Vehicle assembly and methods of making and using the same

A vehicle assembly that can include a frame assembly, a door assembly, a striker assembly, a door latch assembly, a seat belt retractor assembly and a cover assembly. The striker assembly can be mounted on the frame assembly. The door latch assembly can be mounted on the door assembly. The door latch assembly can include a latch mechanism configured to releasably engage the striker assembly when the door assembly is in the closed position. The seat belt retractor assembly selectively wind and unwind a seat belt. The seat belt retractor assembly can be mounted on a first portion of the frame assembly. The seat belt retractor assembly can be spaced away from a second portion of the frame assembly by a gap. The cover assembly can be mounted on the frame assembly. The cover assembly can cover at least a portion of the gap and the striker assembly.

BACKGROUND

The disclosed subject matter relates to a vehicle assembly that includes a cover assembly. More particularly, the disclosed subject matter relates to a cover assembly that covers more than one portion of the vehicle assembly.

A vehicle can include one or more doors or door assemblies that can permit ingress/egress to/from a vehicle interior or vehicle storage area. A door assembly of a vehicle can be pivotally attached to a frame or other supporting structure of a vehicle. For example, a door assembly can be pivotally attached by a hinge so as to allow the door assembly to be opened and closed. A door assembly of a vehicle can include and/or be associated with various components. The components can include a latch assembly for a door and a striker assembly that is mounted on the frame. The latch assembly can engage the striker assembly so as to secure the door in a the closed position. The vehicle can also include a seat belt retractor assembly to provide securement of an occupant in the vehicle.

However, known arrangements of door assemblies, as well as components associated with door assemblies have deficiencies.

SUMMARY OF THE INVENTION

Some embodiments are directed toward a vehicle assembly that can include a frame assembly, a door assembly, a striker assembly, a door latch assembly, a seat belt retractor assembly and a cover assembly. The door assembly can mounted on the frame assembly and can be movable relative to the frame assembly between a closed position and an opened position. The striker assembly can be mounted on the frame assembly. The door latch assembly can be mounted on the door assembly. The door latch assembly can include a latch mechanism configured to releasably engage the striker assembly when the door assembly is in the closed position. The seat belt retractor assembly can be configured to selectively wind and unwind a seat belt. The seat belt retractor assembly can be mounted on a first portion of the frame assembly. The seat belt retractor assembly can be spaced away from a second portion of the frame assembly by a gap. The cover assembly can be mounted on the frame assembly. The cover assembly can cover the striker assembly and at least a portion of the gap.

Some embodiments are directed toward a vehicle that can include a frame assembly, a door assembly, a striker assembly, a door latch assembly, a seat belt retractor assembly and a cover assembly. The frame assembly can frame a door opening and can include a first frame member extending along the door opening in a vertical direction of the vehicle, and grab bar connected to and extending away from the first frame member in a transverse direction of the vehicle. The door assembly can be mounted on the frame assembly and movable relative to the frame assembly between a closed position and an opened position. The striker assembly can be mounted on the frame assembly. The door latch assembly can be mounted on the first door assembly. The door latch assembly can include a latch mechanism that is configured to releasably engage the striker assembly when the first door assembly is in the closed position. The seat belt retractor assembly can be configured to selectively wind and unwind a seat belt. The seat belt retractor assembly can be mounted on a first portion of the frame assembly. The seat belt retractor assembly can be spaced away from a second portion of the frame assembly by a gap. The cover assembly can be mounted on the frame assembly. The cover assembly can cover the gap and at least one of the door latch assembly and the striker.

Some embodiments are directed toward an all-terrain vehicle that can include a frame assembly, a plurality of wheels, a first door assembly, a second door assembly, a striker assembly, a door latch assembly, seat belt retractor assembly and a cover assembly. The frame assembly can include a plurality of frame members connected together to extend around a passenger area and to form a first door opening and a second door opening. The plurality of frame members can include a first frame member extending along a vertical direction of the vehicle, a second frame member connected to the first frame assembly and extending away from the first frame member along a transverse direction of the vehicle, and a third frame member extending along the vertical direction of the vehicle. The first frame member can extend between the first door opening and the second door opening, and the second door opening can extend between the first frame member and the third frame member. The plurality of wheels can be connected to the frame assembly. At least one of the wheels is configured to be driven by a powertrain. The first door assembly can be pivotally connected to the first frame member. The second door assembly can be pivotally connected to the third frame member. The striker assembly can be mounted on the first frame member. The door latch assembly can be mounted on the second door assembly. The door latch assembly can include a latch mechanism that is configured to releasably engage the striker assembly when the second door assembly is in the closed position. The seat belt retractor assembly can be configured to selectively wind and unwind a seat belt, the seat belt retractor assembly is mounted on the second frame member. The seat belt retractor assembly can be spaced away from a second frame member by a gap. The cover assembly can be mounted on the frame first frame member. The cover assembly can cover the striker assembly and at least a portion of the gap.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

A vehicle assembly is provided that includes a cover assembly. The cover assembly can cover and/or be beneficially associated with various components or assemblies of the vehicle that are provided with a door assembly of the vehicle. Such various components or assemblies can include a striker assembly mounted on a frame assembly of the vehicle, a door latch assembly mounted on a door assembly, and a seat belt retractor assembly mounted on the frame assembly. One or more of these components or assemblies may include one or more openings or one or more gaps between adjacent components/assemblies that may be aesthetically unpleasing. Further, objects external to the vehicle, such as but not limited to dirt, small stones/rocks, small plant material can enter the nay of the gaps/openings that exposed on a vehicle that intended for use on an unimproved path or on an unmarked path. Thus, it may be desirable to cover any exposed openings in and gaps between components/assemblies. For example, a cover assembly can cover at least a portion of a gap between the seat belt retractor assembly and a portion of the frame assembly. The cover assembly can also cover the striker assembly and or the latch assembly. The cover assembly can prevent access to gaps between components or assemblies of the vehicle and provide an aesthetically pleasing appearance,

The vehicle10shown inFIG. 1is specialized for use on an unimproved path or on an unmarked path, and can be referred to as a multipurpose utility vehicle (MUV) or as a side-by-side all-terrain vehicle (SxS, or SxS ATV). However, the disclosed vehicle frame assembly with door assembly can be used with any vehicle that is configured for travel along any one or combination of improved, unimproved, and unmarked paths. For example, embodiments are intended to include or otherwise cover any type of automobile, including a passenger car, minivan, truck, other types of all-terrain vehicle (ATV), semi-tractor, off-highway vehicle, etc.

Referring toFIGS. 1 and 3, the vehicle10can include a body12, a pair of front wheels,14L,14R, a pair of rear wheels16L,16R, a frame assembly18, a pair of front door assemblies70,78, a pair of rear door assemblies73,79, and a powertrain. Portions of the frame assembly18are hidden from view inFIG. 1by the body12(but are shown inFIG. 3, for example), and the powertrain is omitted for simplicity and clarity of the drawings.

The vehicle10can include a pair of front seats22L,22R and a pair of rear seats23L,23R mounted in a passenger area of the vehicle10. The frame assembly18can include a roll cage28configured to extend around and above the seats22L,22R,23L,23R and the passenger area. The roll cage28can cooperate with the body12and/or at least a portion of the frame assembly18to define door openings through which a passenger may pass in order to enter or exit the passenger area.

The door assemblies70,73,78,79, which occupy the door openings, each can include a panel door assembly, and can be configured to selectively open and close access through the door openings by moving between a closed position and a partially opened or fully opened position. In the closed position, the door assemblies70,73,78,79, can span the respective door openings to obstruct access to or from the passenger area via the door openings. In the closed position or disposition, the front portion of each door assembly70,73,78,79can be latched to the roll cage28. The partially opened position (or disposition) or the fully opened position (or disposition) can be any position where the door assemblies70,73,78,79are pivoted away from the respective door openings to provide substantially unobstructed access to the passenger area via the door openings.

FIG. 3shows the left-side door assemblies70,73in the open position and the right-side door assemblies78,79in the closed position. Each of the door assemblies70,73,78,79can be constructed as desired. For example, with reference to the left side of the vehicle as shown inFIG. 2, the door assemblies can be constructed of one or more panels of a respective panel assembly40,42. Each of the panel assemblies can have an uninterrupted exterior surface. Alternatively, the door panel assemblies40,42can be constructed in various other manners as may be desired. For example, each of the door panel assemblies40,42can include an inner door panel that faces toward the passenger area of the vehicle10and an outer door panel that faces toward the exterior of the vehicle10. The outer door panel is shown inFIGS. 1-3. The inner door panel can be connected to the outer door panel such that a space is enclosed therebetween. One or more of the door panel assemblies40,42can have a continuous outer surface or an outer surface that is interrupted by one or more holes, ridges and/or other contour or character features.

The vehicle10can include a powertrain. The powertrain can include an internal combustion engine, one or more electric motor(s) or a hybrid of an internal combustion engine and one or more electric motor(s), or other known engine/motor. The powertrain can have the engine/motor output axis oriented in the longitudinal direction L or in the traverse direction T of the vehicle10. The powertrain can be configured to drive only the front wheels14L,14R, or configured to drive only the rear wheels16L,16R, or configured to drive all of the wheels14L,14R,16L,16R, or configured to drive the rear wheels16L,16R and selectively drive the front wheels14L,14R, or configured to drive the front wheels14L,14R and selectively drive the rear wheels16L,16R.

Referring toFIGS. 1 and 3, the body12can be formed of one or more panels mounted on the frame assembly18. For example, the body12can include a panel extending around each of the wheels14L,14R,16L,16R, a roof panel13, one or more panels that form a cargo/storage area15at the rear of the vehicle10. The roof panel13is omitted fromFIG. 3in order to better illustrate a passenger area of the vehicle10.

The frame assembly18can be configured to support the body12, door assemblies70,73,78,79, seats22L,22R,23L,23R, suspension components for the wheels14L,14R,16L,16R, powertrain, steering system, control pedal assemblies, passengers and cargo items, for example. The frame assembly18can be configured to withstand various modes of operation, including operation on unimproved paths, and can be configured to surround the passenger area. The frame assembly18can include a main frame assembly30, a front frame assembly32and a rear frame assembly36.

The main frame assembly30can define the passenger area of the vehicle10. The main frame assembly30can also provide an overall bending stiffness and torsional stiffness characteristic for the vehicle10that can be advantageous for rugged terrain of an unimproved path.

The front frame assembly32can be connected to the front end of the main frame assembly30. The front frame assembly32can be configured with mounting points for the front suspension components and any appropriate components/systems, such as but not limited to portions of the body12, a front final drive assembly, steering system components, engine cooling system, headlights, etc.

A front bumper assembly can be connected to the front end of the front frame assembly32, such that the front frame assembly32can be located between the front bumper assembly and the main frame assembly30. A front bumper assembly can extend beyond the exterior of the body12, or alternatively, one or more portions of the body12can conceal a front bumper assembly.

The rear frame assembly36can be connected to the rear end of the main frame assembly30such that the passenger compartment is located between the front frame assembly32and the rear frame assembly36. The rear frame assembly36can be configured with mounting points for the rear suspension components and any appropriate components/systems, such as but not limited to portions of the body12, a rear final drive assembly, taillights, etc.

The main frame assembly30, front frame assembly32and rear frame assembly36can be made from any appropriate structural element(s), such as but not limited to tubes, beams, stampings, etc., that can provide sufficient strength and rigidity for a vehicle passenger area. The frame assembly18can be formed from a single type of structural element, or alternatively the frame member18can be formed from any combination of these structural elements. The structural elements can have any appropriate cross-sectional shape, such as but not limited to circular, rectangular, regular polygonal, irregular polygonal, hollow, solid, variable along the length of the structural element, etc.

The structural elements can be formed by any appropriate process, such as but not limited to rolling, hydroforming, bending, welding, extruding, stamping, any combination of these processes, etc. Each structural element of the frame assembly18can be formed from any appropriate material, such as but not limited to steel, aluminum, titanium, magnesium, plastic, fiber-reinforced plastic, carbon fiber, ceramic, a composite formed from any combination of these exemplary materials, etc. Each structural element of the frame assembly18can be connected to each adjoining structural element in any appropriate manner, such as but not limited to mechanical fasteners, welding, adhesive, any combination thereof, etc.

Further referring toFIG. 1andFIG. 2and the left side of the vehicle, the front frame assembly32can be connected to a lower cross member and a first cage side member61of the main frame assembly30. Referring toFIG. 1, the front frame assembly32can be configured to support a front suspension and wheel assembly57(FIG. 1), and other components such as but not limited to a radiator, a steering rack assembly and a front final drive assembly. The front suspension and wheel assembly57can include a front suspension member on each side of the front frame assembly32, and a damper and spring assembly on each side of the front frame assembly32.

The front frame assembly32can include or be connected to front lower frame members, as well as other associated frame members, which can be configured as hollow metal tubes having a substantially circular cross-section. However, any combination of the front frame members can be or have a cross-sectional shape that is different from a substantially circular cross-sectional shape. Further, any combination of the front frame members, including front frame members and other associated frame members, can be formed of a material other than metal, such as but not limited to carbon fiber, plastic, carbon fiber reinforced plastic, ceramic, pulp, or glass fiber reinforced plastic.

Further, the front lower frame members and other associated frame members can be welded to each other to form the structure described above. Embodiments are intended to include or otherwise cover any combination of the front lower frame members and other associated frame members connected by threaded fasteners, adhesives, a combination of brackets and threaded fasteners, rivets, or other known connective structures, materials, or methods.

Further referring toFIG. 1, the rear frame assembly36can be configured to support a rear suspension and wheel assembly58, and other components such as but not limited to a power source, a transmission and a rear final drive assembly. The rear suspension and wheel assembly58can include, for example, at least one rear suspension member on each side of the rear frame assembly36, a rear damper and spring assembly on each side of the rear frame assembly36, a rear hub assembly on each side of the rear frame assembly36, and the rear wheels16L,16R.

The rear frame assembly36can be connected to and can extend away from the main frame assembly30in the longitudinal direction L of the vehicle10.

The rear frame assembly36in conjunction with other support components can be configured to support a powertrain assembly. For example, an exemplary powertrain, as described above, can include a power source such as but not limited to an internal combustion engine (having a single cylinder or a plurality of cylinders), an electric motor, or a hybrid system that includes an internal combustion engine and an electric motor. The powertrain also can include a transmission connected to the power source and a final drive structure. The transmission can include various types of transmissions including a stepped speed ratio assembly or a continuously variable speed ratio assembly. The transmission can be configured as an automatic transmission, a manual transmission, or a semi-automatic transmission. A power source and the transmission can be connected to the rear frame assembly36in any appropriate manner such as but not limited to brackets and mechanical fasteners, welds, rivets, rubber mounting assembly(ies), fluid filled mounting assembly(ies), or any combination thereof.

Further referring toFIGS. 1-3, the main frame assembly30can define the passenger area and can include the roll cage28, longitudinal frame members38on opposing sides of the vehicle, lower cross members, and other frame members. Frame members can be connected together to form a fixed frame assembly or modular frame assembly in which selective removal and attachment is not or is intended. That is, the frame members can be intended to remain fixed to each other unless a destructive process such as but not limited to sawing, cutting, crushing, ripping, melting, etc., is applied to the fixed frame assembly. In contrast, some frame members can be intended to be selectively removable and attachable to a remainder of the main frame assembly30, for example, without requiring a destructive process such as but not limited to sawing, cutting, crushing, ripping, melting, etc. The longitudinal members38can extend in the longitudinal direction L of the vehicle10, from the front of the passenger area to the rear of the passenger area. The longitudinal members38can each be configured as a substantially straight, hollow beam having a substantially rectangular cross-sectional shape.

As shown inFIG. 3, a roll cage28generally defines the passenger area or compartment. The roll cage28can extend in the longitudinal direction L of the vehicle10, from the front end of the passenger area to the rear end of the passenger area. The roll cage28can define the limits of the passenger area in the transverse direction T of the vehicle10, the longitudinal direction L of the vehicle10and in the vertical direction V of the vehicle10. The roll cage28can be configured to support the door assemblies70,73,78,79and any appropriate portion(s) of the body12, such as but not limited to flexible side panel(s) (transparent, opaque, or a combination thereof), rigid side panel(s), roof panel (rigid or flexible), flexible or rigid rear panel (transparent, opaque, or a combination thereof), etc.

The roll cage28can be configured to resist, impede, or minimize deformation that could be caused by a load or kinetic energy input into the roll cage28. The roll cage28can be configured with any shape and contour that can be advantageous to mate the structural performance and aesthetic appeal desired for the vehicle10. The roll cage28can be formed from any appropriate number of structural elements, from one to any number greater than one. For example and referring toFIGS. 1 and 3, the roll cage28can include a plurality of cage cross members52,54, and56and a plurality of cage side members61,62,63,64and65, and the right side of the vehicle can be mirror image to the left side of the vehicle shown inFIG. 1. Each of the cage members can be configured as a hollow tube having a substantially circular or oval cross-section shape. The cage members can be configured with any appropriate elongated shape that can provide the desired dimensionality of the passenger area and advantageously conform to the aesthetic appearance desired for the vehicle10. For example, the cage members can be made from one or more lengths of a metal tube. Any one of the tubular cage members can be bent in one or more locations into a predetermined shape.

Each of the first cage side members61can be referred to as an A-pillar. Each of the first cage side members61can be connected at one end to a respective one of the longitudinal members38adjacent the front end of the respective one of the longitudinal members38. Each of the first cage side members61can extend along each of the vertical direction V, the transverse direction T and the longitudinal direction L of the vehicle10.

As shown inFIG. 3, the roll cage28may also include fourth cage side members64. Each of the fourth cage side members64can be referred to as a roof rail or a top rail. Each of the fourth cage side members64can extend from and connect to a respective one of the first cage side members61. Each of the fourth cage side members64can connect to a respective one of the third cage side members63. Each of the fourth cage side members64can connect to a respective one of second cage side members62. Each of the fourth cage side members64can connect to a respective one of the fifth cage side members65. Each of the fourth cage side members64can extend along at least the longitudinal direction L of the vehicle10.

The first cage cross member52can be connected to either the first cage side members61or the fourth cage side members64at a location that is adjacent to or at the junction of the first cage side members61and the fourth cage side members64. Alternatively, the first cage cross member52can be connected at the junction of the first cage side members61and the fourth cage side members64.

Each of second cage side members62can be referred to as a B-pillar. Each of the second cage side members62can be connected at a first end to a respective one of the longitudinal members38along the side of the respective one of the longitudinal members38. Each of the second cage side members62can be connected to an outer side of the respective one of the longitudinal members38.

Each of the second cage side members62can be connected at a second end to a respective one of the fourth cage side members64. The second cage cross member54can be connected to either the fourth cage side members64, or the second cage side members62, or a location that is adjacent to or at the junction of the fourth cage side members64and the second cage side members62.

Each of third cage side members63can be referred to as a C-pillar. Each of the third cage side members63can be connected at a first end to a respective one of the longitudinal members38along the side or at the rear end of the respective one of the longitudinal members38. Each of the third cage side members63can be connected to an outer side of the respective one of the longitudinal members38.

Each of the third cage side members63can be connected at a second end to either a respective one of the fourth cage side members64or a respective one of fifth cage side members65at a location that is adjacent to or at a junction of the respective one of the fourth cage side members64and the respective one of the fifth cage side members65. Alternatively, each of the third cage side members63can be connected at the second end to the junction of the respective one of the fourth cage side members64and the respective one of the fifth cage side members65.

The third cage cross member56can be connected to either the fourth cage side members64, or the third cage side members63, or the fifth cage side members65, or alternatively, at a location that is adjacent to or at the junction of the fourth cage side members64, or the third cage side members63, or the fifth cage side members65.

Each of the fifth cage side members65can be connected to and extend away from a respective one of the fourth cage side members64along the longitudinal direction L of the vehicle10.

The cage cross members52,54,56, can extend in the transverse direction T of the vehicle10from the left side of the roll cage28to the right side of the roll cage28. The cage cross members52,54,56, can be connected to each of respective pair(s) of the cage side members at respective locations spaced apart along the longitudinal direction L of the vehicle10. The cage cross members52,54,56, can be configured to maintain a predetermined spacing between the cage side members61,62,63,64,65in the transverse direction T. The cage cross members52,54,56can define limits of the passenger area in the longitudinal direction L of the vehicle10and the vertical direction V of the vehicle10. The cage cross members52,54,56can be configured to manage load and/or energy inputs so that deflection of the frame assembly18in the vicinity of the passenger area can be controlled in an advantageous predetermined manner. In the exemplary embodiment ofFIG. 3, the cage cross members52,54,56can be connected to a respective left-side and right-side pair of the cage side members61,62,63,64,65by welding.

As shown inFIG. 2, the vehicle10can include a rear door assembly73. The rear door assembly73can include a rear portion75. The rear door assembly73may be pivotally supported by a hinge assembly at or adjacent to the rear portion75so as to allow movement of the rear door assembly73between a closed position and an open position. The rear door assembly73can include a front portion74.

As shown inFIG. 2, the vehicle10can include a front door assembly70. The front door assembly70can include a front portion71and a rear portion72. The front door assembly70may be pivotally supported by a front hinge assembly95(schematically represented by a dotted line inFIG. 2) at or adjacent to the rear portion72so as to allow movement of the front door assembly70between a closed position and an open position.

Each of the door assemblies70,73,78,79can include a net assembly80that includes a mesh netting81and a frame82that surrounds the mesh netting81. The frame82can be connected to each of the frame assembly18and a respective one of the door panel assemblies40,42. Accordingly, a respective net assembly80can be positioned above the front door panel assembly40and/or above the rear door panel assembly42. The net assembly80can serve to block or close off an upper portion of an opening in the vehicle frame or vehicle frame assembly18. The net assembly80can operate in conjunction with one or more door panels, of a door, to selectively open and close an opening in the vehicle frame assembly18.

Each of the door assemblies70,73,78,79can include a latch assembly85, and handle assembly86, and a connecting mechanism87, as schematically represented inFIG. 3. The latch assembly85can be constituted by structure that slides, rotates, or otherwise moves so as to releasably engage with a striker88(FIG. 4) mounted on the frame18of the vehicle10. As a result of such engagement, the particular door, upon which the latch assembly85is mounted, can be releasably held in a closed position. For example, the latch assembly85can include or be in the form of one or more movable claw(s) or hook(s) that engage(s) the striker88when the door assembly is in the closed position. The latch assembly85can be mechanically attached or connected to the handle assembly86by a connecting mechanism87. The connecting mechanism87can be a rotating rod, for example.

The striker88can be attached to or be a component of the frame assembly18of the vehicle10as described below. The striker88can have any appropriate structure that can be selectively engaged and disengaged by the latch assembly85. For example, the striker88can be formed from a metal rod that is bent into a substantially U-shape or n-shape, with the free ends of the striker88connected to a striker base89in any appropriate manner such as but nit limited to welding, adhesive, mechanical fasteners. The striker88and the striker base89collectively can be referred to as a striker assembly112. A striker assembly112for the front door assembly70can be mounted to the first cage side member61directly or indirectly via a bracket that is secured to the first cage side member61by any appropriate manner such as but not limited to welding, adhesive, and mechanical fasteners. A striker assembly112for the rear door assembly73can be mounted to the second cage side member62directly or indirectly via a bracket that is secured to the second cage side member62by any appropriate manner such as abut not limited to welding, adhesive, and mechanical fasteners. Further details of the striker assembly112will be discussed below.

In accordance with one or more embodiments of the disclosure, the vehicle10can include a cover assembly90. The cover assembly90can include a first cover member91and a second cover member92.FIG. 4is a side view of as viewed from the exterior of the left side of the vehicle10and shows the first cover number91, in accordance with one or more embodiments of the disclosure.FIG. 6is a side view as viewed from the interior of the vehicle and toward the left side of the vehicle10and shows the second cover assembly92connected to a frame assembly and to the first cover91, in accordance with one or more embodiments of the disclosure.

FIG. 4also shows various components or assemblies associated with the cover assembly90. The cover assembly90and the various components or assemblies associated with the cover assembly90can collectively be characterized as a vehicle assembly93. The vehicle assembly93can include a portion of frame assembly18including the second cage side member or B-pillar62. The vehicle assembly93can also include a grab bar94. The grab bar94can be attached to and extend from a rear side of the second cage side member62. Referring toFIG. 3, the grab bar94can extend across the vehicle10along the transverse direction of the vehicle10and can be attached to the second cage side member62on the right side of the vehicle. Alternatively, the grab bar94can extend across the vehicle to some interim location, such as halfway or approximately halfway across the vehicle. In this alternate embodiment, the grab bar94can be combined with a similar or mirror image grab bar94on the right-hand side of the vehicle such that each of the rear seats23L,23R is aligned with a respective grab bar. The grab bar94can be welded or otherwise attached to a rear side of the second cage side member62. The grab bar94and the second cage side member62collectively can be referred to as a frame sub-assembly, or as a frame assembly62,94.

The vehicle assembly93can also include the front hinge assembly95. The front hinge assembly95can extend from a front side of the second cage side member62. The front hinge assembly95can be connected to the second cage side member62in any appropriate manner such as but not limited to welding, adhesive, and mechanical fasteners. The front hinge assembly95can include a forwardly extending horizontal portion that is connected to a downwardly oriented or vertical door support portion. The door support portion can support the front door panel assembly40. Further details are described below with reference toFIG. 5. The vehicle10can include a rear hinge assembly99that has structure identical to or similar to the front hinge assembly95.FIG. 3schematically represents the rear hinge assembly99. The front hinge assembly95can be configured as a single bent pipe. However, alternate embodiments can include a plurality of parts that are connected to together, or a pair of plate parts that are connected by a common pin such that the plate parts can pivot relative to each other, and one of the plate parts is fixed to the door panel assembly40and the other of the plate parts is fixed to the second cage side member62.

The vehicle assembly93can also include a seat belt retractor assembly96. The seat belt retractor assembly96can include a spool housing97and a seatbelt retractor bracket98. The spool housing97can house a spool, which can be attached to one end of a strap or belt. Inside the spool housing97, a spring or other mechanical device can be utilized to provide a retractor mechanism that can apply a rotational force to the spool. The rotational force and mechanical arrangement of the spool can be configured to selectively wind and unwind a seatbelt, as well as configured to apply a tension force and lock the seat belt in tension. In the exemplary embodiment ofFIGS. 4-6, the spool housing97can be in the form of a square or rectangular box provided with rounded corners.

The spool housing97can be attached to the second cage side member62by the seat belt retractor bracket98. The seatbelt retractor bracket98can be attached to the spool housing97by welding, mechanical fasteners, etc.FIGS. 5 and 6show a threaded fastener assembly100releasably connecting the spool housing97to the seatbelt retractor bracket98. The seatbelt retractor bracket98can be attached to the second cage side member62by welding, mechanical fasteners, etc. The spool housing97, as supported by the seat belt retractor bracket98, can be spaced away from the grab bar94. Additionally, the seatbelt retractor bracket98can be spaced away from the second cage side member62.

Referring toFIGS. 4-6, the first cover member91can be outboard of the second cover member92such that the first cover member91can be located between the left rear door assembly73and the second cover92when the left door assembly73is in the closed position. The first cover member91can be attached to or mated with the second cover member92. The first cover member91and the second cover member92can be formed form any appropriate material such as but not limited to plastic, metal, carbon fiber, a composite material, and any combination of these materials. In the exemplary embodiment ofFIGS. 1-6, the cover members91,92can be constructed of injection molded plastic.

The first cover member91can include a first sleeve portion101. The first sleeve portion101can include or be in the shape of a circumferential portion of a cylinder. Accordingly, the first sleeve portion101can encompass or wraparound a portion of the second cage side member62, which accordingly can be characterized as including the first portion102of the frame assembly18. The first portion of the second cage member62can also be referred to as a first portion102of a frame assembly such as but not limited to the frame assembly18and the frame assembly62,94. The first sleeve portion101can be concave on an interior thereof so as to effectively mate with the second cage side member62.

The first cover member91can include a main body portion103. The main body portion103can include a flat or substantially flat member. The main body portion103can extend from the first sleeve portion101at an integral junction104such that the sleeve portion101is continuous with and curves outwardly away from an exterior surface of the main body portion103and the sleeve portion101has a convex shape with respect to the exterior surface of the main body portion103. The main body portion103can be supported, at least in part, by the first sleeve portion101. The first sleeve portion101can include an upper mounting surface105and a lower mounting surface106. Each of the mounting surfaces105,106can be flat and can include a through hole such that a mechanical fastener can through the first sleeve portion101and into the second cage side member62to secure the first cover member91to the second cage side member62. The mounting surfaces105,106can be on raised member that extends away from the curved surface of the sleeve portion101such that the mounting surfaces105,106are spaced away from the curved surface of the sleeve portion101. In an alternate embodiment, the mounting surfaces205can be recessed below a portion of the curved surface of the sleeve portion101.

The first cover member91can include a peripheral wall107. The peripheral wall107can include a peripheral lower wall108and a peripheral forward wall109. A junction110of the peripheral lower wall108and the peripheral forward wall109can include a curved wall portion. The peripheral wall107can extend inwardly or in an inboard direction along a periphery of the main body portion103. Accordingly, an edge of the peripheral wall107can be attached along a portion of the periphery of the main body portion103. The peripheral wall107can extend away from the main body portion103and toward an interior of the vehicle10along the transverse direction T of the vehicle10.

The main body portion103can include an opening111. The opening111can be shaped so as to allow access to the striker assembly112and/or so as to allow the striker assembly112to extend outwardly through the opening111. The striker88can be positioned relative to the first cover91, the second cages side member62and the rear door assembly73so as to be engageable with a latch assembly85when the rear door assembly73is in the closed position. Also, the opening111can provide access to an upper striker fastener113and a lower striker fastener114. The striker fasteners113,114can serve to attach the striker assembly112to a striker bracket115, described further below. For example, the opening111can be in the shape of a hexagon or 6-sided polygon. However, the opening111is not limited to any particular shape. The opening111can include and be defined by an inner flange116that extends around and that defines the opening111. The inner flange116can provide structural strength and be aesthetically pleasing. The inner flange116can extend away form the main body portion103and toward the interior of the vehicle10along the transverse direction T of the vehicle10.

The main body portion103can also include a bumper area117. The bumper area117can include a recessed area, as shown inFIG. 4, that can house or support a bumper120and a bumper fastener121. The bumper120can be provided to engage with rear door assembly73and cushion the rear door assembly73in closing the rear door assembly73. For example, the bumper120can be constructed of rubber and be in the shape of a disk that extends through the main body portion103and is supported by the main body portion103. The bumper fastener121can include a bolt or other suitable fastener that can secure to the bumper120to the first cover91and/or to the second cage side member62. The bumper area117can be recessed or concave so as to support, center and orient the bumper120. In the exemplary embodiment ofFIG. 4, the bumper fastener121can secure the bumper120and the first cover91to the striker bracket115.

The first cover member91can also include a top body portion122. The top body portion122can extend along and from an upper portion of the main body portion103. More specifically, a lower central portion of the top body portion122can be continuous with and extend away the upper portion of the main body portion103. A lower rear portion of the top body portion122can be continuous with and extend away from an upper portion of the first sleeve portion101. A lower front portion of the top body portion122can extend from the main body portion103so as to define, in part, a forward extension123of the top body portion122. The top body portion122including the extension123can serve to enclose, along with the second cover member92, the front hinge assembly95.

As shown inFIG. 4, the top body portion122can be provided with convex portion124and concave portion125. The convex portion124and the concave portion125can be provided for aesthetic appeal. The convex portion124and the concave portion125extend along a first portion of the front hinge assembly95.

The first cover member91can also include a second sleeve portion126. The second sleeve portion126can include or be in the shape of a circumferential portion of a cylinder. Accordingly, the second sleeve portion126can encompass or wraparound a portion of the grab bar94. The portion of the grab bar94encompassed or wrapped by the second sleeve portion can be referred to as a second portion127of a frame assembly such as but not limited to the frame assembly18and the frame assembly62,94. The second sleeve portion126can be concave in shape so as to mate with a portion of an outer surface of the grab bar94. Alternatively, the second sleeve portion126can be spaced from an outboard, outer surface of the grab bar94. The second sleeve portion126can include mounting surface128. The mounting surface128can provide access to, support, or house a suitable fastener that is used to attach the second sleeve portion126to the grab bar94. The mounting surface128can be of similar or same structure as the mounting surfaces105,106on the first sleeve portion101such that a mechanical fastener can pass through the second sleeve portion126and into the grab bar94.

As shown inFIG. 4, the top body portion122can include a rear portion129. The rear portion129can extend rearwardly beyond the second cage side member62along the longitudinal direction L of the vehicle10and on an outboard side of the second cage side member62. The rear portion129can include an upper edge130that can abut the cylindrical shape of the second cage side member62and that sweeps around an outer surface of the second cage side member62.

The first cover member91can also include a bridge portion131. The bridge portion131can extend rearwardly along the longitudinal direction L of the vehicle10from the rear portion129, of the top body portion122, and rearwardly along the longitudinal direction L of the vehicle10from an upper, rear portion of the first sleeve portion101. As is shown inFIG. 4, the bridge portion131can be shaped and include a contoured surface132so as to be closely fit with and/or mate with exterior shape of the spool housing97of the seatbelt retractor assembly96. Accordingly, the contoured surface132can include angled, flat, curved, recessed, and/or other geometrical shapes so as to closely fit with and/or mate with the seatbelt retractor assembly96.

A rear portion of the bridge portion131and a rear, upper portion of the second sleeve portion126can be attached to and support an extension member133. The extension member133can extend toward the interior of the vehicle10along the transverse direction T of the vehicle10and away from its attachment with the bridge portion131and the second sleeve portion126. In particular, the extension member133can extend through and occupy a gap between the seatbelt retractor assembly96and a portion of the grab bar94that corresponds to the second portion127of the frame assembly18or frame assembly62,94. The extension member133can include a bottom wall134, a front wall135, a rear wall136and a top wall137.

The bottom wall134can be continuous with and extend away from the second sleeve portion126. The front wall135can be continuous with and extend away from the bridge portion131. More specifically, the bottom wall134can be joined with the second sleeve portion126along a lower portion or extent of a transitional surface or fillet138. The front wall135, of the extension member133, can be continuous with and extend away from the bridge portion131along an upper portion or extent of the transitional surface or fillet138. The second sleeve portion126, the first sleeve portion101, the main body portion103, the top body portion122, the bridge portion131, and the extension member133can be integrally formed, in accordance with one or more embodiments of the disclosure. For example, such components can be integrally formed by an injection molding process.

FIG. 5is a perspective view, from an inboard perspective looking outboard, of a vehicle assembly93, in accordance with one or more embodiments of the disclosure.

FIG. 5shows further details of the extension member133, of the first cover member91. The extension member133can include an inboard wall139. As shown inFIG. 5, the inboard wall139can provide an end of the extension member133. Accordingly, the inboard wall139can provide a wall that connects the front wall135the top wall137the rear wall136and the bottom wall134. The inboard wall139can be planar or flat in contour.FIG. 5also illustrates that the bottom wall134can be concave or include a concave section, portion or area that faces toward the grab bar94.FIG. 5illustrates an inboard edge140of the bottom wall134. Such concavity can be provided to mate with a surface of the grab bar94, i.e. at the second portion127of the frame assembly127. As a result, access into a gap between the seat belt retractor assembly96and the grab bar94can be prevented or obstructed.

As is shown inFIG. 5, the top wall137and the rear wall136can can effectively preclude or obstruct access to a gap between the seat belt retractor assembly96and the grab bar94in conjunction with allowing access to a lower surface or extent of the seatbelt retractor assembly96.

As discussed above, the bridge portion131and the extension member133can extend across the gap and into the gap, respectively, between the grab bar94and the spool housing97of the seat belt retractor assembly96. Although the exemplary embodiments of the bridge portion131and the extension member133abut the grab bar94, at least a portion of either the bridge portion131or the extension member133can be spaced away from the grab bar94. Further, the bridge portion131and/or the extension member133can be spaced away from the spool housing97by any appropriate dimension such that unwanted objects do enter the gap therebetween. Thus, the cover assembly90can cover at least a portion of the gap between the grab bar94and the spool housing97of the seat belt retractor assembly96.

As described above, the top body portion122including the forward extension123can serve to enclose the door support member95. In particular, the top body portion122can cooperate with the second cover92to enclose a horizontal portion143of the front hinge assembly95and a hinge portion144of the front hinge assembly95. The horizontal portion143can be connected to and extend forwardly in the transverse direction T of the vehicle10from the second cage side member or B-pillar62so as to locate or position the hinge portion144at a desired location. Accordingly, a desired pivot point of the front door panel assembly40may be provided. A lower portion of the hinge portion144, which extends into the front door panel assembly40, may be of straight construction, e.g. a straight tube, so as to allow desired pivoting of the front door panel assembly40about the hinge portion144. Suitable bearings or other attachment structure may be utilized so as to allow pivoting of the front door panel assembly40on the hinge portion144.

As shown inFIG. 5, the top body portion122can include a first top flange142. The first top flange142can extend toward the interior of the vehicle10along the transverse direction T of the vehicle10from an upper portion of the top body portion122. The first top flange142can include a first top145, a first angled front146, a first front skirt147and a first front lip148. The first top145and the first angled front146can form a continuous surface, along a top of the top body portion122, so as to wrap around the front hinge assembly95. The first angled front146can terminate at a forward edge thereof with a front skirt147. The front skirt147, along with a connected front lip148, can provide a skirt arrangement that is positioned adjacent to and above the front door assembly70, which rotates relative to the first top flange142. Such skirt arrangement including the front skirt147and the front lip148can be aesthetically pleasing and provide a curved outer surface or edge.

As described above, the front hinge assembly95can be connected to the second cage side member62in any appropriate manner and extend forwardly therefrom along the longitudinal direction L of the vehicle10. For example,FIG. 5illustrates a hinge mounting bracket149connected to and extending away from the second cage side member62along the longitudinal direction L of the vehicle10toward the front of the vehicle10. The hinge mounting bracket149can be connected to the second cage side member62in any appropriate manner such as but not limited to welding, adhesives and mechanical fasteners. The front hinge assembly95can be connected to the hinge mounting bracket149in any appropriate manner such as but not limited to welding, adhesives and mechanical fasteners.

The first cover member91can include an upper fastener post150A and a lower fastener post150B. Each of the fastener posts150A,150B can be include a threaded member insert molded in the first cover91or provided with a threaded interior bore into which a threaded fastener may be secured. The threaded fastener posts150A,150B can be provided for attachment of the first cover member91to the second cover member92. Specifically, as also shown inFIG. 6, a first fastener151may pass through the second cover member92and into the upper fastener post150A. A second fastener152may pass through the second cover member92and into the lower fastener post150B. It is appreciated that other securement arrangements or mechanisms may be provided to attach the second cover member92onto the first cover member91. For example, the fasteners151,152can be self-tapping threaded fasteners such that the bores in the fastener posts150A,150B are plain surfaces and are not threaded.

FIG. 5shows further details of striker bracket115, in accordance with one or more embodiments of the disclosure. The striker bracket115can include a bracket body portion153and an edge flange154that encircles at least a portion of the periphery of the striker bracket115. The edge flange154can be provided to add rigidity and structural support to the striker bracket115. The striker bracket115can include an upper connection portion155a middle connection portion156and a lower connection portion157. Each of the connection portions155,156,157can be attached to the second cage side member62such as by welding or other attachment mechanism. The bracket body portion153, of the striker bracket115, can be provided with any of holes, apertures, reliefs, or structural reinforcement as may be desired. In the exemplary embodiment ofFIG. 5, the striker bracket115can be provided with one or more reliefs158and one or more openings or holes159. The striker bracket115may also be provided with an upper attachment hole160and a lower attachment hole161. The upper attachment hole160can provide pass through of the upper striker fastener113so as to provide securement of the striker bracket115to the upper striker fastener113. The lower attachment hole161can provide pass through of the lower striker fastener114so as to provide securement of the striker bracket115to the lower striker fastener114.

The striker bracket115can also include a hole or aperture so as to allow pass-through of a bumper fastener121, also shown inFIG. 4. As also described above, such bumper fastener121can provide securement and support to a bumper120. The bumper120can be provided to cushion closing of the rear door panel assembly42.

FIG. 6is a perspective view of a vehicle assembly93, in accordance with one or more embodiments of the disclosure. In particular,FIG. 6is a perspective view of the vehicle assembly93looking from the interior of the vehicle in an outboard direction.FIG. 6shows the second cover member92attached to the first cover member91utilizing fasteners151,152.

In general, the second cover member92can be dimensioned end of geometrical shape to both mate with the first cover member91and to provide accommodation for the various components housed within an internal cavity that is created by the first cover member91and the second cover member92. Any number of fasteners or other attachment mechanisms can be utilized to attach the first cover member91to the second cover member92. As described above, fasteners151,152can be used to attach the first cover member91to the second cover member92. Additional fastener163can be utilized to attach the cover members91,92.

The striker bracket115, as shown inFIG. 5, can include a securement tab164. The securement tab164can be provided to threadably receive a fastener165. Such fastener165can also be provided to secure the second cover member92, and specifically to secure the second cover member92to the striker bracket115. Accordingly, the second cover member92can be provided with a fastener hole166. The fastener hole166can provide pass through of the fastener165so as to provide securement of the second cover member92to the securement tab164of the striker bracket115.

The second cover member92can also include a third sleeve portion167. The third sleeve portion167can be of similar shape, but mirror image, to the first sleeve portion101. The third sleeve portion167can be connected along a rear portion of a main body portion168of the second cover member92. The second cover member92can also include a top body portion169. As shown inFIG. 6, the top body portion169can be continuous with and extend from an upper portion of the main body portion168. The top body portion169can be continuous with and extend from an upward forward portion of the second sleeve portion167. The main body portion168can be provided to correspond substantially with the shape of the main body portion103, of the first cover member91. The top body portion169can be provided to correspond substantially with the shape of the top body portion122, of the first cover member91. The second cover member92can be provided with recess170that along which a structure extends for securing a strap of the net assembly80of the front door assembly70.

The second cover member92can include a second top171. The second top171can be of similar shape to the first top flange142. The second top171, of the second cover member92, can be received by the first cover91underneath the first top flange142. In general, structure of the first cover member91can receive therein the second cover member92or portions of the second cover member92. Accordingly, the second cover member92can be “nested” within the first cover member91.

As described above, the second cover member92can include a second sleeve portion167. The second sleeve portion167can be provided with an upper mounting surface172and a lower mounting surface173The mounting surfaces172,173can be same as or similar to the mounting surfaces105,106on the first sleeve portion101of the first cover91. Referring toFIGS. 4 and 6, a threaded fastener assembly174can pass through the holes in the upper mounting surfaces105,172. A threaded fastener assembly175can pass through the holes in the lower mounting surfaces106,173to connect the first sleeve portion101and the second sleeve portion167to the second cage side member62.

FIG. 6also shows retractor bracket98, in accordance with one or more embodiments of the disclosure. The retractor bracket98can include a spacer panel180and an attachment panel181. The spacer panel180can be of desired length and geometry so as to space the attachment panel181, and as a result the spool housing97, at a desired distance from both the second cage side member62and the grab bar94. A fastener182connect the spool housing97to the retractor bracket98. For example, the fastener182can be a bolt that is received into a threaded aperture in the spool housing97.

Retractor bracket98can include an upper bracket flange183and a lower bracket flange184. The bracket flanges183,184can be shaped and of geometrical dimension so as to complement the spacer panel180and the attachment panel181. As should be appreciated, the bracket flanges183,184can provide structural support to the retractor bracket98. The spacer panel180can include openings, holes, or relief areas as may be desired.

While an illustrative cover assembly90has been described as positioned between the front left door and the rear left door, the disclosure is not limited to such arrangement. A cover assembly90of the disclosure can be used with other doors or door assemblies as may be desired.

As described herein, a striker assembly can be provided on the frame assembly and latch assembly can be provided on the door assembly. However, the disclosure is not limited to such arrangement. Accordingly, a striker assembly can be provided on the door assembly and latch assembly can be provided on the frame assembly.

It is appreciated that the various components of embodiments of the disclosure can be made from any of a variety of materials including, for example, metal, plastic, plastic resin, nylon, composite material, leather, and/or rubber, for example, or any other material as may be desired.

The striker bracket115and other components of the cover assembly90can be formed from a sheet or flat plate of metal by a stamping process. An exemplary stamping process can include a step in which a pair of dies cuts a portion of the metal sheet or plate (also referred to as a blank). The stamping process can cut openings, holes or relief areas from the blank, and can bend portions of the blank to produce the edge flange154, for example, such that the flat blank is transformed into the three-dimensional structure of the striker bracket115and the individual features of the striker bracket115discussed above constitute a one-piece, integral, homogenous structure. Thus, the striker bracket115can be referred to as a stamped metal bracket. However, a variety of production techniques can be used to make the apparatuses as described herein. For example, suitable casting and/or injection molding and other molding techniques, extrusion and other manufacturing techniques might be utilized.

While the subject matter has been described in detail with reference to exemplary embodiments thereof, it will be apparent to one skilled in the art that various changes can be made, and equivalents employed, without departing from the scope of the invention.

For example, embodiments are disclosed above in which the first cover member91or portions thereof is constructed of a single or unitary piece. However, embodiments are intended to include or otherwise cover a first cover member91that includes or is constructed of multiple pieces. For example, the multiple pieces of first cover member91can be injection molded in pieces and then connected together such as by heat bonding or adhesive, for example.

For example, embodiments are disclosed above in which the first cover member91and the second cover member92, which make up the cover assembly90, includes a specific shape, geometry, or construction. It is appreciated that shape and structure of components described herein may vary between different types of vehicles. Accordingly, exemplary embodiments are also intended to include or otherwise cover assemblies that include variations in shape, geometry, or construction as dependent on assemblies with which the cover assembly90is intended to be utilized.