Vehicle door and manufacture thereof

A vehicle door which can be used as a tailgate is formed of an outer panel (2) on an outer side of a vehicle, an inner panel (3) on an inner side of the vehicle, and a module plate (4) to which door parts such as a wiper motor (18) are attached, and a lining (6). The inner panel (3) is in a frame shape with only a marginal portion (10) of the whole periphery left and with an opening (11) formed therein. The module plate (4) serves as a reinforcing member and is composed of a first extending portion (13) extending in a right and left direction and a second extending portion (14) extending downward from the first extending portion (13) to be in a substantially T-shape. Connection of the module plate (4) to the outer panel (2) and the inner panel (3) reinforces the tailgate (1).

TECHNICAL FIELD

The present invention relates to a vehicle door and the manufacture thereof, and is usable, for example, as a tailgate, which is also called a back door, and a side door of a vehicle.

BACKGROUND ART

A tailgate which is a back door of a four-wheel vehicle is formed by connecting an outer panel on an outer side of the vehicle and an inner panel on an inner side of the vehicle to each other and by assembling door parts such as a door lock and a key cylinder between these outer and inner panels.

In a tailgate in Japanese Patent Laid-open No. Hei 8-142676, an inner panel is formed in a shape having an upper opening portion corresponding to a window cavity formed in an outer panel and a lower opening portion separated by a partitioning portion extending in a right and left direction relative to this upper opening portion, and a module plate in a substantially square shape which has a size large enough to cover this lower opening portion and to which door parts are attached in advance is fitted in the lower opening portion.

At present, a decrease in vehicle weight is being demanded in order to improve the fuel efficiency of a vehicle. Since a tailgate is a part of a vehicle, this tailgate influences the vehicle weight, but in the tailgate in the aforesaid conventional art, a sufficient measure is not taken for a weight decrease.

An object of the present invention is to provide a vehicle door which can realize a decrease in door weight and contribute to a decrease in vehicle weight and to provide a method of manufacturing the vehicle door.

DISCLOSURE OF THE INVENTION

A vehicle door according to the present invention is a vehicle door composed of an outer panel on an outer side of a vehicle and an inner panel on an inner side of the vehicle which is connected to this outer panel, and it is characterized in that the aforesaid inner panel is in a frame shape, with only a marginal portion of the whole periphery left and with an opening portion formed therein.

According to this vehicle door, since the inner panel is in a frame shape with only the marginal portion of the whole periphery left and with the opening portion formed therein, there is no partitioning portion for partitioning the opening portion into upper and lower portions, so that the weight of the inner panel is reduced accordingly. Consequently, the total weight of the door is reduced, which can contribute to a decrease in weight of the vehicle to which this door is attached.

In the vehicle door as described above, a reinforcing member for enhancing the strength of this inner panel and securing a required door strength is disposed. This reinforcing member may be in any shape such as a substantially square shape, but it is preferable that it includes at least a first extending portion extending in a right and left direction and a second extending portion extending downward from the center or a substantially central part in the right and left direction of this first extending portion, and that the first extending portion extends between right and left marginal portions of the inner panel.

According to this, the reinforcing member is formed of the first extending portion and the second extending portion to be in a T-shape or a substantially T-shape or is formed only of the first extending portion to be in a long and narrow shape which is long in the right and left direction, so that in either case, its area is smaller than that in a substantially square shape to reduce the weight of the reinforcing member and contribute to a reduction in door weight. Furthermore, the first extending portion extends between the right and left marginal portions of the inner panel to reinforce the inner panel and enhance the strength of the door.

When the reinforcing member is formed of the first extending portion and the second extending portion to be in a T-shape or a substantially T-shape, end portions in a longitudinal direction of the first extending portion are joined to the right and left marginal portions of the inner panel respectively and a lower end portion of the second extending portion is joined to a lower marginal portion of the aforesaid inner panel.

When the reinforcing member is formed of the first extending portion and the second extending portion is in a T-shape or a substantially T-shape as described above, this reinforcing member may be simply formed to have a planar structure, but it is preferable that ribs having a rising amount toward the outer side of the vehicle are formed in a lower part of the first extending portion and right and left side parts of the second extending portion and that the rib in the lower part of the first extending portion and the rib in the left side part of the second extending portion are continuously formed and the rib in the lower part of the first extending portion and the rib in the right side part of the second extending portion are continuously formed.

According to this, these ribs enhance the strength of the reinforcing member, and the continuous formation of these ribs along the first extending portion and the second extending portion which are perpendicular or substantially perpendicular to each other enables two-dimensional reinforcement of the whole surface of the vehicle door by the reinforcing member.

When the reinforcing member is formed only of the first extending portion to be in a long and narrow shape which is long in the right and left directions, the end portions in the longitudinal direction of this first extending portion are joined to the right and left marginal portions of the inner panel respectively.

This reinforcing member may also be simply structured to have a planar structure when the reinforcing member is formed only of the first extending portion to be a long and narrow shape which is long in the right and left direction as described above, but it is preferable that this reinforcing member is a bent member having a web whose width direction corresponds to a vertical direction and a flange bending from at least one of upper and lower edge portions of this web.

This enhances the strength of the reinforcing member itself so that the strength of the door can be increased.

Furthermore, when the reinforcing member is a bent member having a web whose width direction corresponds to the vertical direction and a flange bending from this web, the number of flanges provided may be one to form the reinforcing member in an angled shape, but it is preferable that the flanges are provided both along the upper and lower edges of the web and that these two flanges are formed continuously along the longitudinal direction of the aforesaid web.

According to this, the aforesaid reinforcing member formed of the web and the two flanges to be a bent member with a substantially C-shaped cross section becomes a channel shape, so that the two flanges sufficiently increase the strength of the reinforcing member, and furthermore, unlike the case when the reinforcing member is formed of the aforesaid first extending portion and the aforesaid second extending portion to be in a T-shape or a substantially T-shape, the lower flange can be continuously formed, similarly to the upper flange, without ending halfway in the longitudinal direction of the web. Consequently, the strength given by the upper and lower flanges is maintained as it is and the strength of the inner panel reinforced by the reinforcing member and the strength of the door can be increased sufficiently.

Furthermore, when the reinforcing member is composed of the web and the two flanges to be the bent member with the substantially C-shaped cross section, an opening portion of the reinforcing member having the substantially C-shaped cross section faces the outer side of the vehicle and each of the end portions in the longitudinal direction of the reinforcing member is joined to the surface of the inner panel on the inner side of the vehicle.

According to this, the two flanges face the outer side of the vehicle and these flanges are in the state of being accommodated in a space for securing the thickness of the door, so that the thickness of the door can be suppressed to be a predetermined size.

Door parts which are to be assembled onto the vehicle door in plurality may be attached to the reinforcing member, the inner panel, or both of the reinforcing member and the inner panel. When all or a part of the door parts are attached to the reinforcing member, the reinforcing member can be also used as an attaching member to which the door parts are attached, so that one member can serve for plural purposes.

Furthermore, when the door parts are attached to the reinforcing member before this reinforcing member is attached to the inner panel, thereby causing this reinforcing member to be a module member to which the door parts are attached in advance, the attachment of the reinforcing member to the inner panel results in the assembly of the door parts attached to the reinforcing member onto predetermined positions at the same time.

When the reinforcing member is formed of the aforesaid first extending portion and the aforesaid second extending portion to be in a T-shape or a substantially T-shape, with the end portions in the longitudinal direction of the first extending portion joined to the right and left marginal portions of the inner panel respectively, and with the lower end portion of the second extending portion joined to the lower marginal portion of the aforesaid inner panel, various kinds of the door parts can be attached to places of the reinforcing member corresponding to functions of the door parts respectively, making effective use of the shape of this reinforcing member. One example of this is that, when the door parts include a key cylinder, a wiper motor, an outer handle, and a door lock, the key cylinder and the wiper motor are attached to the first extending portion, the outer handle is attached to a connecting portion of the first extending portion and the second extending portion, and the door lock is attached to the second extending portion.

Meanwhile, when the reinforcing member is formed only of the first extending portion to be in a long and narrow shape which is long in the right and left directions and the end portions in the longitudinal direction of this first extending portion are joined to the right and left marginal portions of the inner panel respectively, the wiper motor, the outer handle, and the key cylinder are attached to this reinforcing member and the door lock is attached to the inner panel.

Furthermore, when the marginal portion of the inner panel has a hat-shaped cross section, a cross section of a joining portion of the outer panel, the inner panel, and the reinforcing member can be formed in a box shape, with a peripheral portion of the outer panel joined to the surface of the marginal portion, which has the hat-shaped cross section opening toward the outer side of the vehicle, of the inner panel on the outer side of the vehicle and with the end portions of the reinforcing member joined to the surface of the marginal portion of the inner panel on the inner side of the vehicle.

This greatly strengthens the connecting portion of the outer panel, the inner panel, and the reinforcing member and can enhance the strength of the entire door.

Furthermore, the outer handle used when the door is opened/closed may be attached to the reinforcing member.

This prevents an operating force given to the outer handle from acting directly on the outer panel and causes this operating force to be received by the reinforcing member since the outer handle is not attached to the outer panel. Consequently, the problem caused when the operating force given to the outer handle directly acts on the outer panel, for example, the problem that deformation such as a partial dent occurs in the outer panel can be solved.

Furthermore, when the outer handle is attached to the reinforcing member via a bracket, a license lamp may be attached to this bracket.

This causes the bracket for attaching the outer handle to also serve as a bracket for attaching the license lamp, which can reduce the number of parts accordingly and, as a result of the reduction in the number of the parts, contribute to a weight reduction of the door.

Places of the inner panel to which the end portions of the reinforcing member are joined may be places perpendicular or substantially perpendicular to an opening/closing direction of the door, or may be places parallel or substantially parallel to the opening/closing direction of the door.

In the latter case, rising portions rising in a direction perpendicular or substantially perpendicular to the opening/closing direction of the door are formed on the inner panel in order to form a predetermined thickness of the door with a predetermined spaced interval being secured between the inner panel and the outer panel, so that the end portions of the reinforcing member can be joined to the inner panel using the rising portions. Moreover, unlike the case when the former is adopted, the inner panel can be formed in a gentle shape without an abrupt change in its shape or with a small number of portions where its shape changes abruptly, so that the occurrence of stress concentration due to impact load can be suppressed when the door is opened/closed.

Furthermore, it is preferable that a box-shaped portion having a box-shaped cross section is formed along the whole periphery of the door by forming a hat-shaped portion with a hat-shaped cross section along the whole periphery of the inner panel in the marginal portion of the inner panel and by connecting this inner panel and the outer panel to each other.

This secures the strength of the entire door owing to the box-shaped portion along the whole periphery of the door. The reinforcing member formed of the aforesaid first extending portion and the aforesaid second extending portion to be in a T-shape or a substantially T-shape or the reinforcing member formed only of the aforesaid first extending portion to be in a long and narrow shape which is long in the right and left directions is connected to the inner panel, so that the strength of the door is further increased.

The inner panel may be formed of one blank material or may be formed of a tailored blank which is formed by joining a plurality of blank materials including blank materials having different plate thickness.

When the inner panel is formed in the latter manner, demands for door strength and door weight, which are inconsistent with each other, can both be satisfied at the same time by using a blank material having a large plate thickness in a portion which requires strength.

One example of the case when the inner panel is formed in the latter manner is that the tailored blank is composed of a blank material forming a hinge attaching portion to which a door hinge is attached and a blank material forming a portion other than this hinge attaching portion, and that the blank material forming the hinge attaching portion has a plate thickness larger than the blank material forming the portion other than the hinge attaching portion.

This can secure the strength required for the hinge attaching portion owing to the blank material with a large plate thickness, and furthermore, the portion, which occupies a large area of the inner panel, other than the hinge attaching portion is formed of the blank material having a small plate thickness so that the weight of the door can be reduced.

At least a part of the portion other than the hinge attaching portion may be formed of one blank material or may be formed by joining a plurality of blank materials having the same plate thickness.

In the latter case, a material yield of the blank materials which are blanked by press work can be increased even when at least a part of the portion other than this hinge attaching portion has a complicated shape such as a shape having a bending portion.

Furthermore, in the vehicle door according to the present invention described above, the inner panel and the reinforcing member, and the outer panel and the reinforcing member may be joined to each other by welding such as spot welding or by using a connecting tool such as a bolt and a nut.

A manufacturing method of a vehicle door according to the present invention is a method of manufacturing a vehicle door by connecting an outer panel on an outer side of a vehicle, an inner panel on an inner side of the vehicle in a frame shape, with only a marginal portion of the whole periphery left and with a large opening portion formed therein, and a reinforcing member having at least a first extending portion extending in a right and left direction and a second extending portion extending downward from the central part or a substantially central part of this first extending portion, and it is characterized in that, after the work of joining each of the end portions of the aforesaid reinforcing member to a marginal portion of the aforesaid inner panel is carried out and after the work of connecting the aforesaid outer panel and the aforesaid inner panel to each other is carried out, the work of painting the aforesaid outer panel, the aforesaid inner panel, and the aforesaid reinforcing member integrally connected is carried out, and subsequently, the work of attaching door parts to the aforesaid reinforcing member and/or the aforesaid inner panel is carried out.

According to this manufacturing method, the outer panel, the inner panel, and the reinforcing member are painted after they are integrally connected, so that it becomes unnecessary to carry out the painting work for them as individual works, and consequently, workability is improved. Furthermore, even when the inner panel and the reinforcing member, and the outer panel and the reinforcing member are joined to each other by welding such as spot welding, all of the welded portions can be painted by the painting work.

In this manufacturing method, the work of assembling door parts after the work of painting the outer panel, the inner panel, and the reinforcing member may be carried out by attaching all the door parts to the inner panel or the reinforcing member, or by attaching a part of the door parts to the inner panel and the other door parts to the reinforcing member respectively.

Furthermore, a manufacturing method of a vehicle door according to the present invention is a method of manufacturing a vehicle door by connecting an outer panel on an outer side of a vehicle, an inner panel on an inner side of the vehicle in a frame shape, with only a marginal portion of the whole periphery left and with a large opening portion formed therein, and a reinforcing member having at least a first extending portion extending in a right and left direction and a second extending portion extending downward from the central part or a substantially central part of this first extending portion, and it is characterized in that the aforesaid outer panel and the aforesaid inner panel are integrally connected in advance, subsequently these outer and inner panels are painted, and thereafter the aforesaid reinforcing member to which door parts are attached is attached to the aforesaid inner panel.

According to this manufacturing method, the outer panel and the inner panel are painted after they are integrally connected to each other, so that it become unnecessary to carry out painting works for them as individual works, thereby improving workability accordingly. Moreover, the door parts are attached to the reinforcing member in advance, so that the work of assembling the door parts, which are attached to the reinforcing member, to a door is finished at the same time when the work of disposing this reinforcing member to extend between the right and left side marginal portions in the marginal portion of the inner panel is carried out, and furthermore, the work of attaching the door parts to the reinforcing member can be carried out in a place having an open surrounding space, so that workability is improved.

Incidentally, since the work of painting the outer panel and the inner panel is already finished when the work of joining the reinforcing member and the inner panel and the work of joining the reinforcing member and the outer panel in this manufacturing method are carried out, it is preferable that the work of joining the reinforcing member and the inner panel and the work of joining the reinforcing member and the outer panel are carried out by using a connecting tool such as a bolt and a nut.

Furthermore, in this manufacturing method, the door parts which are attached to the reinforcing member in advance may be all of the door parts or may be a part of the door parts.

Furthermore, the vehicle door according to the present invention described hitherto may be a tailgate or a side door.

When the vehicle door according to the present invention is a tailgate, this tailgate may be a tailgate of a vertically opening/closing type, with hinges around which the tailgate opens/closes being disposed in an upper portion thereof, or may be a tailgate of a horizontally opening/closing type, with hinges being disposed on the side parts thereof. Moreover, when the vehicle door according to the present invention is a side door, it may be a side door of a hinged door type which opens/closes by hinges, or may be a side door of a sliding type which opens/closes by sliding movement.

BEST MODE FOR CARRYING OUT THE INVENTION

In order to describe the present invention in more detail, the explanation on this will be given with reference to the attached drawings.

FIG. 1is an exploded perspective view of a tailgate1which is a vehicle door according to a first embodiment of the present invention. This tailgate1is composed of an outer panel2on an outer side of a vehicle, an inner panel3on an inner side of the vehicle, which is connected to this outer panel2, a module plate4serving as a reinforcing member, which is connected to the outer panel2and inner panel3, the tailgate parts5which are door parts attached to a surface of this module plate4on the outer side of the vehicle, and a lining6fixed to a surface of the module plate on the inner side of the vehicle and a surface of the inner panel3on the inner side of the vehicle. The outer panel2, the inner panel3, and the module plate4are made of metal plates and the lining6is made of synthetic resin.

In a substantially upper half of the outer panel2, a window cavity7in which a glass is fitted is formed, and under this, there is a shielding portion9having a recessed portion8to which a license plate is attached.

The inner panel3, which has an entire shape and size corresponding to those of the outer panel2, is formed by press work, blanking work, trimming work, and so on of a sheet metal, and this inner panel3is in a frame shape with a marginal portion10of the whole periphery left and with a large opening portion11formed therein. A substantially upper half of this opening portion11has a size and a shape corresponding to those of the window cavity7of the outer panel2, and the opening portion11extends downward beyond this window cavity7, so that its size in a vertical direction is large. Meanwhile, in the marginal portion10of the inner panel3, a lower marginal portion10A is larger in width size than right and left marginal portions10B,10C and an upper marginal portion10D, and a bulging portion12bulging out in an outward direction of the vehicle from the inner side of the vehicle is provided in this lower marginal portion10A.

The module plate4is formed by folding work, blanking work, and so on of a sheet metal and its entire shape is in a substantially T-shape. More specifically, the module plate4is formed of a first extending portion13extending in a right and left direction and a second extending portion14extending downward from a substantially central part of this first extending portion13. In a lower part of the first extending portion13and right and left side parts of the second extending portion14, ribs15having a rising amount toward the outer side of the vehicle are formed, and these two ribs15are continuously formed from the lower part of the first extending portion13to the left side part of the second extending portion14and from the lower part of the first extending portion13to the right side part of the second extending portion14respectively. Furthermore, in a lower part of the second extending portion14, a standing portion16extending in the right and left direction and standing toward the outer side of the vehicle is formed.

The tailgate parts5include a key cylinder17, a wiper motor18, an outer handle19, and a door lock20. These tailgate parts5are attached to respective predetermined positions on a surface of the module plate4on the outer side of the vehicle as shown in FIG.2. To specifically explain this, the key cylinder17and the wiper motor18are attached separately to a left portion and a right portion of the first extending portion13respectively, the outer handle19is attached to a connecting part of the first extending portion13and the second extending portion14via right and left brackets21,22, and the door lock20is attached to the standing portion16in the lower part of the second extending portion14.

The key cylinder17, the wiper motor18, and the door lock20are connected to the module plate4with a bolt, the brackets21,22are joined to the module plate4by spot welding, and the outer handle19is connected to these brackets21,22with bolts and nuts.

Moreover, a rod23for transmitting an operational force to the door lock20when the key cylinder17is operated with a key is suspended between the key cylinder17and the door lock20, and between the outer handle19and the door lock20, a rod24for transmitting an operational force to the door lock20when the outer handle19is manually operated is also suspended. These rods23,24are disposed along the second extending portion14extending in a vertical direction of the module plate4.

Furthermore, in the first extending portion13extending in the right and left direction of the module plate4, a harness25extending from a left end portion of the first extending portion13inFIG. 2to the wiper motor18is wired, and in an end portion of this harness25opposite the wiper motor18, a coupler26is provided.

The lining6shown inFIG. 1is in a substantially square shape having a larger area than the module plate4, so that the lining6can cover the entire module plate4from the inner side of the vehicle. Furthermore, on a surface of this lining6on the outer side of the vehicle, a plurality of clips27to be inserted into and caught by catching holes formed in the inner panel3and the module plate4are provided.

The marginal portion10of the inner panel3has a cross section in a hat shape opening toward the outer side of the vehicle as shown in FIG.4. This hat-shaped portion28is formed along the substantially entire periphery of the inner panel3excluding the bulging portion12shown inFIG. 1, namely, along the substantially entire periphery of the aforesaid opening portion11, and in addition, the hat-shaped portion28in the lower marginal portion10A, the right and left marginal portions10B,10C, and the upper marginal portion10D of the inner panel3is formed to have the width size and height size corresponding to the width size and so on of these lower marginal portion10A, right and left marginal portions10B,10C, and upper marginal portion10D.

As shown inFIG. 4, a flange portion28A is provided in an outer end portion of the hat-shaped portion28, and hemming work of folding the outer end portion2A and caulking the outer end portion2A to this flange portion28A is carried out, and furthermore, the outer panel2and the inner panel3are spot-welded, so that the outer panel2and the inner panel3are connected to each other.

While the outer panel2is thus connected to the surface of the inner panel3on the outer side of the vehicle, in the module plate4, the right and left end portions of the first extending portion13are connected to the surfaces of the right and left marginal portions10B,10C of the inner panel3on the inner side of the vehicle, and the lower end portion of the second extending portion14is connected to the surface of the lower marginal portion10A of the inner panel on the inner side of the vehicle, respectively. They are connected by screwing and fastening a nut29A to a stud bolt29provided in the marginal portion10of the inner panel3, as shown inFIG. 4showing the structure of joining the left end portion of the first extending portion13of the module plate4and the left marginal portion10B of the inner panel3to each other. Incidentally, since the standing portion16is provided in the lower part of the second extending portion14, the joining between the lower end portion of the second extending portion14of the module plate4and the lower marginal portion10A of the inner panel3using the stud bolt29and the nut29A is carried out in a place slightly above the standing portion16.

Through the above-described processes, the outer panel2, the inner panel3, and the module plate4are joined to one another at three end portions of the module plate4in a substantially T-shape, and as shown inFIG. 4, their joining portion has a cross section in a box shape in which the peripheral portion of the outer panel2is connected to the surface of the marginal portion10, whose cross section is in a hat shape opening toward the outer side of the vehicle, of the inner panel3on the outer side of the vehicle and in which the end portion of the module plate4is fixed to the surface on the inner side of the vehicle.

FIG. 5shows the structure of joining the upper peripheral portion of the first extending portion13of the module plate4to a lower peripheral portion2B of the aforesaid window cavity7in which the glass30in the outer panel2is fitted. The stud bolt29is provided in the peripheral portion2B, and the nut29A is screwed and fastened to this stud bolt29so that the upper peripheral portion of the first extending portion13of the module plate4is joined to the peripheral portion2B.

FIG. 3is a perspective view of the inner panel3seen from the outer side of the vehicle after the outer panel2, the inner panel3, and the module plate4are connected together as described above, in which the outer panel2is shown by the two-dotted line. The module plate4is disposed in a portion corresponding to the substantially lower half of the large opening portion11which is formed in the inner panel3with only the marginal portion10of its whole periphery left, and the module plate4does not protrude to the substantially upper half, which faces the window cavity7of the outer panel2, of the opening portion11. Moreover, the module plate4is thus disposed in and fixed to the predetermined position of the inner panel3and the outer panel2, so that the key cylinder17, the wiper motor18, the outer handle19, and the door lock20as the tailgate parts5attached to the module plate4are disposed in respective predetermined positions of the tailgate1composed of these outer panel2, inner panel3, module plate4, and so on.

As for the arrangement positions of these tailgate parts5, as shown inFIG. 3, the key cylinder17, the wiper motor18, and the outer handle19are disposed in positions facing the opening portion11of the inner panel3, and the door lock20is disposed in a position corresponding to the aforesaid bulging portion12which is formed in the lower marginal portion10A of the inner panel3. Meanwhile, when the work of connecting the module plate4to the inner panel3and the outer panel2is carried out, the coupler26in the end portion of the harness25, which is shown inFIG. 2, wired to the module plate4is connected to a coupler of a connecting harness which is wired in advance on the surface of the inner panel3on the inner side of the vehicle.

Incidentally, in the aforesaid shielding portion9in the outer panel2which corresponds to the lower part of the opening portion11, formed are holes or opening portions whose arrangement positions relative to each other correspond to the arrangement positions of the key cylinder17, the wiper motor18, and the outer handle19relative to each other, and when the module plate4is disposed in the predetermined position of the inner panel3and the outer panel2, the key cylinder17, the wiper motor18, and the outer handle19face these holes or opening portions to be exposed to the outer side of the vehicle.

After the module plate4is thus connected to the inner panel3and the outer panel2, the work of attaching the lining6shown inFIG. 1to the surface of the module plate4on the inner side of the vehicle and to the surface of the inner panel3on the inner side of the vehicle is carried out. This attaching work is carried out by having the aforesaid clips27, which are provided on the lining6, inserted into and caught by the catching holes formed in the inner panel3and the module plate4. After this work of attaching the lining6is carried out, an upper portion6A of the lining6bending toward the outer side of the vehicle hides the joining portion of the upper peripheral portion of the first extending portion13of the module plate4and the peripheral portion2B of the outer panel2, as shown in FIG.5.

Furthermore, the lining6is in a substantially square shape having a larger area than the substantially lower half of the opening portion11of the inner panel3in which the module plate4is disposed, so that, when the lining6is attached to the predetermined position, the entire module plate4is covered with it on the inner side of the vehicle and the substantially lower half of the opening11is hidden.

According to this embodiment described hitherto, the inner panel3which is a constituent member of the tailgate1is in a frame shape with only the marginal portion10of the whole periphery10left and with the large opening portion11formed therein, and is not in a shape having a partitioning portion partitioning the opening portion into upper and lower portions, which can reduce the weight of the inner panel3by the weight of the partitioning portion, compared with an inner panel provided with this partitioning portion. This reduces the total weight of the tailgate1and can contribute to the weight reduction of the vehicle to which this tailgate1is attached.

Moreover, the tailgate parts5are attached to the module plate4and this module plate4is connected to the inner panel3and the outer panel2, so that, when this connecting work is carried out, the work of disposing the tailgate parts5in the predetermined positions of the tailgate1can be carried out simply and in a short time.

Moreover, the module plate4is composed of the first extending portion13extending in the right and left direction and the second extending portion14extending downward from the substantially central part of this first extending portion13to be in a substantially T-shape, so that the weight of the module plate4is also reduced, compared with a module plate in a substantially square shape, which makes it possible to further reduce the total weight of the tailgate1accordingly.

Furthermore, in the module plate4in a substantially T-shape, both of the end portions of the first extending portion13are joined to the right and left marginal portions10B,10C of the inner panel3and the lower end portion of the second extending portion14is joined to the lower marginal portion10A of the inner panel3, so that the module plate4is made full use of as the reinforcing member of the tailgate1to enable the strength of the tailgate1to be increased.

Furthermore, the module plate4is formed in a substantially T-shape, so that the places for attaching the key cylinder17, the wiper motor18, the outer handle19, and the door lock20which should be arranged in the tailgate1can also be secured as places corresponding to the functions of these tailgate parts in the module plate4, and the place for wiring the harness25and the places for disposing the rods23,24shown inFIG. 2can also be secured in the module plate4.

Furthermore, the module plate4is formed in a three-dimensional shape provided with the two ribs15having the rising amount in the inner and outer direction of the vehicle, so that the strength of the module plate4itself can be increased, and the increase in the strength of the module plate4which also serves as the reinforcing member of the tailgate1increases the total strength of the tailgate1.

Especially, these two ribs15continuously extend from the lower part of the first extending portion13to the left side portion of the second extending portion14and from the lower part of the first extending portion13to the right side portion of the second extending portion14respectively, and the ribs15are continuously formed along the first extending portion13and the second extending portion14which are perpendicular or substantially perpendicular to each other, so that two-dimensional reinforcement over the surface of the tailgate1is made possible by the module plate4.

Furthermore, the cross section of the marginal portion10of the inner panel3is hat-shaped, with the hat-shaped portion28formed therein, and the cross section of the joining portion of the outer panel2, the inner panel3, and the module plate4is a box-shaped cross section in which the peripheral portion of the outer panel3is connected to the surface of the marginal portion10, which is the hat-shaped portion28opening toward the outer side of the vehicle, of the inner panel3on the outer side of the vehicle, and the end portion of the module panel4is fixed to the surface on the inner side of the vehicle, so that their joining portion has a large strength, and as a result, the total strength of the tailgate1can be further enhanced.

Moreover, the outer handle19used when the tailgate1is opened/closed is attached to the module plate4via the brackets21,22, and not attached to the outer panel2, so that the operational force given to the outer handle19does not act directly on the outer panel2and acts on the module plate4which also serves as the reinforcing member of the tailgate1via the brackets21,22. Consequently, the problem that deformation such as a partial dent occurs in the outer panel2due to the operational force given to the outer handle19can be solved.

FIG. 6shows the inner panel33according to another embodiment. This inner panel33is made of a tailored blank which is formed by joining plate materials33A,33B,33C having different thickness via a joining portion34. In this embodiment, the plate material33A is the thickest, the plate material33B is next in thickness, and the plate material33C is the thinnest. This is one example, and the number and the arrangement positions of plate materials with different thickness which are used may be determined in any manner according to the function and so on required for the inner panel. A joining means of the plate materials may be seam welding (including mash-seam welding) or spot welding.

When the inner panel is made of the tailored blank as described above, the inner panel can be formed by effectively combining plate materials having different thicknesses, so that weight reduction and securing of the strength of the inner panel can be achieved at the same time.

FIG. 7shows an embodiment in which license lamps43are attached to brackets41,42via which the outer handle19is attached to the module plate4. As shown inFIG. 8which shows the bracket42, out of the brackets41,42, holes45for inserting lower parts of the license lamps43therethrough are formed in the brackets41,42, and as shown inFIG. 7, flange portions43A of the license lamps43whose lower parts are inserted into the holes45are connected to the brackets41,42using bolts44, so that the license lamps43are attached to the brackets41,42.

According to this embodiment, the brackets41,42for attaching the outer handle also serve as brackets for attaching the license lamps43, which makes it possible to reduce the number of parts used in manufacturing the tailgate1accordingly, and as a result of the reduction in the number of the parts, contribute to a reduction in tailgate weight.

FIG. 9shows a tailgate101of a four-wheel vehicle according to an embodiment different from that of the tailgate in FIG.1. This tailgate101is attached to the vehicle body102with hinges103disposed in an upper part thereof, and is free to open/close in a vertical direction around the hinges103. Furthermore, a wiper apparatus105for cleaning a glass104fitted in a window cavity101A is attached to the tailgate101, and a base end portion of a wiper arm105B is connected to a rocking shaft105A of this wiper apparatus105.

An exploded view of the tailgate101is shown in FIG.10. The tailgate101is formed to include, as its main constituent members, an outer panel110on an outer side of the vehicle, an inner panel111on an inner side of the vehicle, a reinforcing member112whose right and left end portions are joined to a surface of the inner panel111on the inner side of the vehicle, and a lining113disposed on a further inner side of the vehicle than the reinforcing member112, and besides these tailgate parts, a reinforcing member114for attaching a door lock which is attached to the inner panel111is provided. Furthermore, a wiper motor115of the wiper apparatus105, an outer handle116, a key cylinder117, and a door lock118are assembled onto the tailgate101as door parts, and moreover, a harness119extending to the wiper motor115from a vehicle body102side, a harness120extending to the door lock118from the vehicle body102side, a member121for manually operating a door lock suspended between the outer handle116and the door lock118, and a rod122for operating door lock key suspended between the key cylinder117and the door lock118are assembled onto the tailgate101, and in end portions of the harnesses119and120on the vehicle body102side, couplers123connected to harnesses wired on the vehicle body102side are disposed.

The outer panel110, the inner panel111, the reinforcing member112, and the reinforcing member114for attaching door lock are sheet metal pressed products and the lining113is a synthetic resin product.

The outer panel110shown inFIG. 11has a recessed portion110B, which is formed below a window cavity101A in which a glass104shown inFIG. 9is fitted, for fitting a license plate therein, and in an upper side portion of this recessed portion110B, holes110C and110D for exposing the outer handle116and the key cylinder117from the outer panel110are provided, and furthermore, between the window cavity101A and the recessed portion110B, a hole110E for exposing the rocking shaft105A of the wiper apparatus105shown inFIG. 9from the outer panel110is formed.

The total size and shape of the inner panel111shown inFIG. 12are substantially the same as those of the outer panel110, but this inner panel111has only a marginal portion130of the whole periphery, with a large opening portion131formed inside the marginal portion130, so that the inner panel111is in a frame shape as a whole. The marginal portion130is composed of an upper marginal portion130A, right and left side marginal portions130B and130C, and a lower marginal portion130D, with a hollow portion132sinking in an inward direction of the vehicle being formed in the lower marginal portion130D, with a lower surface of this hollow portion132being a horizontal or substantially horizontal surface132A for attaching door lock, and with an opening portion133allowing a lock member, which extrudes and recesses from the door lock118to lock the tailgate101to the vehicle body102and release locking, to pass therethrough being provided in this surface132A. Furthermore, an opening portion134is also formed in an inclined upper surface132B of the hollow portion132, so that the door lock118can be placed in and attached to the surface132A reinforced by the aforesaid reinforcing member114for attaching door lock by inserting the door lock118into this opening portion134from above.

Furthermore, on the right and left side marginal portions130B,130C and the lower marginal portion130D in the marginal portion130, a ridge portion135bulging in an outward direction of the vehicle is formed continuously along these side marginal portions130B,130C and the lower marginal portion130D, and this ridge portion135is for forming a predetermined spaced interval between the outer panel110disposed on a further outer side of the vehicle than the ridge portion135and the inner panel111to secure a predetermined thickness of the tailgate101. In the ridge portion135, portions formed on the right and left side marginal portions130B,130C are rising portions135A having a large bulging amount, and on base end portions of the rising portions135A, flat surfaces135B are provided, as shown in FIG.14and inFIG. 16which is a cross sectional view taken along the line S16—S16in FIG.14and in which the outer panel110when connected to the inner panel111is also shown. The flat surfaces135B are perpendicular or substantially perpendicular to the direction of opening/closing of the tailgate101around the hinges103shown inFIG. 9, and the rising portions135A are parallel or substantially parallel to the opening/closing direction of this tailgate101.

Moreover, a hat-shaped portion136having a cross section in a hat shape and opening toward the outer side of the vehicle is formed in the marginal portion130of the inner panel111as shown inFIG. 16, and this hat-shaped portion136is formed continuously along the whole periphery of the inner panel111, though its width and depth differ depending on each portion of the inner panel111as shown in FIG.12. As shown inFIG. 16, when the inner panel111and the outer panel110are connected to each other, the opening side of the hat-shaped portion136is covered with the outer panel110, so that a box-shaped portion137having a cross section in a box shape is formed along the whole periphery of the tailgate101.

As shown inFIG. 12, holes140to142are formed in appropriate places of the marginal portion130of the inner panel111, and these holes140to142are used for wiring the aforesaid harnesses119,120and the member121for manually operating door lock on the inner panel111.

Furthermore, the inner panel111is formed of constituent elements144to149joined together via joining portions143by laser welding. In other words, the inner panel111is formed by joining totally six blank materials, which are materials for the constituent elements144to149, by laser welding which is carried out by facing end portions of the adjoining blank materials with each other, thereby forming a tailored blank, and thereafter, by press-forming and blank-forming this tailored blank with a press machine.

Incidentally, the manufacturing of the tailored blank by joining the totally six blank materials together by laser welding may be carried out in such a manner that each of the blank materials is press-formed and blank-formed with the press machine in advance and thereafter, these blank materials are welded by laser welding.

The constituent elements145,146out of the constituent elements144to149form hinge attaching portions to which the hinges103inFIG. 9are attached, and the other constituent elements144, and147to149form portions other than the hinge attaching portions. The blank materials for the constituent elements145,146, which have a larger plate thickness than that of the constituent elements144and147to149, have a plate thickness of, for example, 1.4 mm, and the plate thickness of the blank materials for the constituent elements144and147to149is, for example, 0.6 mm. Therefore, in the tailgate101, which is formed using the blank materials having two different plate thickness, the blank materials in the hinge attaching portions have a larger plate thickness than that of the blank materials in the portions other than the hinge attaching portions, and a portion except the hinge attaching portions and except the portion of the constituent element144is formed by joining totally three blank materials having the same plate thickness. Since this portion is formed of the constituent elements147to149, it has a bending shape.

The entire shape of the reinforcing member112shown inFIG. 13is a long and narrow shape which is long in a right and left direction. Therefore, while the module plate4in the previously described embodiment shown inFIG. 2is formed of the first extending portion13extending in the right and left direction and the second extending portion14extending downward from the substantially central part of this first extending portion13to have a substantially T-shape, the reinforcing member112in this embodiment is formed only of a portion corresponding to the first extending portion, so that it is lightened to a greater extent than the module plate4.

Moreover, this reinforcing member112is a bent member including two flanges151,152which bend toward the outer side of the vehicle from upper and lower end portions of a web150whose width direction corresponds to a vertical direction, so that the web150and the two flanges151,152formed along the whole length of this web150cause this reinforcing member112to have a cross section in a substantially C-shape, in other words, a channel shape. In addition, lips151A,152A are provided along edges of the flanges151,152respectively, and joining pieces153joined to the flat surfaces135B in the ridge portion135of the inner panel111shown in FIG.14andFIG. 16are provided along right and left end portions of the reinforcing member112.

A hole154for inserting a wiper motor115attached to the reinforcing member112therethrough from the inner side of the vehicle is formed in the web150, and adjacent to this hole154, a connecting surface155for having a bracket115A (refer to FIG.17andFIG. 19) of the wiper motor115connected thereon with a bolt and a nut is formed. Incidentally, the rocking shaft105A of the wiper apparatus105shown inFIG. 9is provided in the wiper motor115as shown in FIG.17. Furthermore, an extending piece156hangs from the lower flange152of the reinforcing member112as shown inFIG. 13, and in this extending piece156to which the outer handle116and the key cylinder117shown inFIG. 9are attached, a hole157for having the aforesaid member121for manually operating door lock, which is connected to the outer handle116, inserted therethrough and a hole158for having the key cylinder117inserted therethrough are formed.

Manufacturing works of the tailgate101are carried out as follows.

First, the reinforcing member114for attaching door lock is attached to the surface132A for attaching door lock of the inner panel111by spot welding. An opening portion159is formed in this reinforcing member114for attaching door lock as shown inFIG. 14, and this opening portion159is communicated with the opening portion133shown inFIG. 12, so that the locking member which extrudes and recesses from the door lock118to lock the tailgate101to the vehicle body102and release locking can pass through the opening portions133and159when the door lock118is attached to the surface132A reinforced by the reinforcing member114.

Thereafter, the work of disposing the reinforcing member112in a long and narrow shape which is long in the right and left direction to extend between the right and left side marginal portions130B and130C in the marginal portion130of the inner panel111from the inner side of the vehicle is carried out, and as shown inFIG. 14, this disposing work is carried out in such a manner that the two upper and lower flanges151,152of the reinforcing member112are faced with the outer side of the vehicle, the joining pieces153in the right and left end portions of the reinforcing member112are brought in contact with the flat surfaces135B of the ridge portion135of the inner panel111from the inner side of the vehicle, and the joining pieces153and the flat surfaces135B are joined together by spot welding. The arrangement position of the reinforcing member112in terms of the vertical direction of the inner panel111at this time is such that the position of the upper flange151of the reinforcing member112corresponds to a position slightly lower than a lower side portion of the window cavity101A of the outer panel110shown in FIG.11. This state is shown in FIG.14.

InFIG. 16showing the state after the outer panel110and the inner panel111are connected to each other, the state in which the joining piece153of the reinforcing member112and the flat surface135B of the ridge portion135of the inner panel111are joined together via a welding portion160by spot welding is shown.

Next, the work of connecting the outer panel110and the inner panel111to each other is carried out. As shown inFIG. 16, this connecting work is carried out in such a manner that a hemming work of folding an outer peripheral portion110F of the outer panel110and pressing it onto an outer peripheral portion111A of the inner panel111on which an adhesive is applied in advance is carried out, and thereafter, the outer peripheral portions110F,111A of the outer panel110and the inner panel111are joined together by spot welding, or a hemming work of folding the outer peripheral portion110F of the outer panel110and pressing it onto the outer peripheral portion111A of the inner panel111on which a heat curable adhesive is applied in advance is carried out, and thereafter, the heat curable adhesive is heated to be cured, and this work is carried out along the whole peripheries of the outer panel110and the inner panel111. Meanwhile, a sealer161is applied on a peripheral portion of the inner panel111on the side of the aforesaid opening portion131, namely, an inner peripheral portion111B, thereby preventing the inner peripheral portion111B from coming in direct contact with the outer panel110. This sealer161is applied discontinuously in portions along the whole periphery of the inner peripheral portion111B except portions corresponding to a place in which the glass104shown inFIG. 9is fitted and corresponding to the aforesaid lip151A of the reinforcing member112shown in FIG.14.

Incidentally, the places in the inner peripheral portion111B of the inner panel111on which the sealer161is not applied are spot-welded to the outer panel110.

As described above, when the work of connecting the outer panel110and the inner panel111to each other is carried out, the opening side of the aforesaid hat-shaped portion136of the inner panel111shown inFIG. 16is covered with the outer panel110, so that this hat-shaped portion136becomes the box-shaped portion137.

Meanwhile, the lip151A of the upper flange151of the reinforcing member112and a peripheral portion110G forming the lower side portion of the window cavity101A in the outer panel110are joined together via a welding portion162by spot welding as shown inFIG. 15which is a cross sectional view taken along the line S15—S15in FIG.14and in which the outer panel110connected to the inner panel111is also shown. A sealer163is applied continuously or discontinuously along the whole length of the lip152A of the lower flange152of the reinforcing member112. This sealer163prevents the lip152A from coming in direct contact with the outer panel110.

Through the above-described works, the outer panel110, the inner panel111, and the reinforcing member112are integrally connected. Thereafter, these outer panel110, inner panel111, and reinforcing member112are painted and surface finish work is given to each of them. This painting work includes electrodeposition coating of the outer panel110, the inner panel111, and the reinforcing member112, the electrodeposition coating being carried out by soaking them in an electrodeposition solution contained in an electrodeposition bath. By this electrodeposition coating, surfaces of the outer panel110, the inner panel111, and the reinforcing member112including the welding portions160,162are painted. The electrodeposition solution is surely absorbed inside the box-shaped portion137shown inFIG. 16since the sealer161is applied discontinuously along the inner peripheral portion111B of the inner panel111, so that the inner surface of this box-shaped portion137is also painted.

Thereafter, the work of assembling the wiper motor115, the outer handle116, the key cylinder117, and the door lock118which are door parts is carried out. The work of assembling the wiper motor115is carried out in such a manner that the wiper motor115is inserted through the hole154of the reinforcing member.112shown inFIG. 13from the inner side of the vehicle and the brackets115A of the wiper motor115shown inFIG. 17are connected to the surface of a connecting surface155of the reinforcing member112on the inner side of the vehicle using bolts and nuts. The work of assembling the outer handle116is carried out in such a manner that the outer handle116is connected using a bolt and a nut to the position of the extending piece156of the reinforcing member112where the hole157is formed, and the work of assembling the key cylinder117is carried out in such a manner that the key cylinder117is inserted into the hole158which is formed in the extending piece156of the reinforcing member112and a bracket117A (refer toFIG. 19) of the key cylinder117is connected to the extending piece156using a bolt and a nut.

Furthermore, the work of assembling the door lock118is carried out in such a manner that the door lock118is inserted from above to the opening portion134which is formed in the inclined upper surface132B of the hollow portion132of the inner panel111shown inFIG. 12, thereby placing the door lock118on the surface132A which is reinforced by the aforesaid reinforcing member114for attaching door lock, and the door lock118is connected to this surface132A via a bolt and a nut.

When the above-described works are finished, the outer handle116, the key cylinder117, the rocking shaft105A of the wiper motor115are exposed from the hole110C, the hole110D, the hole110E of the outer panel110shown inFIG. 11, respectively.

Next, the aforesaid harnesses119,120are inserted from the inner side of the vehicle through the hole140of the inner panel111shown inFIG. 12, and these harnesses119,120are inserted through the inner part of the aforesaid box-shaped portion137, with an end portion of the harness119protruded from the hole141of the inner panel111shown inFIG. 12to be connected to the wiper motor115and with an end portion of the harness120connected to the door lock118by the work from the aforesaid opening portion134of the inner panel111. Furthermore, the aforesaid member121for manually operating door lock is inserted through the hole142of the inner panel111shown in FIG.12and the hole157of the reinforcing member112shown inFIG. 13, so that it is suspended between the outer handle116and the door lock118, and the aforesaid rod122for operating the door lock key is inserted to the aforesaid opening portion134of the inner panel111, so that it is suspended between the key cylinder117and the door lock118.

The state after this work is finished is shown in FIG.17. InFIG. 17, the outer panel110is omitted.

Incidentally, as shown inFIG. 18in which the outer panel110is similarly omitted, the member121for manually operating door lock may be inserted through the hole141to omit the hole142.

After the above-described works are finished, the work of attaching the lining113shown inFIG. 10to the surfaces of the reinforcing member112and the inner panel111on the inner side of the vehicle is carried out in such a manner that catching members170such as the clips provided on the lining113are caught in caught portions such as holes formed in the reinforcing member112and the inner panel111, and the work of fitting the glass104in the window cavity101A shown inFIG. 9is carried out. The work of attaching the lining113causes the reinforcing member112, the wiper motor115, and so on to be hidden from the inner side of the vehicle.

According to the embodiment explained above, the inner panel111as a main component of the tailgate101is also in a frame shape, having only the marginal portion130of the whole periphery, so that it becomes light, thereby enabling the total weight of the tailgate101to be reduced.

Furthermore, the reinforcing member112extends between the right and left side marginal portions130B,130C in the marginal portion130of the inner panel111, so that the reinforcing member112reinforces the inner panel111to secure the strength of the inner panel111after the reinforcing member112is connected thereto. Moreover, the reinforcing member112is in a long and narrow shape which is long in the right and left direction and does not have a large area, so that the reinforcing member112is light, and consequently, the weight of the inner panel111and the total weight of the tailgate101after the reinforcing member112is connected thereto are not increased very much.

Furthermore, the reinforcing member112does not have a flat plate shape but is a bent member having the web150and the flanges151,152bending from the web150, so that the strength of the reinforcing member112itself is increased, thereby enabling the strength of the inner panel111and the strength of the tailgate101to be increased when the reinforcing member112is connected thereto.

Especially, the reinforcing member112according to this embodiment has a substantially C-shaped cross section, in which the two flanges151,152bend from the upper and lower edge portions of the web150whose width direction corresponds to the vertical direction, and these flanges151,152are formed continuously in the longitudinal direction of the web150, and, unlike the case when this reinforcing member has a front section in a T-shape and so on, the lower flange152does not come to an end halfway in the longitudinal direction of the web150. Consequently, in the strength of the reinforcing member112, the strength owing to the upper and the lower flanges151,152is kept as it is, so that the strength of the inner panel111and the strength of the tailgate101can be sufficiently increased after the reinforcing member112is connected thereto.

Furthermore, the reinforcing member112is connected to the inner panel111with the opening portion thereof, whose cross section is in a substantially C-shape, facing the outer side of the vehicle, in other words, with the upper and lower flanges151,152facing the outer side of the vehicle, and these flanges151,152are in the state of being accommodated in a space inside the thickness of the tailgate101which is secured by the ridge portion135formed in the inner panel111, so that the thickness of the tailgate101can be suppressed to a predetermined size even when these flanges151,152for sufficiently increasing the strength of the reinforcing member112are provided in the reinforcing member112.

Furthermore, the marginal portion130of the inner panel111has the hat-shaped portion136formed along the whole periphery of the inner panel, and by connecting this inner panel111and the outer panel110to each other, the box-shaped portion137is formed along the whole periphery of the door, so that this structure together with the reinforcing member112having a substantially C-shaped cross section can further increase the total strength of the tailgate101.

Furthermore, the inner panel111is formed of the tailored blank which is formed by joining the blank materials having different thickness, and only the blank materials in the hinge attaching portions requiring a larger strength than the other portions has a larger plate thickness, so that securing of the strength required for the inner panel111and weight reduction can both be achieved at the same time.

Furthermore, since the portion except the hinge attaching portions and except the portion of the constituent element144is formed by joining three blank materials having the same plate thickness, unlike the case when this portion occupying a large area of the inner panel111and having a bending shape is formed of one blank material having a large area, blank materials having the same area and shape as or a little larger area and shape than those of the constituent elements147to149can be used as the three blank materials in the portion corresponding to the constituent elements147to149when the inner panel111is formed of the tailored blank consisting of the blank materials for the respective constituent elements144to149, so that the inner panel111can be manufactured with an improved material yield.

Meanwhile, in this embodiment, the work of painting the outer panel110, the inner panel111, and the reinforcing member112is carried out after the outer panel110, the inner panel111, and the reinforcing member112are integrally connected by welding and before the work of assembling the door parts such as the door lock118is carried out, so that it becomes unnecessary to carry out the painting work separately for these outer panel110, inner panel111, and reinforcing member112, thereby enhancing workability of the painting work. Furthermore, the welding portion160between the inner panel111and the reinforcing member112and the welding portion162between the outer panel110and the reinforcing member112can also be painted at the same time when the outer panel110, the inner panel111, and the reinforcing member112are painted.

Furthermore, the wiper motor115, the outer handle116, the key cylinder117as the door parts are attached to the reinforcing member112, so that the reinforcing member112is also used as the attaching member for having these parts attached thereto, thereby eliminating the necessity of specially preparing an attaching member for the wiper motor115, the outer handle116, and the key cylinder117.

FIG. 19toFIG. 21show an embodiment when the tailgate101is manufactured in a different work order from that of the manufacturing works described above.

In the manufacturing work of this embodiment, the inner panel111and the outer panel110are connected together by the aforesaid hemming work and so on after the reinforcing member114for attaching door lock is connected to the surface132A for attaching door lock of the inner panel111by spot welding. Thereafter, the work of painting the outer panel110and the inner panel111integrally connected together is carried out, and subsequently, the door lock118is attached to the surface132A reinforced by the reinforcing member114for attaching door lock of the inner panel111through the same work as the aforesaid manufacturing work.

After the above-described works or synchronously with them, the work of attaching the wiper motor115, the outer handle116, and the key cylinder117to the reinforcing member112is carried out to turn the reinforcing member112to a module member provided with these wiper motor115, outer handle116, and key cylinder117in advance, as shown in FIG.19. This reinforcing member112is made of a material on which surface treatment is given in advance, namely, for example, a galvanized steel plate or a painted steel plate which is painted in advance.

Next, the work of connecting the peripheral portion110G forming the lower side portion of the window cavity101A in the outer panel110and the lip151A of the upper flange151of the reinforcing member112using a stud bolt180and a nut181joined in advance to this peripheral portion110G as shown inFIG. 20, and the work of joining the joining piece153of the reinforcing member112to the flat surface135B of the marginal portion130of the inner panel111using a nut182and a bolt183joined in advance to this flat surface135B as shown inFIG. 21are carried out, and then, the work of applying the sealer163onto the lip152A of the lower flange152of the reinforcing member112as shown in FIG.20and the work of applying the sealer161onto the inner peripheral portion111B of the inner panel111on the opening portion131side as shown inFIG. 21are carried out. Thereby, the work of disposing the reinforcing member112to extend between the right and left side marginal portions130B,130C in the marginal portion130of the inner panel111is carried out while joining the reinforcing member112to the outer panel110.

Moreover, through the above works, the outer panel110, the inner panel111, and the reinforcing member112are integrally connected, and the work of assembling the wiper motor115, the outer handle116, the key cylinder117, and the door lock118is finished.

Thereafter, similarly to the manufacturing works according to the aforesaid embodiment, the work of wiring the harnesses119,120, the work of suspending the member121for manually operating the door lock and the rod122for operating the door lock key, the work of attaching the lining113to the surfaces of the reinforcing member112and the inner panel111on the inner side of the vehicle, and the work of fitting the glass104in the window cavity101A are carried out.

In the manufacturing works of the tailgate according this embodiment, the outer panel110and the inner panel111are painted after they are integrally connected, so that it becomes unnecessary to paint the outer panel110and the inner panel111separately, thereby enhancing the workability of the painting work accordingly.

Furthermore, the wiper motor115, the outer handle116, and the key cylinder117as the door parts are attached to the reinforcing member112before this reinforcing member112is disposed to extend between the right and left marginal portions130B,130C in the marginal portion130of the inner panel111, so that this attaching work can be carried out in a work space having an open surrounding space, thereby enhancing workability.

Furthermore, the reinforcing member112is a module member to which these door parts are attached in advance, so that the assembling work of these door parts are carried out at the same time when the work of connecting the reinforcing member112to the inner panel111is carried out, thereby simplifying this assembling work.

As shown inFIG. 22, a marginal portion230of the inner panel211in a frame shape according to this embodiment is also composed of an upper marginal portion230A, right and left side marginal portions230B,230C, and a lower marginal portion230D, and rising portions235A in the right and left marginal portions230B,230C exist in a ridge portion235, but portions corresponding to the flat surfaces135B shown inFIG. 12,FIG. 14, andFIG. 16do not exist. Portions corresponding to the joining pieces153shown inFIG. 13,FIG. 14, andFIG. 16do not exist, either, in a reinforcing member212according to this embodiment as shown inFIG. 23which is a cross sectional view taken along the line S23—S23in FIG.22and which also shows the outer panel110connected to the inner panel211.

Furthermore, similarly to the aforesaid embodiment, the reinforcing member212has a substantially C-shaped cross section with two flanges251,252bending toward the outer side of the vehicle from upper and lower edge portions of a web250whose width direction corresponds to the vertical direction, and lips251A,252A are provided in the end portions of these flanges251,252, as shown inFIG. 22, but as shown inFIG. 24which is a cross sectional view taken along the line S24—S24in FIG.22and which also shows the outer panel110connected to the inner panel211, the lip252A has a joining piece253formed along the surface of the rising portion235A of the inner panel211on the inner side of the vehicle, and this joining piece253is joined to the rising portion235A via a welding portion260by spot welding. Though not shown in the drawing, a joining piece along the surface of the rising portion235A on the inner side of the vehicle is also formed in the lip251A, and this joining piece is also joined to the rising portion235A via the welding portion260by spot welding.

Consequently, according to this embodiment, the right and left end portions of the reinforcing member212in a long and narrow shape which is long in the right and left direction are joined to the rising portions235A of the inner panel211which are parallel or substantially parallel to the direction of opening/closing of the tailgate around the hinges103which are shown inFIG. 9, so that this reinforcing member212extends between the right and left side marginal portions230B,230C in the marginal portion230of the inner panel211.

According to this embodiment, the reinforcing member212and the inner panel211can be joined together, making use of the rising portions235A of the ridge portion235which is provided in the inner panel211in order to cause the tailgate to have a predetermined thickness.

Furthermore, the portions corresponding to the flat surfaces135B shown inFIG. 12,FIG. 14, andFIG. 16do not exist in the inner panel211, so that, unlike the case when the flat surfaces135B and the rising portions135A are both provided in the inner panel as shown inFIG. 16, the inner panel211can be formed in a gentle shape without portions or with the small number of portions where its shape changes abruptly. As a result, impact load acts on no place or does not act on many places as stress concentration when the tailgate is opened/closed around the hinges103, which will be an effective measure against load.

Incidentally, the above-described joining of the right and left end portions of the reinforcing member212to the portions parallel or substantially parallel to the opening/closing direction of the tailgate in the inner panel211is applicable to the case when the tailgate is manufactured through manufacturing according to two kinds of the embodiments previously described, and when the tailgate is manufactured through manufacturing according to the embodiment shown inFIG. 19toFIG. 21in which the reinforcing member212is a module member to which the door parts are attached in advance, the aforesaid joining piece of the reinforcing member212is joined to the rising portion235A using a nut joined to the rising portion235A of the inner panel211in advance and a bolt screwed to this nut, instead of using the welding portion260in FIG.24.

Industrial Availability

As described hitherto, the vehicle door and the manufacturing method thereof according to the present invention are suitable for manufacturing a tailgate or a side door of a vehicle door with an outer panel, an inner panel and a reinforcing member.