 1, the door frame18includes a frame body portion24and a flange portion26. The frame body portion24has a hollow portion22inside. The flange portion26extends outward in the vehicle width direction from the upper end portion of the outer side of the frame body portion24in the vehicle width direction.

The frame body portion24has a trapezoidal shape in cross section taken along the vehicle up-and-down direction. The frame body portion24includes an upper wall portion24A, a lower wall portion24B, an inner wall portion24C and an outer wall portion24D. The upper wall portion24A is located at the upper portion in the vehicle up-and-down direction. The lower wall portion24B is located at the lower portion in the vehicle up-and-down direction. The inner wall portion24C is located at the inner side in the vehicle width direction. The outer wall portion24D is located at the outer side in the vehicle width direction.

In the frame body portion24, the outer wall portion24D (described later) and the inner wall portion24C are formed along the vehicle up-and-down direction, and the lower wall portion24B that connects the lower end portion of the outer wall portion24D to the lower end portion of the inner wall portion24C is formed along the vehicle width direction. The outer wall portion24D is formed so as to be longer than the inner wall portion24C. The upper wall portion24A that connects the upper end portion of the outer wall portion24D to the upper end portion of the inner wall portion24C is formed so as to be inclined upward in the vehicle up-and-down direction (vehicle upper side) as shifting toward the outer wall portion24D.

Here, an outer wall recessed groove24D1that is recessed toward the inner wall portion24C is formed in the outer wall portion24D along the longitudinal direction of the frame body portion24, an outer wall upper portion24D2is on the upper side of the outer wall recessed groove24D1, and an outer wall lower portion24D3is on the lower side of the outer wall, recessed groove24D1.

The door frame18is, for example, formed of an aluminum alloy by roll forming. One end portion of a plate material in the lateral direction that intersects with the longitudinal direction before the door frame18is formed is sandwiched by the other end side of the door frame18in the lateral direction in a state where the door frame18is formed. Therefore, as shown inFIG. 3, three sheets of plate materials are overlapped at the flange portion26of the door frame18, and two sheets of plate materials are overlapped at the outer wall upper portion24D2.

An engaging piece28extends outward in the vehicle width direction from the upper end portion of the inner wall portion24C of the frame body portion24so as to be substantially parallel to the upper wall portion24A. Furthermore, an engaging pawl30protrudes from the upper end portion of the outer wall portion24D of the frame body portion24so as to face the engaging piece28. A weather strip32is attached to the frame body portion24via the engaging pawl30and the engaging piece28. In consideration of easiness of the drawings, the weather strip32is not shown inFIG. 1andFIG. 2, and a glass run channel40(described later) is also not shown inFIG. 1andFIG. 2as in the case of the weather strip32.

The weather strip32shown inFIG. 3is formed of a tubular elastic material, such as rubber. In the cross-sectional shape taken along the vehicle up-and-down direction and the vehicle width direction, the weather strip32includes a body portion32A and leg portions32B,32C. The body portion32A has a circular shape. The leg portions32B,32C project along the vehicle width direction of the body portion32A. The leg portions32B,32C are respectively engaged with the engaging piece28and the engaging pawl30. On the other hand, the body portion32A is in press contact with a side outer panel36that constitutes part of a roof side rail34, and that is arranged at the outer side in the vehicle width direction. The body portion32A seals the gap between the roof side rail34and the door frame18.

An opening weather strip38is provided at the outer peripheral portion of the roof side rail34in the vehicle width direction. A body portion38A of the opening weather strip38is in press contact with the inner wall portion24C of the door frame18and the engaging piece28, and seals the gap between the roof side rail34and the door frame18together with the weather strip32.

On the other hand, the glass run channel40is attached to the door frame18. The glass run channel40is formed of an elastic material, such as rubber. In the cross-sectional shape taken along the vehicle up-and-down direction, the glass run channel40includes a U-shaped sandwiching portion42that is open at the inner side in the vehicle width direction. In a state where the sandwiching portion42sandwiches the flange portion26formed in the door frame18, the glass run channel40is attached to the door frame18.

The sandwiching portion42includes an upper wall42A, a side wall42B and a lower wall42C. A pair of lip portions44extends upward in the vehicle up-and-down direction from the upper surface of the upper wall42A. The lip portions44extend in the vehicle longitudinal direction, and contact the side outer panel36when the rear side door10(seeFIG. 5) is closed.

A trailing wall42B1is sagging downward in the vehicle up-and-down direction from the side wall42B of the sandwiching portion42. The trailing wall42B1is contactable with a terminal cap48that is fitted to the upper end portion of a pillar frame46(described later). The trailing wall42B1inhibits the terminal cap48from falling off, and buries the gap from the terminal cap48.

Next, a bracket50will be described. As shown inFIG. 5, the bracket50is connected to the rear side of the door frame18in the vehicle longitudinal direction. The bracket50is a member for connecting the door frame18to the pillar frame46, and has a long plate shape so as to extend in the vehicle up-and-down direction.

As shown inFIG. 1, a connecting portion52projects from a bracket body50A at the upper portion of the bracket50. The connecting portion52serves as a first connecting portion that is bent rearward in the vehicle longitudinal direction. An upper end portion52A of the connecting portion52is, for example, arc-welded to the outer wall upper portion24D2of the door frame.18(connecting portion55shown inFIG. 2). The bracket50is connected to the door frame18via the connecting portion52.

A circular-arc cutout portion54is formed at the proximal portion of the connecting portion52of the bracket50. The cutout portion54is cut out inward in the vehicle width direction in the bracket body50A. The connecting portion52is bent with respect to the bracket body50A via the cutout portion54. A relief portion56is provided at the lower portion of the bracket50. The relief portion56serves as a second connecting portion that is recessed rearward in the vehicle longitudinal direction. A fastening hole56A is formed through the center portion of the relief portion56. A countersunk screw58that serves as a fastener is screwed to the fastening hole56A.

Here, the pillar frame46extends in the vehicle up-and-down direction. The pillar frame46is, for example, formed of an aluminum alloy by roll forming. As shown inFIG. 4, the cross-sectional shape of the pillar frame46, taken along the vehicle longitudinal direction, is substantially an I shape.

A substantially U-shaped mounting portion59is provided at the front portion of the pillar frame46in the vehicle longitudinal direction. The mounting portion59is open at the front side in the vehicle longitudinal direction. A glass run channel60(indicated by the imaginary line) is mounted on the mounting portion59. The glass run channel60sandwiches the side end portion of the door, glass16.

A substantially U-shaped mounting portion62is provided at the rear portion of the pillar frame46in the vehicle longitudinal direction. The mounting portion62shares a bottom wall59A of the mounting portion59and is open at the rear side in the vehicle longitudinal direction. A glass run channel66(indicated by the imaginary line) is mounted on the mounting portion62. The glass run channel66sandwiches the end portion of a door glass64.

An insertion hole67through which the countersunk screw58is inserted is formed in the pillar frame46. A recessed seat portion68is provided at the inner peripheral portion of the insertion hole67. The seat portion68has a truncated cone shape toward the rear side in the vehicle longitudinal direction. A head portion58A of the countersunk screw58that is screwed to the fastening hole56A formed in the bracket50is accommodated in the seat portion68. The relief portion56is provided in the bracket50, and avoids interference with the seat portion68of the pillar frame46.

With the above-described configuration, as shown inFIG. 2, the connecting portion52of the bracket50is welded to the door frame18, and the pillar frame46is fastened to the bracket50with the countersunk screw58(seeFIG. 4). Thus, the pillar frame46is connected to the door frame18via the bracket50.

Operation and Advantageous Effect of Vehicle Side Door Structure

As shown inFIG. 3, in the present embodiment, the flange portion26is formed at the outer side of the door frame18in the vehicle width direction. In a state where the glass run channel40that sandwiches the end portion of the door glass16sandwiches the flange portion26, the glass run channel40is attached to the door frame18.

The bracket50for indirectly connecting the pillar frame46to the door frame18is welded to the outer wall upper portion24D2of the door frame18. That is, the bracket50is connected to a portion (outer wall upper portion24D2) of the door frame18, which is different from the flange portion26, and the pillar frame46is connected, to the door frame18via the bracket50so as to extend in the vehicle up-and-down direction on the inner side of the door frame18.

For example, it is assumed that a fastener is fastened (connected) to a bracket at the flange portion26of the door frame18although not shown in the drawing. In this case, the glass run channel that is attached so as to sandwich the flange portion needs to change its cross-sectional shape by, for example, forming a cutout portion (forming a cross-section sudden change portion) in order to avoid interference with the fastener. Because the glass run channel extends or contracts in proportion to the temperature, stress easily concentrates at the cross-section sudden change portion, with the result that a deformation easily occurs at the design surface due to external force. Stress easily concentrates at the cross-section sudden change portion due to external force at the time of assembling work or at the time of parts transportation, and a deformation may occur at the design surface.

However, in the present embodiment, as shown inFIG. 2, because the bracket50is welded to the portion (outer wall upper portion24D2) of the door frame18(connecting portion55), which is different from the flange portion26, it is possible to ensure continuity in the cross-sectional shape of the glass run channel40attached so as to sandwich the flange portion26.

That is, in the cross-sectional shape of the glass run channel40, there is no cross-section sudden change portion that can be formed by connecting the bracket50. Thus, according to the present embodiment, even when the glass run channel40is attached to the door frame18so as to sandwich the flange portion26of the door frame18, it is possible to inhibit a deformation of the design surface of the glass run channel40due to thermal effect, or the like.

In the present embodiment, as shown inFIG. 1, the connecting portion52of the bracket50is connected to the door frame18, and the pillar frame46is connected to the bracket50, with the countersunk screw58. Thus, the pillar frame46is connected to the door frame18via the bracket50. Thus, it is possible to change the shape of the bracket50in accordance with the shape and connecting method of the door frame18and the pillar frame46, so general versatility is high.

Furthermore, in the present embodiment, as shown inFIG. 4, the seat portion68is provided in the pillar frame46, and the head portion58A of the countersunk screw58screwed to the fastening hole56A is accommodated in the seat portion68. Thus, it is possible for the head portion58A of the countersunk screw58not to protrude from the surface of the bottom wall59A of the mounting portion59of the pillar frame46. The mounting portion59to which the glass run channel40is attached is provided in the pillar frame46, so it is possible to avoid interference between the head portion58A of the countersunk screw58and the glass run channel40.

In the present embodiment, the bracket50has the relief portion56for avoiding interference with the seat portion68formed in the pillar frame46. Thus, it is possible to overlappingly arrange the pillar frame46and the bracket50at least at a portion other than the seat portion68, so it is possible to improve the stiffness of the pillar frame46.

The connecting portion52is bent at the upper portion of the bracket50rearward in the vehicle longitudinal direction with respect to the bracket body50A, and the cutout portion54cut out inward in the vehicle width direction is formed at the proximal portion of the connecting portion52. In this way, by forming the cutout portion54at the proximal portion of the connecting portion52, bending force is not caused to directly act on the bracket body50A when the connecting portion52is bent with respect to the bracket body50A. Thus, it is possible to ensure the flatness of the bracket body50A and to form an R shape at a boundary portion between the bracket body50A and the connecting portion52.

Other Embodiments

As shown inFIG. 1, in the present embodiment, the connecting portion52is provided at the upper portion of the bracket50, and the upper end portion52A of the connecting portion52is arc-welded to the outer wall upper portion24D2of the door frame18. In this way, when the bracket50is arc-welded to the door frame18, it is possible to reduce cost in comparison with, for example, the case where a fastening hole for fastening the bracket50is formed in the door frame18. However, in the present embodiment, it is just required to be able to connect the bracket50to a portion of the door frame18, which is different from the flange portion26, so the connecting portion52does not always need to be the outer wall upper portion24D2of the door frame18. The welding method used for the connecting portion52is also not limited to arc welding, and may be laser welding or spot welding. Furthermore, the connecting method used for the connecting portion52is also not limited to welding.

For example, as shown inFIG. 6andFIG. 7, a bracket72may be fastened and connected to the lower wall portion24B of the door frame18. In this case, the position of a connecting portion74that serves as a first connecting portion in the bracket72is on the inner side of the outer wall upper portion24D2in the vehicle width direction. Therefore, the connecting portion74and a bracket body72A need to ensure a predetermined distance in the vehicle width direction.

For example, a bent piece76bent forward in the vehicle longitudinal direction is provided at the upper portion of the bracket body72A, and the connecting portion74that is bent inward in the vehicle width direction is provided at the lower end portion of the bent piece76. Thus, it is possible to project the connecting portion74inward in the vehicle width direction with respect to the bracket body72A and to ensure a predetermined distance in the vehicle width direction between the connecting portion74and the bracket body72A.

A through-hole74A is formed at the center portion of the connecting portion74, and a through-hole24B1is formed at the lower wall portion24B of the door frame18. A grommet78is inserted in the through-hole24B1, and a bolt80is allowed to be fastened via the grommet78. On the other hand, the bracket body72A, which serves as the second connecting portion, and a pillar frame82may be connected to each other by spot welding, or the like.

In the above-described embodiment, the door frame18is formed by roll forming; instead, the door frame may be formed by extrusion molding. In this case, for example, as shown inFIG. 8, it is possible to change the thickness of a door frame84. Therefore, in a lower wall portion86A that constitutes part of a frame body portion86of the door frame84, it is possible to tap a screw thread86A1for fastening a bolt80. When the door frame is formed by extrusion molding, it is possible to reduce weight and cost in comparison with the case where the door frame is formed by roll forming. The door frame may be formed by another working method, such as drawing, other than extrusion molding.

In the present embodiment, the rear side door10is described; however, the same applies to a front side door.

The embodiment of the invention is described above; however, the invention is not limited to the above embodiment. The invention may be, of course, implemented in various modes other than the above-described embodiment without departing from the scope of the invention.