Modular vehicle door

A modular door assembly is adapted for installation on existing open frame vehicles formed of tubular members. A novel tubular hinge construction provides support for the door assembly while allowing rotational movement of the door in use. Alternative vehicle elements may also be secured to and operable on the novel hinge.

BACKGROUND

The invention pertains to modular doors and similar access panels intended to be secured, or secured to, previously assembled personal vehicles such as automobiles. The design and configuration of available personal vehicles are currently changing. There are a number of vehicles that combine elements of motorcycles and other “open” cockpit vehicles with the concept of the closed compartment automobile. Some of these include an open frame construction using tubular structural members to form an open cockpit configuration but with conventional seats. However, in many cases, there is a need to provide additional containment, such as doors or similar access elements. What is desired is a design and mechanism to secure moveable door elements to an open frame construction vehicle body.

SUMMARY OF THE INVENTION

The invention includes a door assembly and a securing mechanism that provides a rigid support for a vehicle door while enabling convenient rotational movement of the door during use by a passenger of the associated vehicle. The securing mechanism includes a flexible hinge formed of a flexible slotted tube configured to be retained on a vehicle tubular structural member without interconnecting fasteners or other joining mechanisms.

In other configurations of the invention, the same hinge tube element is used to support other functional elements of the vehicle such as a wind diverter. In various embodiments, the invention includes a kit or system including alternatively interchangable functional elements including a door assembly and others that may be secured in like manner to a novel hinge tube. In various configurations, a vehicle according to the invention may include multiple hinge tubes located on different tubular structures of the vehicle, each configured to receive one or more functional elements.

Other novel aspects of the invention are made apparent in the following description of specific embodiments of the invention and the associated figures. The scope of the invention is intended to be defined by the accompanying claims.

DETAILS OF EMBODIMENTS OF THE INVENTION

FIG. 1is a perspective view of the inventive door system. A vehicle body100is shown in part including a vehicle user opening. A door assembly20is configured to effective cover and close the vehicle opening. The body100is formed, in part, by structural members formed of tubular sections110. This form of construction is essential for operation of the invention as desired. A door assembly20is secured to the body100by way of a cylindrically shaped hinge tube30. Conventional fasteners32are used to secure the door assembly20to the hinge tube30. Preferably the fasteners32are configured to be alternatively secured and removed without the use of tools. The hinge tube30is in turn pivotably secured to a tubular section110. By proper selection of size and material of the hinge tube30, the hinge tube30can support the door assembly in a number of different rigid configurations—by rotating the hinge tube30and door assembly, together, about the associated tubular section110.

FIGS. 2 and 3are end section views of the door assembly20with a secured hinge tube30supported on a tubular section110. The inner diameter dimension HD of the hinge tube30, separate from the tubular section110, is slightly smaller (in the prejoined unstressed state) than the outer diameter of the tubular section110. Expressed in other terms, the tubular section110resides in the hinge tube30with an interference fit such that the larger diameter of the tubular section110maintains an outward displacement of the hinge tube30thereby induces stress in the hinge tube30and reacting force against the surface of the tubular section110. In the figure, a gap between these elements is shown only for clarity of illustration of the respective elements. The hinge tube30is formed of a flexible resilient material, such that when the hinge tube30is in place on the tubular section110, the hinge tube30is biased continuously into a more closed (smaller diameter) condition, such as to maintain a forced contact and consequent friction with the tubular section110. To enable this while also ensuring that relative rotation between these elements is still possible, the hinge tube30is formed of a flexible non-metallic material. Preferably, the hinge tube is formed of unfilled ABS (substantially acrylonitrile-butadiene-styrene) plastic having flexural and tensile modulai of about 300,000 psi (pounds per square inch) or greater. A high modulas is required to provide the necessary rigidity of the open form of the hinge when in place. ABS plastic materials may also include other compounds such as colorantes. The tube shape may be formed by conventional methods such as heat forming. Receptors for retaining male fastening elements, such as standard threaded nuts, are formed integral with the hinge tube30to mate with the fasteners32. The desired function of the hinge tube30requires that no fasteners or fastening mechanism join or connect the hinge tube and the vehicle tubular section110. That is, at all times, these two elements have a sliding interrelationship that allows the rotational movement of the hinge tube30.

Because the inventive system is designed for use on existing vehicles, the appropriate tubular body section for securing the door assembly is most likely found without an free end. For this reason, the hinge tube30must be configured to engage the tubular section110laterally, by forcing the tubular section110through a longitudinal slot33in the hinge tube30. The slot33must must have a width dimension LC sufficient so that, together with the resilient flexibility of the hinge tube30material and construction, the slot33may be forced to a large width to allow passage therethrough of the tubular section110. At the same time. The slot33must be small enough that, together with the rigidity and strength of the hinge tube30construction, the hinge tube once installed over the tubular section110provides a secure attachment for the door assembly20. The particulars of these design elements may depend on the diameter of the tubular section110and the weight of the door assembly20.

It is suggested that engagement of the hinge tube30with the tubular section110be initiated by forcing the tubular section110through one end of the slot33, enlarging then end the slot33as required (allowing the remaining portions of the slot to narrow in reaction). The tubular section110may then be gradually pushed into and through the remaining length of slot33with reduced maximum force.

Once engaged with the tubular section110, the biasing force of hinge tube30to close onto the tubular section110provides a friction force resisting rotation of the hinge tube30on the tubular section110. This static friction force is preferably greater than the resulting torque force of the door assembly when at all use positions. In this manner, external or secondary supports for the door assembly is not necessary. For this requirement, the hinge tube30must have sufficient longitudinal length.

FIG. 4is a detailed perspective view of the hinge tube30. To provide sufficient stiffness and strength the hinge tube30is suggested to be formed of ABS sheet having a thickness sufficient to provide general gross rigidity. The slot33extends the entire length LL between the opposing ends34,35of the hinge tube30.

FIG. 5illustrates a second vehicle component, namely a wind diverter40configured to be supported on the hinge tube30and there operable for various different functions. The diverter40is sized substantially smaller in size—smaller than the door assembly20and the associated vehicle door opening. The diverter40is preferably a rigid flat structure. The specific size and shape of the diverter40is not critical but may be altered as desired to carry out the desired function in association with the respective vehicle. Generally, the diverter40is designed to direct flowing air, during normal travel of the vehicle body100, away or into the passenger compartment.FIG. 6is an enlarged view of the diverter40ofFIG. 5illustrating the relative flow of air during use.

FIG. 7assembly or kit of multiple functional elements each supportable and operable on a single hinge tube30. In this embodiment, both a wind diverter40and a door assembly20are provided and configured to be interchangeably secured to and operated on the hinge tube30.

FIG. 8illustrates a vehicle300including multiple functional elements, each supported on a respective hinge tube30. In this embodiment a second hinge tube52is positioned on a distinct hinge tubular element of the vehicle. The second hinge tube52supports a second functional element50, in this case a sun shade that may be rotated by the user during use to alter its effect. The construction of the second hinge tube52and the manner of securing and operating the second functional element50is the same as described above respecting the hinge tube. The advantages of alternative removal of the second functional element50and its rotational adjustment and operation is provided in the same way by the novel aspect of the second hinge tube52. Examples of functional elements adaptable to the invention include a rigid flat thin blade configured as a sun shade.