VEHICLE DOOR WITH SPLIT OUTER PANEL

Abstract: A split outer panel construction for a vehicle door includes an upper/outer panel member (14) fixed to the window frame (18) of the inner door panel (12). The lower edge (26) of the upper/outer panel (14) includes a fin (28) which fits within a slot (30) formed in the upper inboard edge of a removably attachable lower/outer panel member (16). Door hardware can be easily assembled onto the exposed inner panel prior to attaching the lower/outer panel (16) to the door.

Description: This invention relates to a vehicle door having an upper window frame portion and defining a lower cavity of sufficient depth to receive at least a mechanism for regulating a window, a split outer panel construction having an upper outer panel member and a lower outer panel member, the upper outer panel member being fixed to the window frame portion of the inner panel, the top edge of the lower outer panel member being adapted to be detachably connected such that said connection brings the faces of the upper outer panel member and the lower outer panel member into alignment thus minimizing vibration related noise and permitting hardware to be assembled in the lower cavity of the inner panel prior to attaching the lower outer panel member. FR-A-25 74 109 describes such a vehicle door including an inner and outer panel fixed together about its edges thereby forming a hollow shell in the interior lower portions thereof. The detachable connection of the upper and lower outer panel comprises bolts or an indirect coupling by a plastic fixing strip, which connection interrupts the continuity of the exterior door surface. The inner panel is rigid and does not include access openings to permit hardware such as window regulator mechanisms and the like to be inserted therethrough and attached during the typical online assembly process. However, such access openings are provided in many other conventional vehicle doors, as mentioned in the description of the prior art in FR-25 74 109, page 1, lines 15 to 19. It is the object of the invention to create a vehicle door construction providing a solid, yet easily removably attachable fastening reducing vibration of the ultimate assembly and insuring a cosmetic fit. This object is achieved according to the present invention in that the lower outer panel member has a pocket formed inboard from the outer face thereof and extending along the top edge of the lower outer panel member, this pocket providing a receptacle for receiving a fin depending from the upper outer panel member. Advantageously said fin runs longitudinally along a lower edge of the upper outer panel member and depends downwardly therefrom. Preferably said pocket is generally U-shaped and integrally formed from the same material as the lower outer panel member. Conveniently said lower outer panel member is made of fiber reinforced plastic material. It is favourable that said pocket includes resilient sealing means, said sealing means cooperating with walls of the pocket to provide a substantially tight fit with the fin. It is advantageous that said inner panel and upper outer panel member are stamped metal sections. Preferably fastener means are used for securing vertical sides and the bottom of the lower outer panel member to the inner panel. It is convenient that said fastener means comprises a plurality of fastening areas disposed along peripheral portions of the lower outer panel member, each of said fastening areas including a flange spaced inboard from an inner face of the lower outer panel member, said flange having one or more locating openings therein; a tapping plate at least partially lying in the space between the flange and the inner face; and a threaded fastener having a head engaging an inner face of the inner panel and a threaded shank portion engaging the tapping plate whereby rotation of the fastener from the interior of the vehicle draws the lower outer panel member and inner panel together. The vehicle door according to the invention has a solid, yet removably attachable fastening. The vibration of the ultimate assembly is reduced. The cosmetic fit of the outer panel members is not only pleasing but also provides a mechanically sound fit. The invention is further described with reference to the drawings in which: Fig. 1 is an exploded perspective view of a vehicle door made in accordance with the teachings of the present invention; Fig. 2 is a partial perspective view of the completed door assembly with parts broken away; Fig. 3 is a partial cross sectional view along the lines 3-3 of Figure 2; and Fig. 4 is a partial exploded perspective view with parts broken away illustrating the preferred mode of attachment of the various door parts. The vehicle door 10 shown in Fig 1 to 4 consists of three main parts namely an inner panel 12 and a split outer panel consisting of an upper outer panel member 14 and a lower outer panel member 16. The inner panel 12 is fairly typical and generally is formed from a metal stamping defining a lower hollow shell portion 17 and an upper window frame portion 18. As is known in the art, the lower shell portion 17 is provided with suitable attachment means onto which hardware (not shown) such as window regulator mechanisms, door lock assemblies and the like are attached. The window frame portion 18 also includes weather stripping (not shown) and the like as is well known in the art. The upper outer panel 14 is defined by three sides 20, 22 and 24 which generally correspond with the sides of window frame 18 and a lower edge 26 that runs along the longitudinal length of the door at the belt line. The lower edge 26 includes a depending fin 28 located inboard of the plane of the outer face 27 of the edge 26 as seen most clearly in Fig 3. Upper outer panel 14, in this embodiment, is a sheet metal stamping and the fin 28 is formed by a reverse fold or Dutch hem as seen most clearly in Fig 4. The upper outer panel member 14 is attached to inner panel 12 so that member 14 encloses the window frame 18. Since upper outer member 14 is also a sheet metal stamping in this embodiment, conventional sheet metal attachment techniques can be used to permanently affix the two stampings together. In Fig 2 the outer upper panel member 14 is shown hemmed to the window frame 18 portion of inner panel 12. It will be appreciated that the partially assembled door still permits the on-line assembly worker to have access to the interior cavity 17 for mounting the necessary door hardware. This is because the lower outer panel member 16 is not attached to the door until the hardware mounting operations have been completed. All such operations can be conveniently accomplished from the exterior of the vehicle thereby greatly facilitating the assembly process. Once the door hardware has been assembled, the lower outer panel member 16 is detachably fastened to the inner panel 12 and to the upper, outer panel member l4. The lower outer panel member 16 is preferably made from fiber-reinforced plastic and includes a pocket or slot 30 that is preferably integrally molded with the remainder of the lower outer panel 16 and is located inboard from the outer face 31 thereof. A flexible seal 32 runs along the inboard wall 34 of slot 30. As can be seen most clearly in Fig 3 and 4, the space between seal 32 and the opposite wall 36 provides a receptacle for receiving the fin 28 of the upper outer panel member 14. The mating parts are dimensioned so that there is a rather tight fit substantially devoid of any relative movement which could cause rattling or other vibration related noise. Thus, the joint along the adjacent longitudinal edges of the upper 14 and lower 16 outer panel members is not only cosmetically pleasing but also provides a mechanically sound fit. Attachment around the other three edges of the lower/outer panel member 16 can be accomplished by a variety of means. In the preferred embodiment, the plastic lower outer panel 16 is provided with integral flanges 38 which are spaced from the inner surface 40 a sufficient distance to receive a tapping plate 42. The flange 38 has one or more openings 44 through which tangs 46 of plate 42 protrude thereby giving tapping plate 42 a certain range of adjustment. Plate 42 includes an internally threaded boss 48 for receiving the threaded shank of a fastener 50 whose enlarged head draws the inner panel 12 and lower outer panel member 16 together upon tightening.

Claims: A vehicle door with an inner panel (12) having an upper window frame portion (18) and defining a lower cavity (17) of sufficient depth to receive at least a mechanism for regulating a window, a split outer panel construction having an upper outer panel member (14) and a lower outer panel member (16), the upper outer panel member (14) being fixed to the window frame portion (18) of the inner panel (12), the top edge of the lower outer panel member (16) being adapted to be detachably connected such that said connection brings the faces of the upper outer panel member (14) and the lower outer panel member (16) into alignment thus minimizing vibration related noise and permitting hardware to be assembled in the lower cavity (17) of the inner panel (12) prior to attaching the lower outer panel member (16), characterized in that the lower outer panel member (16) has a pocket (30) formed inboard from the outer face (31) thereof and extending along the top edge of the lower outer panel member (16), this pocket (30) providing a receptacle for receiving a fin (28) depending from the upper outer panel member (14). A vehicle door according to claim 1, characterized in that said fin (28) runs longitudinally along a lower edge (26) of the upper outer panel member (14) and depends downwardly therefrom. A vehicle door according to claim 1 or 2, characterized in that said pocket (30) is generally U-shaped and integrally formed from the same material as the lower outer panel member (16). A vehicle door according to one of the claims 1 to 3, characterized in that said lower outer panel member (16) is made of fiber reinforced plastic material. A vehicle door according to one of the claims 1 to 4, characterized in that said pocket (30) includes resilient sealing means (32), said sealing means cooperating with walls (34, 36) of the pocket (30) to provide a substantially tight fit with the fin (28). A vehicle door according to one of the claims 1 to 5, characterized in that said inner panel (12) and upper outer panel member (14) are stamped metal sections. A vehicle door according to one of the claims 1 to 6, characterized by fastener means (48, 50) for securing, vertical sides and the bottom of the lower outer panel member (16) to the inner panel (12). A vehicle door according to claim 7 characterized in that said fastener means comprises a plurality of fastening areas disposed along peripheral portions of the lower outer panel member (16), each of said fastening areas including a flange (38) spaced inboard from an inner face (40) of the lower outer panel member (16), said flange (38) having one or more locating openings (44) therein; a tapping plate (42) at least partially lying in the space between the flange (38) and the inner face (40); and a threaded fastener (50) having a head engaging an inner face of the inner panel (12) and a threaded shank portion engaging the tapping plate (42) whereby rotation of the fastener (50) from the interior of the vehicle draws the lower outer panel member (16) and inner panel (12) together.

Inventors: GRIER, DONALD ALEXANDER, NIELSON, THEODORE OLIVER, JR.
Applicants: THE BUDD COMPANY
Application year: 1988
Main classification: B60J5
IPC codes: B60J5