Upright pillar sash of vehicle door frame

An upright pillar sash of a vehicle door frame includes an outer member including a glass run fitting portion, and an inner member including an inner frame portion having a box-shaped cross section surrounding the glass run fitting portion. An outwardly extending portion, extending toward the edge portion of the glass run fitting portion toward the vehicle exterior, of the inner member and an overlapping edge, extending alongside the outwardly extending portion toward the vehicle exterior, of the outer member are spot welded with the overlapping edge superposing the outwardly extending portion. The outer member includes a side holding portion formed inside the glass run fitting portion to hold the glass run by contacting a side thereof, and a clearance recessed portion positioned between the side holding portion and the overlapping edge to allow a welding tool to enter.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an upright pillar sash which constitutes a member of a door frame of a vehicle door.

2. Description of Related Art

It is known in the art for a sash portion of a door frame of a vehicle door, especially the upright pillar sash (side sash) that extends along a center pillar of a vehicle body, to have a structure in which a sash portion is made by joining an outer side (vehicle exterior side) molded part (i.e., an outer member) which is provided with a glass run fitting portion (glass run mounting portion) and an inner side (vehicle interior side) molded part (i.e., an inner member) which includes an inner frame portion that has a box-shaped cross section surrounding the glass run fitting portion to each other. In the case where the joint (joined portion) between the outer member and the inner member is positioned on the sash inner edge portion side that is exposed to the window opening of the door frame, there has been a demand to reduce the amount of projection of this joint into the window opening as much as possible to widen the view at the peripheral edge of the window opening. For instance, in the invention disclosed in Japanese Unexamined Patent Publication 2008-302788, in the type of upright pillar sash in which the outer member and the inner member are joined together by hemming, a structure reducing the amount of projection of the hemming joint into the window opening has been proposed.

Although the structure disclosed shown in the above-mentioned Japanese Unexamined Patent Publication 2008-302788 is effective in the case where the outer member and the inner member are joined together by hemming, it has been required in recent years to improve the degree of freedom in the shape of the periphery of the joint between the outer member and the inner member to provide a wider view at the peripheral edge of the window opening.

SUMMARY OF THE INVENTION

The present invention provides an upright pillar sash of a vehicle door frame, wherein the upright pillar sash has a high degree of freedom in shape and makes it possible to provide a wide view at the peripheral edge of the window opening.

According to an aspect of the present invention, an upright pillar sash of a vehicle door frame is provided, including an outer member which is positioned on a vehicle exterior side and includes a glass run fitting portion that retains a glass run therein; and an inner member which is positioned on a vehicle interior side and includes an inner frame portion having a box-shaped cross section surrounding the glass run fitting portion. An edge portion of the inner frame portion of the inner member and an edge portion of the glass run fitting portion of the outer member are joined together. The inner frame portion of the inner member includes an outwardly extending portion which extends toward the edge portion of the glass run fitting portion in a direction from the vehicle interior to the vehicle exterior. The edge portion of the glass run fitting portion of the outer member includes an overlapping edge which extends alongside the outwardly extending portion in the direction from the vehicle interior to the vehicle exterior. The outwardly extending portion of the inner member and the overlapping edge of the outer member are joined together by spot welding with the overlapping edge superposing the outwardly extending portion. The outer member includes a side holding portion which is formed inside the glass run fitting portion to hold the glass run by contacting a side of the glass run, and a clearance recessed portion which is positioned between the side holding portion and the overlapping edge to allow a welding tool to enter when the spot welding is performed.

It is desirable for the overlapping edge of the outer member to include a bent end portion which is positioned on an extension of the outwardly extending portion on the vehicle exterior side.

According to the upright pillar sash of a vehicle door frame that is devised according to the present invention, since the outwardly extending portion of the inner member, which extends in a direction from the vehicle interior to the vehicle exterior, and the overlapping edge of the outer member, which extends along the outwardly extending portion, are joined together by spot welding with the overlapping edge of the outer member lying on the outwardly extending portion of the inner member, a higher degree of freedom in the shape of the outwardly extending portion and the overlapping edge is achieved than the case where the outwardly extending portion of the inner member and the overlapping edge of the outer member are joined together by hemming, which makes it possible to form the joint between the outer member and the inner member into a shape such that the amount of projection of the joint into the window opening is reduced. This makes it possible to provide a wide view at the peripheral edge of the window opening with a simple structure, thereby improving the viewability through the window opening from the vehicle interior side.

The present disclosure relates to subject matter contained in Japanese Patent Application No.2012-176591 (filed on Aug. 9, 2012) which is expressly incorporated herein by reference in its entirety.

DESCRIPTION OF THE EMBODIMENTS

A motor-vehicle side door10shown inFIG. 1is provided with a door panel11and a door frame12which is formed into a frame on top of the door panel11. A window pane14(partly shown by a two-dot chain line inFIGS. 2 through 4) moves up and down in a window opening13which is surrounded by the upper edge of the door panel11and the inner edge of the door frame12. The door frame12is provided with an upper sash portion15which forms the upper edge of the door10and an upright pillar sash portion (side sash portion/ side sash)16which is formed to extend substantially vertical from the rear of the door panel11. When the door10is closed, the upper sash portion15is positioned along the associated lateral side edge of a roof panel (not shown) of a vehicle body (in other words, along the upper edge of the associated door opening of a vehicle body), while the upright pillar sash portion16is positioned along the adjacent center pillar (not shown) of the vehicle body.

The present embodiment of the door10, to which an upright pillar sash structure according to the present invention has been applied, is a front door (specifically left front door), and directional expressions such as “the front”, “the rear”, “the vehicle interior side” and “the vehicle exterior side”, mentioned in the following descriptions, designate directions determined with reference to the vehicle body to which the door10is fixed. In addition, the side (left-hand side with respect toFIG. 2) of the upright pillar sash portion16on which the window opening13is formed will be hereinafter referred to as the sash inner edge portion side, and the other side (right-hand side with respect toFIG. 2) of the upright pillar sash portion16that is exposed to the associated door opening of the vehicle body (i.e., to the adjacent center pillar (not shown) of the vehicle body) will be hereinafter referred to as the sash outer edge portion side. In a closed state of the door10, the direction that the sash inner edge portion faces substantially corresponds to the direction toward the front of the vehicle, and the direction that the sash outer edge portion faces substantially corresponds to the direction toward the rear of the vehicle. Additionally, the direction which connects the vehicle interior side and the vehicle exterior side in a closed state of the door10will be hereinafter referred to as the direction of the thickness of the door10.

FIG. 2shows a cross-section structure of a first embodiment of the upright pillar sash portion according to the present invention. The upright pillar sash portion16is configured from a combination of an outer member20, an inner member21and a supplemental member22.

The outer member20is provided with an exterior decorative portion20a, a folded-back portion20b, a base portion20c, a vehicle-inner-side projecting portion20d, a vehicle-outer-side projecting portion (side holding portion)20e, a vehicle-inner-side projecting portion (clearance recessed portion)20fand a frame overlapping edge20g. The exterior design portion20afaces toward the vehicle exterior, the folded-back portion20bis formed by folding back the edge (left edge with respect toFIG. 2) of the exterior design portion20aon the sash inner edge portion side inwardly toward the vehicle interior. The base portion20cextends toward the vehicle interior from the sash outer edge portion of the exterior design portion20a. The vehicle-inner-side projecting portion20dis continuous with the base portion20cand shaped into a protrusion which projects toward the vehicle interior. The vehicle-outer-side projecting portion20eis continuous with the vehicle-inner-side projecting portion20dand shaped into a protrusion which projects toward the vehicle exterior. The vehicle-inner-side projecting portion20fis continuous with the vehicle-outer-side projecting portion20eand shaped into a protrusion which projects toward the vehicle interior. The frame overlapping edge20gis formed by bending the end of the vehicle-inner-side projecting portion20fon the sash inner edge portion side outwardly toward the vehicle exterior. The outer member20is provided with a glass run fitting portion (glass run guide portion/glass run mounting portion)20hwhich is composed of (defined by) the exterior design portion20a, the folded-back portion20b, the base portion20c, the vehicle-inner-side projecting portion20d, the vehicle-outer-side projecting portion20e, the vehicle-inner-side projecting portion20fand the frame overlapping edge20g. The glass run fitting portion20his in the shape of a bottomed box which is open at the sash inner edge portion side (to the window opening13side).

The inner member21is provided with an exterior design portion21a, a folded-back portion21b, an inwardly extending portion21c, a connecting portion21dand an outwardly extending portion21e, in that order from the sash outer edge portion side (the vehicle rear side). The exterior design portion21afaces toward the vehicle exterior, similar to the exterior design portion20a. The folded-back portion21bis formed by folding back the edge (right edge with respect toFIG. 2) of the exterior design portion21aon the sash outer edge portion side inwardly toward the vehicle interior. The inwardly extending portion21cis formed to extend toward the vehicle interior alongside the base portion20cof the outer member20by bending a portion of the exterior design portion21aon the sash inner edge portion side. The connecting portion21dis continuous with the inwardly extending portion21cand extends along the vehicle forward/rearward direction. The outwardly extending portion21eis formed by bending a portion of the connecting portion21don the sash inner edge portion side to extend toward the vehicle exterior. The inwardly extending portion21cis an inclined portion which is inclined toward the sash inner edge portion side (i.e., forward) in the direction from the vehicle exterior to the vehicle interior. The outwardly extending portion21eis very slightly inclined to the forward/rearward direction in the direction from the vehicle interior to the vehicle exterior (in the direction of the thickness of the door10, which is substantially orthogonal to the exterior design portion20a, with reference to the exterior design portion20a), and a portion of the outwardly extending portion21ewith a predetermined width (length in the vertical direction with respect toFIG. 2) in the vicinity of the edge (lower edge with respect toFIG. 2) thereof is overlaid on the frame overlapping edge20gof the outer member20. The inwardly extending portion21cis joined to a surface of the base portion20cof the outer member20on the sash outer edge portion side, the outwardly extending portion21eis joined to the surface of the frame overlapping edge20gof the outer member20on the sash inner edge portion side, and the inwardly extending portion21c, the connecting portion21dand the outwardly extending portion21esurround the glass run fitting portion20hto form an inner frame portion21fwhich projects toward the vehicle interior from the vehicle exterior side. The inner frame portion21fhas a box-shaped cross section, the width thereof progressively reducing in a direction from the vehicle exterior toward the vehicle interior in accordance with the inclination of the inwardly extending portion21c.

The supplemental member22is provided with a base portion22aand a pair of retaining portions22band22c. The base portion22ais joined to a surface of the inwardly extending portion21con the sash outer edge portion side, the retaining portion22bis formed by bending an edge of the base portion22aon the vehicle exterior side, and the retaining portion22cis formed by bending an edge of the base portion22aon the vehicle interior side. The base portion22a, the retaining portions22band22cof the supplemental member22and the external decorative portion21aof the inner member21define a weather strip retaining recessed portion in which a weather strip (not shown) is fitted and held thereby. This weather strip includes a leg portion which is engaged in the pair of retaining portions22band22cof the supplemental member22and an elastic contact portion which projects toward the sash outer edge portion from the aforementioned leg portion. The elastic contact portion of the weather strip comes into contact with the associated center pillar of the vehicle body and is elastically deformed to prevent water from entering inside of the vehicle when the door10is closed.

The outer member20, the inner member21and the supplemental member22are initially formed as separate members and thereafter joined together. The outer member20, the inner member21and the supplemental member22are fixed together by welding the base portion20c, the inwardly extending portion21cand the base portion22atogether with the base portion20c, the inwardly extending portion21cand the base portion22asuperposed onto each other.

In addition, the frame overlapping edge20gof the outer member20and the outwardly extending portion21eof the inner member21are fixed to each other. More specifically, the frame overlapping edge20gand the outwardly extending portion21eextend in the direction of the thickness of the vehicle door10(toward the vehicle exterior) as substantially parallel plates and are positioned relative to each other so that the outwardly extending portion21eoverlaps the surface of the frame overlapping edge20gon the sash inner edge portion side as mentioned above; the edge portions of the outwardly extending portion21eand the frame overlapping edge20gwhich superpose each other are fixed to each other by spot welding.

This spot-welded part is shown by a mark “X” designated by a letter W inFIG. 2. This spot welding is carried out at a plurality of points in the lengthwise direction of the upright pillar sash16, as shown inFIG. 7, (substantially in the vertical direction with respect toFIG. 1). When this spot welding is performed, a welding tool (not shown) is inserted into the glass run fitting portion20h, and the vehicle-inner-side projecting portion20fof the outer member20serves as a clearance recessed portion which allows this welding tool to enter.

As shown inFIG. 2, a glass run30is fitted in the glass run fitting portion20hwith the outer member20, the inner member21and the supplemental member22joined together. The glass run30is provided with a base portion30a, a pair of side portions30band30c, a retaining projection30d, a retaining projection30eand a pair of elastic lips30fand30g. The base portion30aabuts against the base portion20cof the outer member20. The position of the side portion30bin the direction toward the vehicle exterior (the downward direction with respect toFIG. 2) is limited by the external decorative portion20aof the outer member20, and the position of the side portion30cin the direction toward the vehicle interior (the upward direction with respect toFIG. 2) is limited by the vehicle-outer-side projecting portion (side holding portion)20eof the outer member20. The retaining projection30dis engaged with the folded-back portion20bof the outer member20, and the retaining projection30eis engaged with the vehicle-inner-side projecting portion20dof the outer member20. The pair of elastic lips30fand30gare formed to extend obliquely rearwards in directions approaching each other from the front ends of the pair of side portions30band30c, respectively. The glass run30is prevented from coming off the glass run fitting portion20hin the forward direction (leftward with respect toFIG. 2) by the engagement of the retaining projection30dand the retaining projection30ewith the folded-back portion20band the vehicle-outer-side projecting portion20e, respectively. The pair of elastic lips30fand30gcome in contact with and are elastically deformed by the window pane14that enters the glass run fitting portion20hto suppress vibrations of the window pane14and noise caused in association therewith. InFIG. 2, the pair of elastic lips30fand30gare in a free state before being elastically deformed by the window pane14. The base end (front end of the side portion30b) of the elastic lip30f, which is positioned closer to the vehicle exterior side than the elastic lip30g, is engaged with the folded portion of the outer member20between the exterior decorative portion20aand the folded-back portion20b, and this folded portion supports the elastic lip30fso that the elastic lip30fcontacts the vehicle external side surface of the window pane14with a moderate pressure. In addition, the base end (front end of the side portion30c) of the elastic lip30g, which is positioned closer to the vehicle interior side than the elastic lip30f, is engaged with the outwardly extending portion21eof the inner member21in the vicinity of the edge (lower edge with respect toFIG. 2) of the outwardly extending portion21e, and the engaging portion of the outwardly extending portion21esupports the elastic lip30gso that the elastic lip30gcontacts the vehicle internal side surface of the window pane14with a moderate pressure.

In the upright pillar sash portion16that has the above described structure, the glass run fitting portion20hof the outer member20and the inner frame portion21fof the inner member21are joined together by spot-welding the frame overlapping edge20gand the outwardly extending portion21ewith the frame overlapping edge20gand the outwardly extending portion21eoverlapping each other. According to this structure, the spot welding creates no portions that jut out forward on the sash inner edge portion side (the window opening13side). In addition, because of this spot-welding structure, constraints to the shapes of the outwardly extending portion21eof the inner member21and the frame overlapping edge20gof the outer member20(in the direction of extension thereof) are few, so that the shapes of the outwardly extending portion21eand the frame overlapping edge20gcan each be set small with a small amount of projection forward on the sash inner edge portion side (the window opening13side). In the upright pillar sash portion16, the part in the vicinity of the joint between the outwardly extending portion21eand the frame overlapping edge20gis the innermost part of the door frame12, and accordingly, if the amount of projection of the outwardly extending portion21eand the frame overlapping edge20ginto the window opening13is small, a wider practical opening space at the peripheral edge of the window opening can be provided by that much. In other words, a wide view at the peripheral edge of the window opening13can be provided, which improves the viewability through the window opening13from the vehicle interior side.

In addition, since a portion of the outwardly extending portion21e, which is a large flat portion of the inner member21, is simply overlaid on and spot-welded to the frame overlapping edge20gof the outer member20, the strength of this joint between the inner member21and the outer member20can be easily ensured even though the structure of this joint is simple. Additionally, since the joint surface (joint area) between the outwardly extending portion21eand the frame overlapping edge20gis not exposed at the window opening13side, the glass run30does not have to be extended by a large amount toward the vehicle interior to improve the appearance of the joint, which makes miniaturization of the glass run30possible. As shown inFIG. 2, a portion of the glass run30in the vicinity of the front end of the side portion30cis engaged with the edge (lower edge with respect toFIG. 2) of the outwardly extending portion21e; however, the glass run30has a small shape that does not cover the remaining portion of the outwardly extending portion21ethat is positioned on the vehicle interior side from the aforementioned edge thereof.

FIG. 3shows a second embodiment of the upright pillar sash portion according to the present invention. In the upright pillar sash portion116shown inFIG. 3, in addition to the structure of the outer member20in the first embodiment of the upright pillar sash portion16, the outer member20is further provided, at the edge of the frame overlapping edge20gon the vehicle exterior side, with a protective bent portion (bent end portion)20iwhich is formed by bending the edge of the frame overlapping edge20gon the vehicle exterior side in the forward direction. The protective bent portion20ilies on an extension of the outwardly extending portion21eof the inner member21on the vehicle exterior side to extend alongside the side portion30cof the glass run30. The engagement of the protective bent portion20iwith the side portion30cof the glass run30eliminates the possibility of the glass run30being damaged by an end (edge) of the outwardly extending portion21eor the protective bent portion20i, thus improving the protective performance for the glass run30. The length of the protective bent portion20iin the forward direction is set so that the protective bent portion20isubstantially fits within the range of the above-mentioned extension of the outwardly extending portion21ein the forward/rearward direction, and therefore, a wide view at the peripheral edge of the window opening13that is comparable with that in the first embodiment of the upright pillar sash portion can be secured.

FIG. 4shows a third embodiment of the upright pillar sash portion according to the present invention. In the upright pillar sash portion216shown inFIG. 4, the outer member20and the inner member21are partly different in cross sectional shape from those of the first embodiment of the upright pillar sash portion16(shown inFIG. 2); however, elements of the upright pillar sash portion216which correspond to those of the first embodiment of the upright pillar sash portion16are designated by the same reference numerals even if slightly different in shape, and the description of such elements will be omitted herein. In addition, although not shown inFIG. 4, a glass run is fitted and held in the glass run fitting portion20h, as in the previous embodiments of the upright pillar sash portions. In the upright pillar sash portion216shown inFIG. 4, the outer member20is provided with an external decorative portion20a′ which extends by a large amount from the sash inner edge portion side to the sash outer edge portion side to cover an exterior side portion21a′ (which corresponds to the exterior design portion21ashown inFIG. 2) of the inner member21from the vehicle exterior side. Accordingly, the entire part of the external decorative portion of the upright pillar sash portion16is formed by the outer member20. A folded-back portion20b′ which is formed at the edge (right edge with respect toFIG. 4) of the exterior design portion20a′ on the sash outer edge portion side fixedly pinches (clamps) the end (right edge with respect toFIG. 4) of the exterior side portion21a′ on the sash outer edge portion side (i.e., this end of the exterior side portion21a′ and the folded-back portion20b′ are joined together by hemming). In addition, a base portion20c′ of the inner member20(which corresponds to the base portion20cshown inFIG. 2) is spaced from an inwardly extending portion21c′ of the outer member21(which corresponds to the inwardly extending portion21cshown inFIG. 2), i.e., the base portion20c′ does not lie on the inwardly extending portion21c′. The joining structure by spot welding between the frame overlapping edge20gand the outwardly extending portion21ein the third embodiment of the upright pillar sash portion is similar to that of the first embodiment of the upright pillar sash portion.

FIGS. 5 and 6show comparative examples of upright pillar sash portions which are compared with the above described first through third embodiments of the upright pillar sash portions. In these comparative examples, elements similar to those of the above described first through third embodiments of the upright pillar sash portions are designated by the same reference numerals.

FIG. 5shows a type of upright pillar sash portion316in which an outwardly extending portion121e(which corresponds to the outwardly extending portion21eshown inFIG. 2) of the inner member21and a frame overlapping edge120g(which corresponds to the frame overlapping edge20gshown inFIG. 2) of the outer member20are joined together by hemming; this joining structure is identical to that disclosed in Japanese Unexamined Patent Publication 2008-302788. The outwardly extending portion121eis shaped to be inclined toward the sash inner edge portion side (i.e., forward) in the direction from the vehicle interior to the vehicle exterior. In a state before the outer member20and the inner member21are joined together, the inner member21is provided at the edge of the outwardly extending portion121eon the vehicle exterior side with a temporary bent portion121g-v(shown by two-dot chain line inFIG. 5) which is formed by being gently angled toward the sash outer edge portion side. The outer member20is provided with a vehicle-inner-side projecting portion120d, a vehicle-outer-side projecting portion120eand a vehicle-inner-side projecting portion120fthat are continuously formed as a wall of the glass run fitting portion20hof the outer member20on the vehicle interior side. The outer member20is further provided with a frame overlapping edge120gwhich is formed continuously with the vehicle-inner-side projecting portion120fto extend obliquely toward the vehicle exterior alongside the outwardly extending portion121e.

As shown inFIG. 5, the outer member20and the inner member21in a temporarily combined state are set on a fixed jig40. The fixed jig40is provided with a support surface which is shaped to correspond to the shapes of the outer surfaces of the connecting portion21dand the outwardly extending portion121eof inner member21. The fixed jig40supports the outer member20and the inner member21so that the outwardly extending portion121elies horizontally. Subsequently, a movable die41having a press projection41ais set so that the press projection41afaces the temporary bent portion121g-v. The movable die41is movable in the direction shown by arrows F inFIG. 5, and the vehicle-inner-side projecting portion120fof the outer member20serves as a recessed portion which is recessed to be prevented from interfering with the press projection41a. After completion of the setting of the movable die41, a press body42is moved in the direction of the arrows F to come into abutting contact with the movable die41. Thereupon, the moving force of the press body42causes the movable die41to move in the direction of the arrows F, which causes the press projection41ato press the temporary bent portion121g-vso as to bring the temporary bent portion121g-vinto intimate contact with the back of the frame overlapping edge120gso that the temporary bent portion121g-vforms into a folded-back portion121g. The folded-back portion121gand the outwardly extending portion121econstitute a hemming joint which sandwiches and fixes the frame overlapping edge120gbetween the folded-back portion121gand the outwardly extending portion121e.

In the comparative example shown inFIG. 5, the internal space of the vehicle-inner-side projecting portion120fof the outer member20has been enlarged to secure a space in which the press projection41aof the movable die41moves when the hemming process is performed, and the outwardly extending portion121eof the inner member21is accordingly formed to project obliquely toward the sash inner edge portion side. Conversely, in each of the above described first through third embodiments of the upright pillar sash portions, a space does not need to be provided for movable die (the press projection41a) for carrying out a hemming process in the vicinity of the vehicle-inner-side projecting portion20fof the glass run fitting portion20hsince the frame overlapping edge20gand the outwardly extending portion21eare joined together by spot welding. Although a welding tool enters the glass run fitting portion20hwhen spot welding is performed, the space required for the insertion of the welding tool is smaller than the space in which the movable die (the press projection41a) for hemming process moves, and accordingly, the degree of freedom in shape setting of the outwardly extending portion21eis high. As can be understood from the comparison between the upright pillar sash portions shown inFIGS. 2 through 4and the upright pillar sash portion shown inFIG. 5, the outwardly extending portion21ein each of the above described first through third embodiments of the upright pillar sash portions shown inFIGS. 2 through 4is smaller in the amount of projection toward the sash inner edge portion side than the outwardly extending portion121ein the comparative example shown inFIG. 5, so that the effect of widening the view at the peripheral edge of the window opening13is obtained.

The comparative example shown inFIG. 6is a type of upright pillar sash portion416in which the outer member20and the inner member21are joined together by arc welding. The inner member21in this comparative example is similar to that in the first embodiment of the upright pillar sash portion that is shown inFIG. 2. The outer member20of the upright pillar sash portion416is provided with a vehicle-inner-side projecting portion220d, a vehicle-outer-side projecting portion220e, and a vehicle-inner-side projecting portion220fthat are continuously formed as a wall of the glass run fitting portion20hof the outer member20, and the outer member20of the upright pillar sash portion416is further provided with a frame joining portion220g. The frame joining portion220gis formed continuously with the vehicle-inner-side projecting portion220f. The frame joining portion220gis shaped to have a U-shaped cross section as shown inFIG. 6; more specifically, the frame joining portion220gfirstly projects toward the vehicle exterior from the vehicle-inner-side projecting portion220f, subsequently bends toward the sash inner edge portion side, and thereafter bends toward the vehicle interior over the edge of the outwardly extending portion21eon the vehicle exterior side to extend toward the vehicle interior alongside a surface of the outwardly extending portion21eon the sash inner edge portion side. The portions of the frame joining portion220gand the outwardly extending portion21ewhich are overlaid onto each other are fixed to each other by arc welding from the sash inner edge portion side to form a welded bead WB. In this comparative example, since the frame joining portion220genvelops the vehicle exterior side edge (the lower edge with respect toFIG. 6) of the outwardly extending portion21eto be positioned closer to the sash inner edge portion side than the outwardly extending portion21eand also since the welded bead WB protrudes forward toward the sash inner edge portion side, the amount of projection of the joint between the outer member20and the inner member21on the window opening13side is greater than that of the joining structure of each of the above described first through third embodiments shown inFIGS. 2 through 4.

Although the present invention has been described based on the above illustrated embodiments, the present invention is not limited solely to these particular embodiments; various modifications to the above illustrated embodiments is possible without departing the spirit and scope of the present invention. For instance, the present invention is characterized in the joint between the outer member and the inner member on the glass run fitting portion side in the upright pillar sash portion of a door frame, and accordingly, the weather strip retaining portion can be modified to have a different structure from that in each of the above described embodiments of the upright pillar sash portions.

Although the present invention has been applied to the upright pillar sash of a front door of a vehicle in each of the above illustrated embodiments, the present invention can also be applied to the upright pillar sash of a rear door of a vehicle.

The entire disclosures of all applications, patents and publications, cited herein and of corresponding Japanese Patent Application No. 2012-176591, filed Aug. 9, 2012 are incorporated by reference herein.