Vehicle door

A vehicle door comprising a first outer layer (70) and second outer layer (80), a foam portion (90) disposed between the first outer layer and the second outer layer, a compartment comprising a first outer member (10) and a second outer member (20) in parallel spaced relation, the first outer member and the second outer member joined by at least one intermediate member (30) having a flexible crease (32), a receiving cavity (A) disposed outwardly of the compartment for engaging the foam portion, the first outer member and the second outer member each disposed substantially flush with a foam portion outer surface (91,92), and the foam portion and the compartment disposed between the first outer layer and the second outer layer.

FIELD OF THE INVENTION

The invention relates to a vehicle door, and more particularly, to a vehicle door comprising a compressible compartment having a first outer member and a second outer member in parallel spaced relation, the first outer member and the second outer member joined by a member having a flexible crease, a receiving cavity disposed outwardly of the compressible compartment for receiving the foam portion, the first outer member and the second outer member each disposed substantially flush with a foam portion outer surface.

BACKGROUND OF THE INVENTION

Each year thousands of vacationers venture across the countryside in recreational vehicles (RV's). Many RV's incorporate all of the luxuries of a permanent residence. RV's usually comprise full bathrooms, sleeping quarters, kitchens with sinks, stoves and microwave ovens.

Exterior doors for recreational vehicles have many inadequacies. Currently available doors have many pieces that require labor intensive manufacturing and assembly processes. These doors consequently are expensive for the consumer. Many small parts also increase chances for mechanical failure.

Expense and fragility are not the only problems associated with currently available RV doors. Some exterior doors have exposed hardware, bulky profiles or seams that cause additional problems and which detract from the appearance of the door and vehicle. They can also increase the vehicle's overall coefficient of drag, which reduces fuel economy. Seams can leak.

Representative of the art is U.S. Pat. No. 6,334,277 which discloses a door assembly for a recreational vehicle has a molded mounting frame and a molded flange. The mounting frame and the door have integral hinge pin lugs. Spring-loaded hinge pins are captured within the hinge pin lugs and allow the door to swing open or close. A latch secures the door assembly in a closed position. The door may be thermally insulated. The hinge pins may be stainless steel. The latch may be a locking mechanism. The door securely conceals the door frame fasteners when the door assembly is in the closed position. One hinge pin may be fixed to one hinge pin lug.

What is needed is a vehicle door comprising a compressible compartment having a first outer member and a second outer member in parallel spaced relation, the first outer member and the second outer member joined by a member having a flexible crease, a receiving cavity disposed outwardly of the compartment for receiving the foam portion, the first outer member and the second outer member each disposed substantially flush with a foam portion outer surface. The present invention meets this need.

SUMMARY OF THE INVENTION

The primary aspect of the invention is to provide a a vehicle door comprising a compressible compartment having a first outer member and a second outer member in parallel spaced relation, the first outer member and the second outer member joined by a member having a flexible crease, a receiving cavity disposed outwardly of the compartment for receiving the foam portion, the first outer member and the second outer member each disposed substantially flush with a foam portion outer surface.

Other aspects of the invention will be pointed out or made obvious by the following description of the invention and the accompanying drawings.

The invention comprises a vehicle door comprising a first outer layer and second outer layer, a foam portion disposed between the first outer layer and the second outer layer, a compressible compartment comprising a first outer member and a second outer member in parallel spaced relation, the first outer member and the second outer member joined by at least one intermediate member having a flexible crease, a receiving cavity disposed outwardly of the compressible compartment for engaging the foam portion, the first outer member and the second outer member each disposed substantially flush with a foam portion outer surface, and the foam portion and the compressible compartment disposed between the first outer layer and the second outer layer.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1is a perspective view of the vehicle door compartment. The compressible compartment100comprises a planar member10and planar member20. Planar member10is held in parallel spaced relation to planar member10by a member30, member40and member50. The compartment further comprises an opening60at an end whereby mechanism(s) can be installed within the compartment.

For example, a power lock solenoid, receiver, and so on can be installed inside the compartment, seeFIG. 6. When the vehicle door is assembled and run through rollers to apply the hot glue and press on the member10and member20, the compartment becomes perfectly flush with the foam core of the vehicle door. Hence, any dimpling that may have been present in the skin of the vehicle door from the mechanicals in the prior art is not evident in the inventive door.

FIG. 2is a side view of the vehicle door compartment. Member30is fastened to planar member10and planar member20by use of a hot melt tack or adhesive31. Member40is fastened to planar member10and planar member20by use of a hot melt tack or adhesive41. Member50is fastened to planar member10and planar member20by use of a hot melt tack or adhesive51.

Member30is recessed from the edge of member10by a distance x. Member40is recessed from the edge of member10by a distance z. Member50is recessed from the edge of member10by a distance y. Each recess forms a receiving cavity A, B, C respectively, into which foam is inserted during vehicle door assembly.

FIG. 3is a top plan view of the vehicle door compartment. Member30comprises a crease32. Member40comprises a crease42. Member50comprises a crease52. Creases32,42,52provide flexibility in the thickness T of the compartment to accommodate variations in a vehicle door thickness during assembly.

FIG. 4is a side elevation view of the vehicle door compartment.

FIG. 5is a cross-sectional detail of the vehicle door at5-5inFIG. 6. To assemble a vehicle door, each cavity A, B, C in the compartment100is engaged with or inserted into foam90. Foam90typically comprises Styrofoam®, but may also comprise any suitable compressible material. Foam portion90comprises the core of the door and also serves to insulate the door from heat and cold.

Next, the compressible compartment100is partially compressed so the members10and20are flush with the outer surface (91,92) of the foam90. After the partial compression, rebound in the foam and flexibility from the creases32,42,52causes the outer surface of the foam to become flush with the edges of members10,20. By doing so the edges of each member10,20are not telegraphed through the vehicle door skin or covering panels70,80. After the compartment is installed in the foam the door outer covering panels70,80are installed as a laminate over the foam and compartment.

After compression there is some clearance in cavity A, B, C, between each crease32,42,52and foam90such that each member30,40,50may flex alone each crease32,42,52respectively.

FIG. 6is a perspective view of the vehicle door. Compartment100is installed in the foam90within a vehicle door (D), shown in partial view. Mechanisms can now be installed through opening60. Once the mechanisms are installed opening60is close using a foam piece91.

The mechanism can include a handle, latch200and striker201(each known in the art) which are installed into the door (D) and door jamb (not shown). The vehicle door (D) further comprises components known in the art, such as hinges (H) for attaching the door to a vehicle wall.

Although a form of the invention has been described herein, it will be obvious to those skilled in the art that variations may be made in the construction and relation of parts and method without departing from the spirit and scope of the invention described herein.