Abstract:
A door striker that may be used in many applications, including numerous applications throughout the automotive industry, includes an improved door striker that is made of a single piece of material. The door striker is stamped and drawn to its final configuration. The edges of the posts of the door striker are rolled and/or curled to provide structurally integrity to the door striker. In addition, the rolled edges provide a compatible mating surface for the associated door latching mechanism. Moreover, the bolt holes formed in the door striker include retaining features to hold the bolts in place during shipment of the door striker, prior to assembly. The bolts may then be manually pushed or threaded into the mounting holes on the automobile.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to a door striker device that may be used with an automobile.  
       BACKGROUND OF THE INVENTION  
       [0002]     It is known that door strikers are used on automobiles to facilitate the latching and unlatching of the door to the frame of the automobile and thus the opening and closing of the automobile&#39;s door. More specifically, the door strikers are mounted to the frame of the automobile and the door includes a latch mechanism that engages the door striker to latch and hold the door to the door striker. By operating the handle of the door, the latch mechanism will unlatch from the door striker, thereby permitting the door to open.  
         [0003]     The known door strikers are made of two components that are assembled together—a striker plate and a striker bar. The striker plate is typically made of flat sheet metal that is fastened to the automobile&#39;s frame. The striker bar is typically a bent wire rod having ends that are typically orbitally riveted, or sometimes staked, to the striker plate.  
         [0004]     The known two component assembly of the door striker suffers from certain drawbacks. The known door strikers are generally costly to manufacture and complex to assemble because of the two component assembly. For example, orbitally riveting or staking the ends of the striker bar to the striker plate adds significant time, cost and complexity to the assembly of the components. Because the striker bar is made of bent wire rod, the shape and configuration of the striker bar is limited by the use of this wire rod. Still other drawbacks and disadvantages of the known door strikers exist, which are overcome by the present invention.  
       SUMMARY OF THE INVENTION  
       [0005]     In an exemplary embodiment, the present invention includes an improved door striker that is made of a single piece of material that is stamped and drawn to its final configuration. That is, the striker bar is formed integral with the striker plate as a one-piece construction. With the invention, the edges of the posts that form the striker bar are rolled and/or curled to provide structurally integrity to the door striker. Additionally, the rolled edges provide a compatible mating surface for the associated door latching mechanism. Moreover, the bolt holes formed in the door striker plate include retaining features to hold the bolts in place during shipment of the door striker and prior to assembly. The bolts can then be manually pushed or threaded into the mounting holes on the automobile frame.  
         [0006]     Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]      FIG. 1  is an isometric view of an exemplary embodiment of a door striker of the present invention.  
         [0008]      FIG. 2  is a top plan view of an alternative embodiment of the door striker of  FIG. 1 .  
         [0009]      FIG. 3  is an isometric view of the door striker of  FIG. 2 .  
         [0010]      FIG. 4  is a top plan view of another alternative embodiment of the door striker of  FIG. 1 .  
         [0011]      FIG. 5  is an isometric view of the door striker of  FIG. 4 .  
         [0012]      FIG. 6  is a top plan view of a yet another alternative embodiment of the door striker of  FIG. 1 .  
         [0013]      FIG. 7  is an isometric view of the door striker of  FIG. 6 .  
         [0014]      FIG. 8  is a top plan view of still another alternative embodiment of the door striker of  FIG. 1 .  
         [0015]      FIG. 9  is an isometric view of the door striker of  FIG. 8 .  
         [0016]      FIGS. 10   a - 10   j  depict an exemplary method of manufacturing an exemplary door striker of the invention. 
     
    
       [0017]     Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.  
       DETAILED DESCRIPTION OF THE EMBODIMENTS  
       [0018]     The present invention may be embodied in many forms. In one exemplary embodiment depicted in  FIG. 1 , the present invention is directed to a one-piece door striker  10  that may be used in numerous applications, including in automobiles. The door striker  10  is made of a high strength, light-weight steel, though other materials may be used to make the door striker. In an exemplary embodiment, the door striker  10  may be stamped and drawn to form the configuration depicted in  FIG. 1 . The striker  10  may be a unitary, one-piece device that defines a striker plate  12 , two striker posts  14 ,  16  formed integral with the striker plate  12  and extending outwardly from the striker plate  12 , and a striker bar  18  joined between the striker posts  14 ,  16 . The striker plate  12  defines one or more mounting holes  20  that further define features for retaining mounting bolts to the striker plate during shipment of the door striker and prior to assembly, as described below.  
         [0019]     The striker plate  12  may define a generally planar configuration for mounting to a mating surface on a vehicle, for example. Alternatively, the striker plate may define numerous other configurations that permit the mounting of the striker plate to a mounting surface. The striker plate  12  may define one or more mounting holes  20  each of which may include alignment and bolt retention tabs  24 . The tabs  24  extend outwardly from the striker plate  12  and toward the center of each hole  20 . The tabs  24  may be four tabs  24  spaced equidistant around the hole  20  and may further define concave-shaped ends  26  that are configured to mate with the cylindrical shape of the bolt, not shown. The tabs  24  will retain the bolt, not shown, in the hole  20  during shipment of the door striker  10  and prior to assembly. The tabs  24  may be further used to align the striker plate  12  to the mounting surface on the vehicle. In other words, the ends  26  of the tabs  24  may align with the mounting holes on the mounting surface of the vehicle to facilitate the alignment and mounting of the door striker to the mounting surface. As should be appreciated, other shapes and configurations of the tabs  24 , and other means for retaining the bolts in the holes  20 , are possible with the invention. The invention is therefore not limited to the particular configuration and spacing of the tabs  24  illustrated in  FIG. 1 . The mounting holes  20  may also be counter-sunk to allow the bolt, not shown, to be recessed in the mounting hole  20 , as understood in the art.  
         [0020]     Each striker post  14 ,  16  may be drawn and punched to form the depicted configuration. Each post extends outwardly from the striker plate  12  and may be rolled and/or curled to define the cylindrical post configuration depicted in  FIG. 1 . The rolled and/or curled features provide the posts with the structural integrity necessary for a door striker. The posts  14 ,  16  define opposing edges  22  that further define a slot  23  between the edges  22 .  
         [0021]     Formed with and joining the striker posts  14 ,  16  is the striker bar  18 . The striker bar  18  may be rolled and/or curled to define the cylindrical configuration depicted in  FIG. 1 . The striker bar  18  is configured to receive the door latch mechanism of the automobile, not shown, to thereby latch the door to the door striker. The striker bar  18  may define numerous other configurations or profiles, including the illustrated cylindrical configuration, or a square, rectangular or wedge configuration.  
         [0022]     The striker plate  12  further defines reinforcing ribs  28 ,  30  that form with and join the posts  14 ,  16 . The reinforcing ribs  28 ,  30  provide additional structural integrity and support to the posts  14 ,  16  at the base of each post. The ribs  28 ,  30  form a slot  32  between the ribs.  
         [0023]     Referring to  FIGS. 2 and 3 , an alternative embodiment of the door striker is depicted. The door striker  40  may be stamped and drawn to form the depicted configuration and may define striker posts  42 ,  44  that are rolled/curled to define the depicted cylindrical configuration. Joined between and formed integral with the striker posts  42 ,  44  is a cylindrical striker bar  46 . The striker bar  46  defines a diameter that is less than the diameter of the striker posts. The striker posts and striker bar are formed integral with the striker plate  48  and form edges  49  that further define a slot  50  between the edges  49 . Reinforcing ribs  52  defining a slot  54  are also formed with the striker plate  48  and join the striker posts at their base to provide additional structural support to the posts. The striker plate  48  may further define one or more holes  55  that may further define counter-sunk mounting edges  56 . The mounting holes  54  may further include the bolt retention tabs, described above. Other configurations of the striker posts and bar are possible with this embodiment.  
         [0024]     Referring to  FIGS. 4 and 5 , another alternative door striker  60  that may be stamped and drawn to form the depicted configuration includes striker posts  62 ,  64  that are joined with and connected by striker bar  66 . The striker posts and striker bar may be rolled/curled to provide structural integrity to the striker posts and bar. The striker posts are formed integral with the striker plate  68  and define opposing edges  69  that further define a slot  70  between the edges  69 . With this embodiment, the striker post  62  defines a diameter that is greater than the diameters of the striker post  64  and striker bar  66 . As depicted, the striker post  64  and the striker bar  66  have generally similar profiles. Similar to the other embodiments, the door striker  60  may include reinforcing ribs  72  that define a slot  74 , and the striker plate  68  may further define one or more mounting holes  78  that may further include counter-sunk edges  79 . Similar to the other embodiments, the holes  78  may include the bolt retention features described above.  
         [0025]     Referring to  FIGS. 6 and 7 , yet another alternative door striker  80  that may be stamped and drawn to form the depicted configuration includes striker posts  82 ,  84  that are joined with and connected by striker bar  86  that defines a wedge-shaped configuration. Similar to the other embodiments, the striker posts and striker bar may be rolled/curled to provide structural integrity to the striker posts and bar. The striker posts  82 ,  84  are formed integral with the striker plate  88  and the striker post  82  defines a diameter or profile that is greater than the diameter or profile of the striker post  84 , as shown in  FIG. 7 . The striker posts further define opposing edges  87  that further define a slot  89  between the edges  87 . Similar to the other embodiments, the door striker  80  may include reinforcing ribs  90  that define an opening  92 , and a striker plate  94  that may further define one or more mounting holes  96  that may further include counter-sunk edges  97 . Similar to the other embodiments, the holes  96  may include the bolt retention features described above.  
         [0026]     Referring to  FIGS. 8 and 9 , still another alternative door striker  100  that may be stamped and drawn to form the depicted configuration includes striker posts  102 ,  104  that are joined with and connected by striker bar  106 . The striker posts and striker bar may be rolled/curled to provide structural integrity to the striker posts and bar and, in this embodiment, may define a uniform configuration. The striker posts are formed integral with the striker plate  108  and similar to the other embodiments define edges  109  that form a slot  110 . With this embodiment, the striker posts  102 ,  104  and striker bar  106  define cross-sections that are uniform. Again, similar to the other embodiments, the door striker  100  may include reinforcing ribs  112  that define a slot  114 . The striker plate  108  may further define one or more mounting holes  116  that may further include counter-sunk edges  117 . Similar to the other embodiments, the holes  116  may include the bolt retention features described above.  
         [0027]     It should be understood that with each of the above embodiments, the shape and configuration of the striker posts and bars may vary depending on the application. That is, depending on the application and the particular latch mechanism for which the door striker will be used, the shape and configuration of the door striker may vary to ensure a proper engagement of the latch mechanism to the door striker.  
         [0028]     Referring to  FIGS. 10   a - 10   j , an exemplary method of manufacturing the door striker may include stamping and drawing the material that forms the door striker to form the final configuration of the door striker. As depicted by  FIGS. 10   a - 10   f , a material  150 , such as high strength, light-weight steel, may be formed using one or more punches and dies that generate a deep extruded draw. These figures illustrate the progression of the various possible forming stages of the material  150  that eventually result in an exemplary configuration depicted in  FIG. 10   f.    
         [0029]      FIGS. 10   g - 10   h  are known as the “cramming” stages during which punches, dies and cams may be used to taper and neck down the material  150  to a closer-to-final-form striker. As depicted in  FIG. 10   g , a punch  154  may be positioned partially in the material  150 . More specifically, in one embodiment, the punch  154  may be positioned approximately half-way into the material  150 . The punch  154  may be used to maintain smooth sidewalls of the material  150 , to prevent collapsing of the sidewalls of the material  150 , known as “tin-canning” of the material, and to maintain the depth of the formed material  150 . A die  152  may be used to further form the sidewalls of the material  150 . During this step, as the die  152  closes on the material  150 , the punch  154  retracts from the material  150  to permit the die  152  to further form the material  150 . As illustrated by  FIG. 10   h , an additional forming stage may include a punch  158  having a slightly smaller cross-section that may be inserted half-way into the material  150 . A die  156  defining a slightly narrower gap between the walls of the die  156  may close on the material  150 , while the punch  158  withdraws from the material  150 . The die  156  further forms the material  150 .  
         [0030]     As shown in  FIGS. 10   i - 10   j , side punch  160  and side cam  162  may be used to further define the side walls of the material  150  and to further form the material  150  closer to its final configuration. The side punch  160  may be used to form the cutout in the door striker, such as the opening formed between the posts  14 ,  16  and bar  18 , as illustrated in  FIG. 1 . The side cam  162  may be used to break sharp edges or corners left after the side punch  160  cuts out the opening formed in the striker to give the door striker a more appealing appearance. The side cam  162  may also be used to roll/curl the posts and bars, as illustrated by  FIG. 1 , to improve the structural integrity of the posts and bars. It should be understood that during these stages, other possible punches and cams may be used to define the material  150  and form it to its desired configuration.  
         [0031]     As can be appreciated, the various manufacturing stages depicted in  FIGS. 10   a - j  are merely exemplary of the possible stages that could be implemented and used to form the door striker. Additionally, the punches, dies and cams are also exemplary of the numerous types and shapes of punches, dies and cams that could be used with the invention to form the desired configuration of the door striker. Moreover, various punches and cams may be used to form the mounting holes and bolt retaining tabs, described above, that are formed in the striker plate of the door striker.  
         [0032]     Variations and modifications of the foregoing are within the scope of the present invention. It should be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.  
         [0033]     Various features of the invention are set forth in the following claims.