Structurally integrating members between vehicle bodies and closures

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

FIELD OF THE INVENTION
 The present invention relates to structurally integrating members between
 vehicle bodies and closures. More particularly, this invention is directed
 to self-aligning structural key members and mating receptacles
 incorporated with vehicle component sub-assemblies, such as hinges and
 latches, to structurally integrate vehicle closures with a vehicle body.
 BACKGROUND OF THE INVENTION
 While known conventional vehicle closure members, such as vehicle doors,
 are attached to a vehicle body, the closure members are not structurally
 integrated with the vehicle body. Consequently, the closure members, which
 are of considerable mass, are simply hanging on the vehicle body. Thus,
 stiffness and overall strength of the vehicle body is reduced, which
 results in a noticeable feeling to a vehicle occupant of shuddering and
 bouncy ride. Idle shake may also be experienced, along with an increase in
 noise and vibration, producing a poor ride and poor vehicle handling.
 Further, in the event of impact or collision with other vehicles, a
 non-integrated closure member can "pop out" from the vehicle body, or cave
 in, such that the closure member is separated from its attachment points.
 Separation of the closure member from the vehicle body causes loss of a
 significant amount of energy absorption that is necessary to protect the
 vehicle occupants from injury during a collision.
 To address these problems, it has been previously proposed to structurally
 integrate a vehicle door with a vehicle body. The door and body
 integration technology as applied to vertically sliding doors is disclosed
 in the following U.S. Patents issued to John A. Townsend: U.S. Pat. No.
 4,801,172 issued Jan. 31, 1989; U.S. Pat. No. 4,940,282 issued Jul. 10,
 1990; U.S. Pat. No. 5,378,036 issued Jan. 3, 1995; and applied to a
 conventional hinged door in U.S. Pat. No. 5,806,917 issued Sep. 15, 1998.
 These disclosures are incorporated herein by reference.
 In operation, when the vehicle doors of the above patents are closed,
 structural key members formed on the edges of the door engage with mating
 receptacles formed in the door jambs of the vehicle body that frame a door
 opening. In the engaged position, each key member and mating receptacle
 pair is able to transmit compressive, tensile and torsional forces between
 the door and the vehicle body, thereby contributing to the overall
 stiffness of the vehicle body.
 However, with current technology precise manufacturing dimensional
 tolerances of a large closure member, such as the vehicle door, that
 incorporate the structural keys and receptacles are difficult to achieve
 such that when the vehicle door is aligned with the vehicle body by
 adjusting hinges and latches on the vehicle door and vehicle body, the
 keys and receptacles are not always properly aligned for mating
 engagement. To insure proper alignment of the keys and receptacles, it has
 been proposed to form the receptacles so as to be considerably larger than
 the keys. With such an arrangement, the keys could be loosely accommodated
 within the receptacles once the closure member had been adjusted into its
 correct position with respect to the vehicle body by means of the hinge
 and latch assemblies. Fast curing metallic epoxy resin was then applied to
 the inside of the receptacles and a resist compound to the keys. The
 closure member was then closed in its final adjustment position with
 reference to the vehicle body. After curing, the keys were mated precisely
 with the key impressions made in the resin within the receptacles. Once
 the keys and receptacles were properly aligned, the keys and receptacles
 provided an excellent structural link between the closure member and the
 vehicle body, due to the precise fit of the keys with the epoxy filled
 receptacle.
 However, the addition of the epoxy resin to the receptacles required an
 additional alignment process on the production line, thereby
 disadvantageously increasing manufacturing time, which translates into
 increased costs. Further, as it is necessary to add the epoxy resin to the
 receptacles on the production line, the alignment of the structural keys
 and receptacles could not be performed by outside suppliers.
 Another disadvantage associated with known structural keys and receptacles
 is that closure members and door jambs are traditionally manufactured by
 stamping metal of a constant gage, such that the thickness of the closure
 member and the door jamb are constant. Consequently, to successfully
 design the keys and receptacles into a closure member and vehicle body,
 the area around the keys and receptacles require considerable localized
 re-enforcing by adding additional metal of a heavier gage, thereby
 increasing production costs.
 While prior art use of the closure member and vehicle body integration
 technology improves the structural integrity of the overall vehicle body
 structure, there are disadvantages with the known use of structural keys
 and mating receptacles. Therefore, there exists a need for improved
 structural integration of a vehicle closure member and vehicle body that
 eliminates special alignment and the reinforcing steps while introducing a
 new metal epoxy technology in the manufacturing process.
 SUMMARY OF THE INVENTION
 To achieve excellent structural integration of closure members and bodies
 while overcoming production difficulties, the present invention is
 directed to vehicle component sub-assemblies that incorporate
 self-aligning structural key members and mating receptacles. Hinges,
 latches and other vehicle components are provided with integral structural
 keys and receptacles such that the keys and receptacles are integrated
 with the hinges, latches, and strikers, as opposed to the closure member
 or body.
 In accordance with one aspect of the invention, wedge-shaped structural key
 members and mating receptacles are manufactured as a precision fit
 integral with and during the same manufacturing operation as a door plate
 and mating body plate of a door hinge, respectively. Once formed the
 entire hinge sub-assembly is connected to the vehicle in a conventional
 manner by bolting the door plate to a closure member, such as a vehicle
 door, and the attached body plate to a vehicle body. The closure member
 and body plates are provided with traditional adjustment capability during
 assembly of the closure member to the vehicle body to insure their proper
 alignment.
 The structural key members and mating receptacles may also be incorporated
 with other vehicle component sub-assemblies having mating parts such as
 brackets and door and hood latch sub-assemblies. For example, when the
 structural keys and receptacles are incorporated into latch and striker
 sub-assemblies, when a latch is in the correct location for mating
 engagement with a striker, the structural keys and receptacles formed
 thereon, will automatically be aligned to a precise fit.
 The incorporation of the structural keys and receptacles with the vehicle
 component sub-assemblies provides important technical and manufacturing
 benefits over the prior art keys and receptacles. First, hinges, latches
 and strikers are traditionally manufactured in a heavier gage than the
 vehicle closure member and corresponding body structure. Therefore, the
 component sub-assemblies are sufficiently strong for the keys and
 receptacles cast therein to provided maximum structural integration of the
 vehicle closure member with the vehicle body without requiring any
 additional reinforcement.
 Further, the manufacture of the structural keys and mating receptacles
 within the hinges, latches and bracket sub-assemblies is greatly
 simplified as compared to the prior art practice of manufacturing the
 structural keys and receptacles as part of the closure member and vehicle
 body as these component sub-assemblies are simple enough to allow for
 traditional tolerances that will permit the necessary precision fit of the
 structural keys to the mating receptacles. Because the hinges, latches and
 brackets sub-assemblies are usually either cast or forged, it is possible
 to form the structural keys and receptacles as large as may be necessary
 while maintaining desirable tight tolerances. Additionally, disadvantages
 such as warping and springback, that were previously associated with
 incorporating stamped keys and receptacles into large components, are
 eliminated, thus reduces dimensional variation.
 Vehicle component sub-assemblies having the structural keys and mating
 receptacles of the present invention may also be easily incorporated to
 existing vehicle doors without necessitating re-design of the vehicle door
 or requiring a special alignment step in the manufacturing process by
 means of additional metal epoxy technology. Therefore, the component
 sub-assemblies may be manufactured at a separate facility by outside
 suppliers from the closure member and vehicle body, permitting
 "just-in-time" incorporation with the vehicle at final vehicle assembly
 and reducing costs associated with inventory control.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
 The following figures depict various mating vehicle component
 sub-assemblies used to integrate a vehicle door to a vehicle body. The
 door and body integration technology serves to transmit compressive,
 tensile and shear forces between the vehicle door and the vehicle body
 with only a minimal amount of modification to an existing vehicle door.
 Referring to FIG. 1, a first embodiment of the present invention is shown
 applied to a conventional door hinge sub-assembly 10. Door hinge 10 has a
 door plate 12 and a mating body plate 14. Door plate 12 is pivotally
 connected to body plate 14 by a pin 16 that extends through sleeves 18 and
 20, of door and body plates 12 and 14, respectively.
 In accordance with the invention, the door plate 12 is provided with a
 structural key member 22 that extends laterally from a front surface 24 of
 door plate 12. In a preferred embodiment, structural key member 22 is
 integral with door plate 12 and has a base portion 26 that narrows to an
 apex 28, such that structural key member 22 is generally wedged-shaped.
 Body plate 14 is provided with a generally wedge-shaped mating receptacle
 30 for complementary engagement with structural key member 22 when the
 door is closed such that compressive, tensile and torsional forces may be
 transmitted between the door and the vehicle body to provide a
 structurally stiffer vehicle. While the wedge shape is preferred, other
 shapes may be employed, as long as the shape of structural key member 22
 is complimentary and appropriately fitted with receptacle 30. Preferably,
 receptacle 30 is formed integral with body plate 14. To insure proper fit
 between structural key member 22 and receptacle 30, either structural key
 member 22, receptacle 30 or both, may optionally be coated with an
 elastomeric material to provide a tight seal therebetween when the vehicle
 door is closed.
 In an alternative embodiment, illustrated in FIG. 2, door plate 12 and body
 plate 14 are provided with a plurality of structural key members 22 and
 mating receptacles 30, respectively. Further, the configurations of door
 plate 12 and body plate 14 may be reversed such that door plate 12 is
 provided with mating receptacles 30 that extend below front surface 24 and
 body plate 14 includes structural key members 22 that extend away from a
 front surface 31 of body plate 14 as seen in FIG. 3. It is also within the
 scope of the invention that door plate 12 and body plate 14 have both
 structural key members that engage mating receptacles 30 on the other
 plate, respectively (not shown).
 For structural key member 22 to precisely mate with the receptacle 30 an
 arc like shape is preferred to follow the mating trajectory of the closing
 components during opening and closing. FIGS. 2 and 3 demonstrate the
 curvature of the keys and receptacles to form the proper mating trajectory
 that facilitates a smooth and precise mating of these components in
 combination with the overall closure components to which they are
 attached.
 To mount door hinge 10 to a vehicle door, a back surface 32 of door plate
 12 is secured to a vehicle door by traditional fasteners or other suitable
 means. Body plate 14 is preferably secured to a vehicle body by
 conventional fasteners 34, such as bolts, in a manner so as insure that
 body plate 14 will be substantially aligned with door plate 12. Because
 structural key members 22 and mating receptacles 30 are formed on door
 hinge 10 components 12 and 14, respectively, the alignment of door plate
 12 and body plate 14 serve to automatically align structural key members
 22 with mating receptacles 30.
 The depth of receptacle 30 typically exceeds the thickness of body plate
 14. Therefore, it may be necessary to provide a small cut-out on the
 vehicle body corresponding to the size of receptacle 30. Generally, the
 cut-out will be slightly larger to permit appropriate positioning of door
 hinge 10 components 12 and 14 with respect to the vehicle door.
 Alternatively, structural key members 22 may have a reduced height and
 mating receptacles 30 a reduced depth such that body plate 14 may be
 provided with a substantially planar back surface, thereby eliminating the
 need for a providing a cut-out on the vehicle body.
 In accordance with another aspect of the invention, following traditional
 process alignment of the vehicle door with the vehicle body, body plate 14
 may be provided with elongated slots 36 for receiving bolts, whereby body
 plate 14 would be axially adjustable.
 The door hinge 10 may be formed as a sheet metal stamping, such that the
 structural key member 22 and mating receptacle 30 may be integrally formed
 in the same operation as the door hinge 10, thereby reducing manufacturing
 costs. Alternatively, door hinge 10 may be cast or forged with the
 integral structural key members 22 and mating receptacles 30 formed
 thereon, thereby making a stronger door hinge 10, and thus a stronger
 structural connection between structural key members 22 and mating
 receptacles 30.
 Other advantages of providing door hinge 10 with structural key member 22
 and mating receptacle 30 include manufacturing of door hinge 10 at a
 separate facility, permitting "just-in-time" incorporation with the
 vehicle door at the vehicle assembly line. Thus inventory control costs
 and costs associated with storage may be reduced. Further, as structural
 keys 22 and receptacles 30 are provided on door plate 12 and body plate
 14, respectively, there is no need to re-design the vehicle door or alter
 the body structure of the vehicle body to insure the proper strength
 reinforcement of structural key members 22 and mating receptacles 30.
 Thus, manufacturing costs are reduced and incorporation of structural key
 members 22 and mating receptacles 30 on existing vehicle doors may be
 accomplished easily.
 FIG. 4 depicts an alternative door hinge 100 having a door plate 112 and a
 body plate 114 pivotally connected together once properly aligned. Body
 plate 114 is L-shaped and includes a substantially planar mounting surface
 116 that is configured to engage a portion of a vehicle body. Mounting
 surface 116 is provided with conventional oversize apertures 118 for
 receiving fasteners, such as bolts for fixedly securing and adjusting body
 plate 114 to the vehicle body. Alternatively, body plate 114 may be welded
 to the vehicle body or attached by other suitable means. Aligned legs 119
 extend away from mounting surface 116 and include apertures 120, to be
 explained in further detail below.
 In accordance with the present invention, a front surface 121 of body plate
 114 is provided with a structural key member 122 extending therefrom.
 Structural key member 122 is slightly angled and curved relative to body
 plate 114, to be explained below, and has a rectangular cross-section.
 Other suitable shapes may be employed for structural key member 122.
 Door plate 112 includes a mounting portion 124 and a bracket portion 126.
 Mounting portion 124 has a substantially planar mounting surface 128 that
 is configured to engage a portion of a vehicle door. Apertures 130 are
 provided in mounting portion 124 for receiving fasteners, such as bolts,
 to adjust and fixedly secure door plate 112 to a vehicle door. Bracket
 portion 126 is connected to mounting portion 124 by webs 132. Bracket
 portion 126 includes an axially extending aperture (not shown) that
 corresponds an apertures 120 on body plate 114 for receiving a pin (not
 shown) in a conventional manner to pivotally connect door plate 112 and
 body plate 114.
 In accordance with the invention, bracket portion 126 further includes a
 receptacle 134 formed therein that has a size and shape that corresponds
 to the size and shape of structural key member 122. Thus, when the vehicle
 door is closed, structural key member 122 engages receptacle 134, similar
 to that of door hinge 10, such that compressive, tensile and torsional
 forces may be transmitted between the door and the vehicle body, thereby
 providing a structurally stronger vehicle.
 Door hinge 100 may be directly mounted to a vehicle without requiring any
 additional modifications to the vehicle. Unlike door hinge 10, there is no
 need for the vehicle door or body to be provided with an additional
 cut-out as receptacle 134 is formed in the bracket portion 126. Thus,
 incorporation of door hinge 100 as a "just-in-time" component to an
 existing vehicle door and body may be accomplished cost-efficiently with a
 minimum of production steps. Further, in accordance with the present
 invention, pre-alignment of structural key member 122 and mating
 receptacle 134 during manufacturing is not disturbed by virtue of the
 alignment of door plate 112 and body plate 114.
 While use of the structural key members 22, 122 and mating receptacles 30,
 134 have thus far been described for use with vehicle door hinges, the
 inventive technology may also be utilized with other vehicle component
 parts, as well. Referring to FIG. 5, in an alternative embodiment a
 vehicle door 200 is shown having a door latch sub-assembly 202 that
 includes a door latch plate 204 and a mating door striker plate 206. Door
 latch plate 204, as more clearly seen in FIG. 5A, is shown mounted on a
 trailing edge 208 of vehicle door 200. Door latch plate 204 has an
 L-shaped cross-section with a first leg 210 and a second leg 212. First
 leg 212 is mounted to an outside surface 214 of trailing edge 208 and
 second leg 212 is mounted to an inside surface 216 of trailing edge 212.
 Door latch plate 204 may be mounted by welding or conventional fasteners,
 such as bolts. Door latch plate 204 carries at least one conventional door
 latch 220. In accordance with the invention, door latch plate 204 further
 includes at least one structural key member 228 formed thereon extending
 laterally from a front surface 229 of second leg 212.
 Door striker plate 206, as more clearly seen in FIG. 6, is mounted along an
 inside surface 230 of a door jamb (not shown) of a vehicle body by welding
 or conventional fasteners so as to be aligned with door latch plate 204.
 Door striker plate 206, includes a least one bar 232 that is captured by
 door latch 220 in a conventional manner. In accordance with the present
 invention, door striker plate 206 further includes a receptacle 240 that
 has a size and shape that corresponds to structural key member 228.
 Because door latch plate 204 and door striker plate 206 are pre-aligned
 during manufacture and properly mated, using traditional door adjustment
 and assembly techniques, when vehicle door 200 is closed, bars 232 extend
 into and are captured by door latch 220. Simultaneously, structural key
 member 228 extends into mating receptacle 240, thereby structurally
 integrating the door and the vehicle body via the door latch sub-assembly
 202. The incorporation of structural key member 228 and mating receptacle
 240 with door latch assembly 202 further insure that door latch 220 will
 remain secured to bar 232 in the event of a collision.
 While only one structural key member 228 has been shown formed on door
 latch plate 204 and one mating receptacle 240 has been shown formed in
 door striker plate 206, alternatively, door latch plate 204 may have
 multiple structural key members 228 formed thereon, as seen in FIGS. 7 and
 7A. Further, door latch plate 204 may be of varying lengths to properly
 accommodate a predetermined number of structural key members 228 formed
 thereon. Similarly, door striker plate 206 may be provided with multiple
 receptacles 240 corresponding to the number of structural key members 228.
 Preferably, either door latch plate 204 or door striker plate 206 is
 provided with a traditional adjustability feature, similar to that
 described with respect to door hinge 10. Referring to FIG. 7A, front
 surface of door latch plate 204 is shown having bolt slots 222 formed
 therein for receiving a bolt 224, such that door latch plate 204 may be
 axially slidable to insure proper alignment of door latch 220 with the
 striker.
 Referring to FIGS. 8-9A, structural key members 328 may optionally have
 alternative orientations and shapes. For example, FIG. 8 shows structural
 key members 328 formed so as to be laterally extending from front surface
 329 of door latch plate 304 at a predetermined angle. Corresponding
 receptacles (not shown) would similarly angled in the door striker plate
 (not shown) such that structural key members 328 would interlock with the
 angled receptacles. FIG. 9 shows structural key members 428 formed in door
 latch plate 404, wherein structural key members 428 are formed so as to be
 curved with a predetermined radius. Corresponding receptacles (not shown)
 would be formed so as to be curved such that structural key members 428
 will interlock with the receptacles when door 400 is closed, thereby
 integrating the vehicle door with the vehicle body via the door latch
 assembly as described above.
 Further, structural key member 228 and receptacles 240 may be interchanged.
 For example, referring to FIGS. 10 and 10A, door latch plate 504 may be
 provided with receptacles 540 and door striker plate 506 provided with
 structural key members 528. Alternatively, door latch plate 504 and door
 striker plate 506 may both be provided with a structural key member and a
 mating receptacle (not shown).
 Referring to FIGS. 11-11D, in another alternative embodiment, multiple door
 latch plates 604, each incorporating at least one structural key member
 628 and corresponding mating door striker plates 606 each incorporating at
 least one mating receptacle 640 therein are shown mounted on leading edge
 608 of vehicle door 600 and door jam 630 of a vehicle body, respectively.
 In accordance with the present invention, once door latch plate 604 is
 properly positioned on door 600 so as to align with mating striker plate
 606; structural key members 628 are automatically aligned with mating
 receptacles 640.
 Referring to FIGS. 12 and 12A, structural key members 728 may alternatively
 be provided on brackets 704 that are mounted on a trailing edge 708 of a
 vehicle door 700. The use of brackets 704 is useful as an after-market
 product when it is desired to integrate an existing vehicle door 700 with
 a vehicle body. Brackets 704 may be mounted to vehicle door 700 by welding
 or conventional fasteners. Preferably, brackets 704 are provided with
 adjustment slots similar to slots 36 described in connection with door
 hinge such that the positioning of bracket 704 is axially adjustable to
 mate up with a corresponding mating bracket (not shown) mounted on the
 vehicle body.
 Similar to door latch plate 204 in FIG. 5, bracket 704 preferably has an
 L-shaped cross section that engages both surfaces adjacent trailing edge
 708 of vehicle door 700. Integral with a first leg 712 is at least one
 structural key member 728. Structural key members 728 are shown as being
 generally wedge-shaped, although other suitable shapes are within the
 scope of the invention, as discussed above. A second corresponding mating
 bracket (not shown) is mounted to a door jam of the vehicle body so as to
 be in substantial alignment with bracket 704 in a similar fashion as door
 striker plate 206 in FIG. 5, wherein the second bracket includes at least
 one receptacle that corresponds in size and shape to structural key member
 728. Thus, when vehicle door 700 is closed, structural key members 704
 interlock with the corresponding receptacles to structurally integrate
 vehicle door 700 and the vehicle body in accordance with the present
 invention.
 Referring to FIGS. 13 and 14, the present invention may also be
 incorporated with sliding vehicle doors 800. In FIG. 13, vehicle door 800
 is provided with a door latch plate 804 mounted along an inside trailing
 edge 808 and a door striker plate (not shown) mounted on the door jam of
 the vehicle body so as to be substantially aligned with door latch plate
 804. Door latch plate 804 carries a door latch 820 that captures an
 engagement member 836 of the door striker plate in a conventional manner
 when vehicle door 800 is closed. In accordance with the present invention,
 door latch plate 804 further includes at least one structural key member
 828 formed thereon. Structural key members 828 are engagable with mating
 receptacles 840 formed on the door striker plate when vehicle door 800 is
 closed. Due to the path of vehicle door 800, structural key members 828
 are curved to insure proper engagement with receptacles 840.
 Alternatively, referring to FIG. 14, the positions of structural key
 members 828 may be reversed such that structural key members 828 are
 connected to the vehicle body and the mating receptacles 840 are carried
 by vehicle door 800. Further, structural key members 828 and receptacles
 840 may optionally be integrally formed with vehicle door 800 and the door
 jam, respectively.
 Referring to FIGS. 15-17, in another alternative embodiment, structural key
 members 928 and mating receptacles 940 are shown incorporated with hood
 latch assemblies 902 for a vehicle hood 900. Referring to FIG. 15, vehicle
 hood 900 is provided with a hood striker plate 906 mounted thereon (as
 best seen in FIG. 16), having an engaging member 936 that generally
 corresponds to door striker plate 206 and engaging member 236 in FIG. 5.
 The vehicle body 901 is provided with a hood latch plate 904 mounted
 thereon that aligns and engages with hood striker plate 906. Hood latch
 plate has a latch 920 that generally corresponds to door latch plate 204
 and door latch 220 in FIG. 5.
 In accordance with the present invention, hood latch plate 904 further
 includes at least one structural key member 928 formed and pre-aligned
 during manufacture to engage at least one mating receptacle 940 formed in
 hood striker plate 906. Because hood latch plate 904 is positioned in
 traditional manner during assembly so as to align with hood striker plate
 906, structural key member 928 and receptacle 940 are automatically
 aligned in accordance with the present invention.
 When vehicle hood 900 is closed and hood latch 920 captures bar 932 in a
 conventional manner and structural key member 928 engages with mating
 receptacle 940, thereby structurally integrating vehicle hood 900 with
 vehicle body 901. Referring to FIG. 17, hood latch plate 904 may
 alternatively be formed with receptacles 940a that engage structural key
 members formed in the hood striker plate. Additionally, the structural key
 members may be formed with a plurality of different shapes, sizes and
 orientations, provided that receptacles 940a have a corresponding shape,
 size and orientation.
 Additional embodiments of the present invention include incorporating
 structural key members and mating receptacles with sunroofs, trunks, etc.
 Preferred embodiments of the present invention have been disclosed. A
 person of ordinary skill in the art would realize, however, that certain
 modifications would come within the teachings of this invention.
 Therefore, the following claims should be studied to determine the true
 scope and content of the invention.