Abstract:
A vehicle body and a door intrusion resistance apparatus for a vehicle with a door that includes a protrusion and a rocker defining a receptacle that receives the protrusion when the door is closed. The door is inhibited from moving above the rocker by the protrusion being received in the receptacle that holds the door against the rocker in a side impact collision.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to safety features for vehicles, and in particular features that mitigate body side intrusions in side impact collisions. 
       BACKGROUND 
       [0002]    A vehicle door may consist of an outer panel facing the exterior of the vehicle and an inner panel facing the cabin of the vehicle. The inner panel includes a lower wall that faces a rocker assembly. In a side impact collision, vehicle doors may collapse inwardly and intrude into the cabin of the vehicle. Excessive door intrusion may adversely affect deployment of a side air bag due to the reduced gap between the door and the occupant. 
         [0003]    Some safety structures may attempt to minimize the door intrusion into the cabin from a side impact collision. Such a structure is disclosed in U.S. Pat. No. 4,462,633. U.S. Pat. No. 4,462,633 discloses a box shaped reinforcing member mounted on a vehicle floor that extends above the side sill or rocker panel. A bracket mounted to the door has a portion engaging the reinforcing member when the door is closed. In a side impact collision, the bracket engages the reinforcing member to inhibit inward movement of the door. The box shaped reinforcing member is visible to an occupant, especially when the door is open. An occupant must step over the rocker panel when entering or exiting the vehicle. A box shaped reinforcing member that is disposed above the rocker panel interferes with the ingress and egress of the occupant. Placing a box shaped reinforcing member above the rocker panel also limits design freedom. The receiver must be of a limited size to reduce interference with the ingress and egress of the occupant. 
         [0004]    The above problems and other problems are addressed by this disclosure as summarized below. 
       SUMMARY 
       [0005]    One aspect of the present disclosure relates to an apparatus for resisting intrusion of a door into a passenger compartment of a vehicle that has a rocker. The apparatus includes a projection extending horizontally from the door and a catcher that is provided on the rocker. The rocker includes a vertically extending wall. When the door is closed, the catcher receives a portion of the projection to hold the door in engagement with the vertically extending wall of the rocker. 
         [0006]    Other aspects of the above apparatus include a reinforcement panel attached to an inner side of an inner panel of the door for supporting the projection. A grommet may be attached to the vertically extending wall of the rocker. The grommet surrounds the catcher and defines a slit extending substantially throughout a length of the catcher. The slit receives the projection when the door is closed. The rocker may include a rocker reinforcement panel attached to the rocker to reinforce the rocker about the catcher. 
         [0007]    The projection of the apparatus may be a loop that includes two legs that are each attached to the reinforcement panel by its respective foot. The door may include an inner panel, and the projection may include a first leg and a second leg extending horizontally and inwardly from the inner panel of the door. The projection also includes a cross-piece connecting a distal end of the first leg to a distal end of the second leg. The reinforcement panel of the apparatus may be attached to the inner panel, wherein the first leg and the second leg are attached to the reinforcement panel at their ends that are opposite their distal ends to support the projection. 
         [0008]    Another aspect of the present disclosure relates to a vehicle body that includes a rocker and a door connected to the vehicle body above the rocker. The door is moveable between an open position and a closed position. The door includes an outer panel and an inner panel attached to the outer panel. The inner panel includes a rocker engaging portion that faces the rocker when the door is in the closed position and a projection attached to the rocker engaging portion. The projection protrudes from the rocker engaging portion. The rocker defines a catcher opening that receives the projection when the door is closed to inhibit the door from moving inboard in a side impact collision. 
         [0009]    The inner panel of the vehicle body may include a door trim portion disposed above the rocker engaging portion. The projection of the vehicle body may be a U-shaped member, a loop, or it may include a first leg extending from the inner panel portion and a second leg also extending from the inner panel portion. The projection may also include a cross-piece perpendicularly attached to the first leg and the second leg. 
         [0010]    The vehicle body may also include a reinforcement panel attached to the inner panel. The vehicle body may further include a reinforcement panel attached to the rocker and disposed on the rocker at an area where the catcher is formed. The vehicle body may also include a floor side inner attached to the vehicle body. The floor side inner and the rocker form a catcher cavity. When the door is closed, a portion of the projection is positioned within the catcher cavity. 
         [0011]    Yet another aspect of the present disclosure relates to a door intrusion resistance apparatus for a vehicle that includes a door including a protrusion and a rocker defining a receptacle that receives the protrusion when the door is closed. In a side impact collision with the door, the door is inhibited from moving above the rocker by the protrusion being received in the receptacle to hold the door against the rocker. 
         [0012]    The protrusion of the door intrusion resistance apparatus may extend horizontally from an inner panel of the door inboard of the vehicle. The protrusion is also positioned below a door trim so that when the door is closed, the protrusion is not visible to an occupant. The rocker of the door intrusion resistance apparatus may also include a wall that extends in a vertical direction. The wall defines the receptacle that receives the protrusion when the door is closed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a perspective view of a vehicle incorporating a door intrusion resistance apparatus of the present disclosure. 
           [0014]      FIG. 2A  is a partial perspective view of a lower inner portion of a front door illustrating a projection. 
           [0015]      FIG. 2B  is a close up view of  FIG. 2A  showing how the projection extends through the inner door. 
           [0016]      FIG. 3A  is a partial perspective view of the opposite side of the lower inner portion of  FIG. 2A  illustrating a reinforcement panel attached to the lower inner portion. 
           [0017]      FIG. 3B  is a close up view of  FIG. 3A  illustrating the legs of the projection with feet that anchor the projection to the door. 
           [0018]      FIG. 4  is a partial side elevation view of the rocker panel illustrating the catcher provided on the rocker. 
           [0019]      FIG. 5  is a cross-sectional view of the rocker panel taken along the lines  5 - 5  in  FIG. 4 . 
           [0020]      FIG. 6  is a partial perspective view of the rocker panel illustrating the catcher provided on the rocker and the grommet covering the catcher. 
           [0021]      FIG. 7  is a partial perspective view of the rocker panel of  FIG. 6  with the projection engaging the catcher. 
           [0022]      FIG. 8  is a cross-sectional view taken along the line  8 - 8  in  FIG. 1  showing the door intrusion resistance apparatus. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts. 
         [0024]    Referring to  FIG. 1 , a vehicle  22  incorporating the door intrusion resistance apparatus includes a front door  24  attached to a vehicle body adjacent to the A-pillar  26 . The vehicle  22  also includes a rear door  28  attached to the vehicle body near the B-pillar  30 . Door  24  includes an upper outer portion  32  and a lower outer portion  34 . The door intrusion resistance apparatus may be incorporated with any of the doors of the vehicle  22 . 
         [0025]    Referring to  FIG. 2A , door  24  includes an upper inner portion  36  and an upper outer portion  32 . In between the upper inner portion  36  and the upper outer portion  32  is a cavity  38  where vehicle accessories may be mounted, such as those for opening and closing the doors and windows, for defrosting the windows, and audio speakers. The accessories may be covered by a door trim or an interior trim panel that may be another inboard side panel mounted to the upper inner portion. Door  24  also includes a lower inner portion  42  disposed below the upper inner portion  36 . The upper inner portion  36  may have an overhang or an offset surface from the lower inner portion  42  to encapsulate the accessories within the cavity formed by the upper inner portion  36  and the upper outer portion  32 . A door seal  40  is attached between the upper inner portion and the lower inner portion. When the door  24  is in a closed position, the lower inner  42  is not visible to an occupant of the vehicle. 
         [0026]    The door intrusion resistance apparatus includes a projection  44  connected to the lower inner portion  42  and extends or protrudes substantially horizontally from the lower inner portion  42 . Thus, the term “protrusion” may also sometimes be used to refer to the projection  44 . The projection  44  may be disposed at a slight angle relative to the lower inner portion  42 . The projection  44  is positioned below the door seal  40  and is in a form of a loop or a U-shaped member. Projection  44  includes a pair of parallel legs  46   a  and  46   b  that extend through the lower inner  42 , and a cross-piece  43  is attached to the distal ends of the legs  46   a  and  46   b  ( FIG. 2B ). 
         [0027]    Legs  46   a  and  46   b  extend through holes that are formed on the lower inner portion  42  and on a reinforcement panel  50  attached to the lower inner  42  ( FIG. 3A ). The reinforcement panel  50  may be made of steel and adds supporting structure that provides rigidity to the lower inner portion so that the projection  44  is not easily detached from the lower inner portion. In addition, the reinforcement panel  50  is adapted to resist crumpling of the lower inner portion in a side impact collision. Referring to  FIG. 3B , a first foot  52   a  is preferably connected to leg  46   a,  and a second foot  52   b  is connected to leg  46   b.  The first foot  52   a  and the second foot  52   b  are substantially perpendicularly connected to their respective legs. The first foot  52   a  and the second foot  52   b  abut the door reinforcement panel  50  to attach and secure the projection  44  to the lower door panel. The feet may also be flattened at their ends to enhance the attachment of the projection  44  to the lower door panel. The projection  44  is attached to the lower inner portion  42  and is not visible to an occupant of the vehicle when the door  24  is closed. This location of the projection  44  provides flexibility in designing and determining the size of the projection  44  because it does not negatively impact the appearance of the door. 
         [0028]    The term “rocker assembly” may be interchanged with the term “rocker” to refer to a portion of the body paneling of a vehicle that is situated below the doorsills of the vehicle. Referring to  FIGS. 4-5 , a rocker assembly  56  includes an outer wall  57 . The outer wall  57  includes a top wall  45 , a bottom wall  47  that is positioned below the top wall  45 , and a vertically extending wall  49  connected to the top wall  45  and the bottom wall  47 . The top wall  45  may provide a door threshold for the vehicle and may be substantially horizontal. In certain embodiments, it is parallel with a vehicle floor. The bottom wall  47  serves as the base of the vehicle body and is a part of the periphery of the vehicle body. The vertically extending wall  49  contacts the lower inner portion  42  of the door  24  when the door is in a closed position. 
         [0029]    The rocker assembly  56  also includes an inner wall  59  opposite the outer wall  57 . The rocker assembly  56  includes a door reinforcement panel  61  attached to the inner wall  59 . The door reinforcement panel  61  may be made of steel. The door intrusion resistance apparatus of the present disclosure includes a catcher  54  that is formed as an opening on the rocker assembly  56  and a reinforcement panel  61  attached to the inner wall  59  of the rocker assembly  56 . More specifically, the catcher  54  is formed on the vertically extending wall  49  of the rocker assembly  56 . The catcher  54  is shaped to receive the projection  44 . For instance, the catcher  54  may be elliptical in shape and may have a semi-major axis diameter that is larger than the width of the cross-piece  43  of the projection  44 . The catcher  54  may also be a rectangular opening that has a length that is larger than the width of the cross-piece  43  of the projection  44 . Referring to  FIG. 6 , a grommet  58 , such as those made of rubber material, may be positioned around the opening of the catcher  54  to seal the catcher and minimize water intrusion to the catcher  54 . The grommet  58  includes a slit  60  extending substantially throughout the length of the catcher  54  to receive the projection  44 . The slit  60  may be single-lined slit across the middle of the catcher that diverges into a V-shaped slit at both ends. In  FIG. 7 , when the door is closed, a portion of the projection  44  is inserted through the slit  60  of the grommet  58 , the catcher  54 , and the reinforcement panel  61  that is attached to the inner wall  59  of the rocker assembly  56 . 
         [0030]    Referring to  FIG. 8 , looking from the rocker assembly, a portion of the projection  44  is preferably received in a cavity  63  that is formed by the rocker assembly  56  and a floor side inner portion  64  of a vehicle. The rocker assembly  56  includes an inner wall  59  where the reinforcement panel  61  is attached. The reinforcement panel  61  may be attached to an area of the inner wall  59  that defines the catcher  54 . Looking from the lower inner portion  66 , the projection  44  of the door intrusion resistance apparatus of the present disclosure is attached to an inner panel of the door, and more specifically the lower inner portion  66  that is below the upper inner portion  68 . Thus, the lower inner portion  66  serves as a rocker engaging portion that faces the rocker. When the door is in a closed position, the upper inner portion  68  is disposed on top of the rocker assembly  56 , more specifically the top wall  45  of the rocker assembly. The upper inner portion  68  may contact a primary door seal  78  that is attached at the boundary of the rocker assembly  56  and the floor side inner portion  64 . The lower inner portion  66  is enforced by an inner reinforcement panel  70  attached to an area of the lower inner portion where the projection  44  is attached. As further shown in  FIG. 5 , the projection  44  is attached to the inner panel portion, which is opposite to the outer panel portion  72 . The lower inner portion  66  where the projection  44  is attached is above a rocker molding  74 , and a secondary door seal  76  may be provided at the boundary of the lower inner portion  66  and the rocker molding  74 . A portion of the projection is received in the catcher and is positioned within the catcher cavity defined by the rocker assembly and the floor inner portion when the door is closed. Movement of the door towards the cabin of the vehicle (door intrusion) is inhibited or at least minimized in a side impact collision because the projection and the catcher hold the door in engagement with the rocker assembly. 
         [0031]    A door intrusion resistance apparatus is provided that is discreetly positioned on a door of a vehicle that does not adversely impact the appearance of the door. The door intrusion resistance apparatus does not adversely impact ingress and the egress of vehicle occupants. The door intrusion resistance apparatus utilizes a catcher defined by an opening in the rocker assembly for receiving the projection. No hooks, boxes, or structures protrude from the rocker assembly that can impact the ingress and egress of the vehicle users. 
         [0032]    While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosed apparatus and method. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure as claimed. The features of various implementing embodiments may be combined to form further embodiments of the disclosed concepts.