Patent Publication Number: US-2019176583-A1

Title: Door for vehicle

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims priority to Korean Patent Application No. 10-2017-0168641 filed on Dec. 8, 2017, the entire contents of which is incorporated herein for all purposes by this reference. 
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to a door of a vehicle. More particularly, the present invention relates to a door of a vehicle capable of reducing weight and cost and improving assembling workability. 
     Description of Related Art 
     Generally, a vehicle door is provided with a door window to improve the ventilation of the internal to the vehicle, the visibility and the habitability of the passenger, and is usually made of a steel material in consideration of collision stability and the like. 
     That is, the door external panel and the door internal panel of the steel material are coupled to each other form a door skeleton, and a door frame is coupled to the upper portion of the panels to form a door window. A door module provided with a regulator for raising and lowering the door window glass is built in the internal space formed by the combination of the door external panel and the door internal panel. 
     Furthermore, the door internal panel is combined with a door trim as an internal material provided with a door switch or window switch, and an impact beam is disposed close to the door external panel to increase the side impact rigidity of the door. 
     However, in the conventional door structure as described above, since the door internal panel and the door frame are usually made of steel, the weight of the door is increased. Since the door internal panel and the door module are separately manufactured so that the number of parts of the door is increased, it is necessary to develop a more innovative vehicle door by reducing the number of parts of the door and reducing the weight of the material. 
     The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and may not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art. 
     BRIEF SUMMARY 
     Various aspects of the present invention are directed to providing a door of a vehicle configured for reducing the number of parts of the door by modularizing a large number of parts forming the door, reducing the weight by making a portion of the door module including a relatively lightweight material instead of a steel material, and reducing assembly man hour and cost. 
     A door of a vehicle according to an exemplary embodiment of the present invention may include a first door module forming a door skeleton, a second door module coupled with the first door module and forming a door window. An impact pad may be provided at the second door module. 
     A door trim may be coupled with the second door module. 
     The first door module may include a door external panel disposed outside a passenger compartment, a door internal panel disposed inside the passenger compartment with respect to the door external panel, a door frame coupled to the top portion of the door internal panel, and an impact beam coupled to the door internal panel. 
     An opening portion may be provided at a center portion of the door internal panel. 
     A reinforcing beam may be coupled to the door internal panel in a form that traverses a portion of the opening portion of the door internal panel. 
     The door frame may include a belt line portion disposed in a belt line portion of the door and two pillar portions extending at both end portions of the belt line portion in the height direction of the vehicle to form an H-shape. 
     The second door module may include a module body of the panel shape, and a door window portion forming the door window and being integrally formed with the module body. 
     The door window portion may include a roof portion corresponding to the roof profile of a vehicle body and a center pillar portion corresponding to a center pillar of the vehicle body when the door is closed to the vehicle body. 
     When the second door module is coupled with the first door module, an internal space is formed therebetween, and a door glass for opening or closing the door window may be inserted into the internal space to be vertically movable. 
     At least one door checker mounting boss for mounting a door checker may be formed to be integrally protruded toward the outside of a passenger compartment at the external surface of the second door module facing the outside of the passenger compartment. 
     At least one assemble protrusion inserted and assembled into an assemble hole formed in the door internal panel, may be integrally protruded toward the outside of the passenger compartment near a belt line of the external surface. 
     An assemble boss for engaging with the door internal panel may be formed to be integrally protruded toward the outside of the passenger compartment at a lower portion of the external surface. 
     A rigid protruding portion may be formed at a lower portion of the door internal panel. The rigid protruding portion may be engaged with the assemble boss for assembling the door internal panel with the second door module. An extending section may be formed between the rigid protrude portion and the door external panel. 
     At least one reinforcing rib may be provided near the roof portion, the center pillar portion and a belt line of the second door module. 
     The reinforcing rib may include a first reinforcing rib extending in the longitudinal direction of a vehicle and a second reinforcing rib extending in the height direction of a vehicle. The first and second reinforcing ribs may be disposed to form lattice pattern together. 
     The external surface of the center pillar portion may be joined with a garnish. A receiving groove may be formed between the garnish and the center pillar portion. A door glass run may be inserted into the receiving groove. 
     The impact pad may be formed in one or more quadrangular block shapes or conical shapes protruding toward the internal to a passenger compartment on the internal surface of the module body facing the internal to the passenger compartment. 
     At least one notch may be formed in the peripheral edge portion of the impact pad. 
     At least one rib may be integrally formed inside the impact pad of the quadrangular block shape. 
     The door for a vehicle according to an exemplary embodiment of the present invention may include the first door module made of metal material, the second door module made of lightweight material compared to steel, and a door trim, reducing the number of parts and weight and cost of the door of a vehicle. 
     Furthermore, since only three door modules need to be assembled to each other, it is possible to reduce assemble man hour, improve assemble workability, and improve the appearance of the door of a vehicle with the simple design of the modules. 
     The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial perspective view of a door of a vehicle according to an exemplary embodiment of the present invention. 
         FIG. 2  is an exploded perspective view of a door of a vehicle according to an exemplary embodiment of the present invention. 
         FIG. 3  is a cross-sectional view taken along line A-A of  FIG. 1 . 
         FIG. 4  is a perspective view of the second door module according to an exemplary embodiment of the present invention. 
         FIG. 5  is a partial enlarged cross-sectional view of  FIG. 3 . 
         FIG. 6  is an internal perspective view of a door of a vehicle according to an exemplary embodiment of the present invention. 
         FIG. 7  is a cross-sectional view taken along line B-B of  FIG. 6 . 
         FIG. 8  is a perspective view of reinforcing ribs formed at the second door module according to an exemplary embodiment of the present invention. 
         FIG. 9  is a perspective view of an impact pad of a door of a vehicle according to an exemplary embodiment of the present invention. 
         FIG. 10  is a cross-sectional view taken along line C-C of  FIG. 9 . 
         FIG. 11  is a perspective view of an impact pad of a door of a vehicle according to another exemplary embodiment of the present invention. 
         FIG. 12  is a cross-sectional view taken along line D-D of  FIG. 11 . 
         FIG. 13  is a perspective view of an impact pad of a door of a vehicle according to yet another exemplary embodiment of the present invention. 
         FIG. 14  is a cross-sectional view taken along line E-E of  FIG. 13 . 
     
    
    
     It may be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particularly intended application and use environment. 
     In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that the present description is not intended to limit the invention(s) to those exemplary embodiments. On the other hand, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims. 
     Exemplary embodiments of the present application will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the present invention are shown. 
     The drawings and description are to be regarded as illustrative in nature and not restrictive. Like reference numerals designate like elements throughout the specification. 
     Since size and thickness of each component illustrated in the drawings are arbitrarily represented for convenience in explanation, the present invention is not limited to the illustrated size and thickness of each component and the thickness is enlarged and illustrated to clearly express various parts and areas. 
     In the following description, dividing names of components into first, second and the like is to divide the names because the names of the components are the same as each other and an order thereof is not particularly limited. 
     Throughout the specification, unless explicitly described to the contrary, the word “comprise” and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of stated elements but not the exclusion of any other elements. 
     As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. 
     Referring to  FIG. 1  and  FIG. 2 , a door of a vehicle according to an exemplary embodiment of the present invention may include a first door module having a door external panel  1 , a door internal panel  2 , a door frame  3  and an impact beam  4 , a second door module  5 , and a door trim  6  as a third door module. 
     The door external panel  1  may be disposed outside a passenger compartment and formed into a perfect panel shape in consideration of door rigidity. The door internal panel  2  may be disposed inside the passenger compartment with respect to the door external panel  1  and have an opening portion  21  at a center portion thereof to reduce weight and cost. 
     The door external panel  1  and the door internal panel  2  may be formed of metal material as steel. 
     A reinforcing beam  22  may be coupled to the door internal panel  2  in a form that transvers a portion of the opening portion  21 . 
     When the door internal panel  2  is combined with the door external panel  1 , the reinforcing beam  22  may be disposed close to the door external panel  1  to support the door external panel  1 . 
     The door frame  3  may be coupled to an upper portion of the door internal panel  2 . 
     The door frame  3  may include a belt line portion  31  and two pillar portions  32  and  33  extending at both end portions of the belt line portion  31  in the height direction of the vehicle to form an H-shape. 
     That is, the conventional door frame has a roof portion corresponding to the roof profile of the vehicle body and a center pillar portion corresponding to the center pillar profile of the vehicle body when the door is closed, while the door frame  3  according to an exemplary embodiment of the present invention removes the conventional roof portion and the center pillar portion. 
     Therefore, the door frame  3  according to an exemplary embodiment of the present invention may reduce weight and cost as compared to the conventional door frame. 
     The impact beam  4  may be coupled to the door internal panel  2  and disposed close to the door external panel  1 , absorbing the impact at the side collision and blocking the intrusion of the door into the passenger compartment. 
     The impact beam  4  and the door frame  3  are coupled to the door internal panel  2  and the door internal panel  2  is coupled to the door external panel  1  so that the first door module as a door skeleton may be formed. 
     The second door module  5  may include a relatively lightweight material, for example, a plastic material, as compared to the first door module. 
     Referring to  FIG. 2  and  FIG. 4 , the second door module  5  may include a module body  51  of the panel shape, and a door window portion  53  forming a door window  52  and being integrally formed with the module body  51 . 
     The door window portion  53  may include a roof portion  531  corresponding to the roof profile of the vehicle body and a center pillar portion  532  corresponding to a center pillar profile of the vehicle body when the door is closed to a vehicle body. 
     When the second door module  5  is coupled with the first door module, an internal space is formed therebetween. A door glass  7  for opening or closing the door window  52  may be inserted into the internal space to be vertically movable via a lifting device such as regulator. 
     Referring to  FIG. 4 , at least one door checker mounting boss  55  for mounting a door checker  8  may be formed to be integrally protruded at the external surface  54  of the second door module  5  facing the outside of the passenger compartment. 
     Furthermore, at least one assemble protrusion  57 , which is inserted into an assemble hole formed at the door internal panel  2  and assembled thereto, may be formed to be integrally protruded in the vicinity of the belt line portion at the external surface  54 , and an assemble boss  58  for assembling with the door internal panel  2  through fastener F may be formed to be integrally protruded toward the outside at a lower portion of the external surface  54 , as shown in  FIG. 5 . 
     Referring to  FIG. 5 , a rigid protruding portion  23  may be formed in a lower portion of the door internal panel  2 . The rigid protruding portion  23  may be engaged with the assemble boss  58  of the second door module  5  via the fastener F. 
     When the door internal panel  2  is coupled to the door external panel  1 , the rigid protruding portion  23  is spaced from the door external panel  1  so that an expanded section S may be formed between the rigid protruding portion  23  and the door external panel  1  to increase rigidity. The rigid protruding portion  23  is configured to increase the coupling rigidity between the door internal panel  2  and the second door module  5 . 
     Referring to  FIG. 4  and  FIG. 6 ,  FIG. 7 , and  FIG. 8 , at least one reinforcing rib  9  may be provided near the roof portion  531 , the center pillar portion  532  and the belt line of the second door module  5 . 
     The reinforcing rib  9  may be formed by a first reinforcing rib  91  extending in the longitudinal direction for a vehicle and a second reinforcing rib  92  extending in the height direction for a vehicle, which are disposed to form lattice pattern. 
     The reinforcing rib  9  is configured to reinforce the rigidity of the second door module  5 . 
     A garnish  65  may be coupled to an external surface of the center pillar portion  532  to improve the external appearance of the door. 
     A receiving groove may be formed between the garnish  65  and the center pillar portion  532 . A door glass run  15 , which is configured to guide and support the door glass  7 , may be inserted into the receiving groove. 
     Furthermore, a door weather strip  25  may be attached to the second door module  5  and a vehicle body weather strip  35  may be attached to a vehicle body, so that the air-tightness may be maintained when the door is closed. 
     Referring to  FIG. 9  and  FIG. 10 , an impact pad  10  may be integrally provided on the internal surface of the second door module  5  facing the internal to the passenger compartment. 
     The impact pad  10  may act to relieve the impact of the passenger by contiguous to the body portion of the passenger when the door is pushed into the internal of the vehicle during a side impact of the vehicle. 
     The impact pad  10  may be formed of a quadrangular block shape and including a plurality of blocks adjacent to each other. 
     The impact pad  10  may have a structure protruding in two steps toward the internal to the passenger compartment. 
     At least one notch  101  may be formed in the peripheral edge portion of the impact pad  10  so that the impact pad  10  may be easily broken from the second door module  5  when it receives an impact from the door trim  6  during a side impact of the vehicle. 
     Referring to  FIG. 11  and  FIG. 12 , an impact pad  110  according to another exemplary embodiment of the present invention may be integrally provided in the second door module  5  in the shape of only one quadrangular block. 
     Furthermore, at least one rib  112  may be integrally formed at a predetermined interval inside the impact pad  110 . At least one notch  111  may be formed at a peripheral edge portion of the impact pad  110 . 
     Referring to  FIG. 13  and  FIG. 14 , an impact pad  120  according to yet another exemplary embodiment of the present invention may be integrally provided in the second door module  5  in a cone shape similar to the exemplary embodiment of the present invention. 
     Furthermore, at least one notch  121  may also be formed in the peripheral edge portion of the impact pad  120 . 
     For convenience in explanation and accurate definition in the appended claims, the terms “upper”, “lower”, “inner”, “outer”, “up”, “down”, “upper”, “lower”, “upwards”, “downwards”, “front”, “rear”, “back”, “inside”, “outside”, “inwardly”, “outwardly”, “internal”, “external”, “inner”, “outer”, “forwards”, and “backwards” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures. 
     The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described to explain certain principles of the invention and their practical application, to enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.