Patent Publication Number: US-2021188061-A1

Title: Convertible skeleton door

Description:
REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 15/882,882 filed Jan. 29, 2018. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to a door for a motor vehicle that includes features for converting from a conventional door to a skeleton door that provides an open air experience. 
     BACKGROUND 
     A conventional vehicle door includes a full outer skin along with window and latch hardware to completely close off a vehicle cabin from the environment. Some vehicles include tubular doors without an outer skin or other hardware to provide an open air experience. The tubular doors allow occupants to experience the outside environment from within the cabin and may provide better visibility for off road operation. The tubular doors provide a reduced structure to provide some protection while still providing the desired open air experience. The tubular open air doors are provided as separate optional doors that require removal and storage of the conventional door. When not in use the tubular open air doors are not typically stored within the vehicle. Storage separate from the vehicle can result in loss or damage. 
     SUMMARY 
     A vehicle door assembly according to an exemplary aspect of the present disclosure includes, among other things, a door housing configured for covering a vehicle access opening. A frame member is disposed within the door housing. A module includes an intrusion beam coupled to the frame member and removable from the door housing. The module is configured to accept attachment of a module hinge and a module latch to provide a secondary door assembly. 
     In a further non-limiting embodiment of the foregoing vehicle door assembly, the module includes a first bracket on one end of the intrusion beam and a second bracket on a second end of the intrusion beam. 
     In a further non-limiting embodiment of any of the foregoing vehicle door assemblies, the intrusion beam includes all the intrusion beams within the door housing. 
     In a further non-limiting embodiment of any of the foregoing vehicle door assemblies, the intrusion beams include tubular structures. 
     In a further non-limiting embodiment of any of the foregoing vehicle door assemblies, the frame member includes a channel and the first bracket and the module includes a tab that slides within the channel to secure the module within the door housing. 
     In a further non-limiting embodiment of any of the foregoing vehicle door assemblies, a door glass assembly is supported within the door housing and the module is spaced apart from the door glass assembly and slidable along the frame member during removal from the door housing. 
     In a further non-limiting embodiment of any of the foregoing vehicle door assemblies, the second bracket is securable to the door housing with removable fasteners. 
     In a further non-limiting embodiment of any of the foregoing vehicle door assemblies, the door housing is removable from the vehicle and the module including a module hinge assembly and a module latch assembly are attachable to the vehicle within the access opening. 
     A modular vehicle door assembly according to an exemplary aspect of the present disclosure includes, among other things, a door housing. A frame member is disposed within the door housing. A module is supported on the frame member and removable from the door housing. A module hinge assembly is attachable to the module once the module is removed from the door housing. A module latch assembly is attachable to the module once removed from the door housing. 
     In a further non-limiting embodiment of the foregoing modular vehicle door assembly, the module includes intrusion beams extending between a first bracket and a second bracket. At least one of the first bracket and the second bracket are securable to the frame member within the door housing. 
     In a further non-limiting embodiment of any of the foregoing modular vehicle door assemblies, the intrusion beams include tubular structures. 
     In a further non-limiting embodiment of any of the foregoing modular vehicle door assemblies, at least one of the frame member and the first and second brackets include a channel and the other of the frame member and the at least one of the first and second brackets include a tab that slides within the channel to secure the module within the door housing. 
     In a further non-limiting embodiment of any of the foregoing modular vehicle door assemblies, a door glass assembly is supported within the door housing and the module is received on the frame member and is spaced apart from the door glass assembly during removal from door housing. 
     A method according to another exemplary aspect of the present disclosure includes, among other things, a module is assembled including the vehicle door intrusion beams such that the module maybe removed from the vehicle door. A module hinge assembly is configured for attachment to the module. A module latch assembly is configured for attachment to the module. The vehicle door is assembled such that it may be removed from a vehicle. The module is configured such that it may be secured by the module hinge assembly to the vehicle in place of the vehicle door. 
     In a further non-limiting embodiment of the foregoing method, the module is configured for removal by securing the module within the vehicle door with removable fasteners. 
     In a further non-limiting embodiment of any of the foregoing methods, the module is assembled to include one of a tab and channel for securement to a frame member within the vehicle door that includes the other of the tab and channel such that the module may slide relative to the frame member for removal from the vehicle door. 
     In a further non-limiting embodiment of any of the foregoing methods, the module is assembled to include a second bracket that receives a portion of the removable fasteners such that the removable fasteners are accessible from an end of the vehicle door and the module is removable by grasping the second bracket and sliding the module out from the vehicle door. 
     In a further non-limiting embodiment of any of the foregoing methods, the module is configured for securing the hinge assembly to a first bracket and the latch assembly to the second bracket. 
     The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic view of a vehicle including an example convertible door. 
         FIG. 2  is a schematic view of the vehicle including with an example skeleton door installed. 
         FIG. 3  is a perspective side view of a vehicle of an example convertible door embodiment. 
         FIG. 4  is another perspective side view the example convertible door embodiment. 
         FIG. 5  is a perspective view of internal structure of the example convertible door embodiment. 
         FIG. 6  is a cross-section of the example vehicle door. 
         FIG. 7  is an internal view of the vehicle door with the module partially removed. 
         FIG. 8  is a schematic view of a method of removing, assembling and installing a skeleton door. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a vehicle  10  includes a door  12  that is disposed within an access opening  14 . The example door  12  includes an internal module  22  that is removable to provide a skeleton door assembly schematically indicated at  30 . The example door  12  includes a housing  16  that is attached to the vehicle  10  by way of hinges  18 . Within the housing  16  is the module  22 . The module  22  is removable from the housing  16  for use as the skeleton door for the vehicle  10 . The module  22  is assembled to a module latch  26  and module hinges  24  that are stored separately from the module  22  and the door housing  16 . The module latch  26  and hinges  24  are of a size that they may be easily and conveniently stored within the vehicle  10 . 
     Referring to  FIG. 2  with continued reference to  FIG. 1 , the example skeleton door assembly  30  is shown assembled to the vehicle  10 . When the skeleton door assembly  30  is assembled to the vehicle  10  there is an open feeling to the vehicle cabin while still providing some protection. Moreover, the door  12  is removed from the vehicle  10  and stored to prevent damage. The reduced obstruction provided by the skeleton door assembly  30  improves visibility and the ability to experience an open air driving experience. 
     Referring to  FIGS. 3 and 4 , the example door  12  includes the hinges  18  and the door housing  16 . The module  22  includes a second bracket  34  that is attached to a side  44  of the door housing  16 . The second bracket  34  is attached by way of fasteners  32  to the door housing  16  and is an integral portion of the door  12  as it is being utilized for normal operation and attached to the vehicle  10 . The door housing  16  includes a window  38  and accompanying structures that enable opening and closing of the window. Moreover, the door housing  16  houses a latch  28  provided to secure the door  16  to the vehicle  10  in a closed position. 
     Referring to  FIG. 5  with continued reference to  FIGS. 3 and 4 , an interior of the door  12  is shown and includes intrusion beams  20  that extend horizontally the width of the door housing  16 . The intrusion beams  20  are a part of the module  22  and provide the structure for collision protection of the door  12 . The intrusion beams  22  extend between a first bracket  36  and the second bracket  34 . The intrusion beams  20  are removable with the module  22  for use as part of the skeleton door assembly  30 . Incorporation of the intrusion beams  20  with the module  22  reduces the number of component parts and weight of the door structure. 
     The module  22  is supported within the door housing  16  at least partially by a frame member  42 . The disclosed frame member  42  is disposed at a top part of the door housing  16 . The example frame member  42  is part of an outer reinforcement structure of the door housing  16 . The example frame member  42  is formed as an extrusion to provide a uniform cross-section along its length. In this example the frame member  42  is provided in 2 separate parts that are spaced apart from each other across the door width. 
     Referring to  FIG. 6  with continued reference to  FIG. 5 , the module  22  is slidable out of the door housing  16  such that it will not interfere and hit or slide against the window  38  or other hardware such as a window regulator that is partially shown schematically at  40  disposed within the door housing  16 . To remove the module  22 , the fasteners  32  are removed from the second bracket  34  disposed on the side  44  of the door housing  16 . The module  22  is then free to be removed from the interior portion of the door housing  16 . 
     Referring to  FIG. 7  with continued reference to  FIG. 6 , sliding removal of the module  22  occurs by grasping the second bracket  34  and pulling it away from the side  44  of the door housing  16 . The first bracket  36  is engaged to the frame member  42 . The example frame member  42  includes two separate parts separated across the width of the door housing  16 . 
     The example frame members  42  each include a channel  46 . The channel  46  is configured to receive a tab  48  that extends from the first bracket  36  along the intrusion beam  20  to the second bracket  34 . The tab  48  is received within the channel  46  and maintains an orientation of the module  22  including the intrusion beams  20  as it is removed from the door housing  16 . 
     Reinstallation of the door module  22  is conducted by inserting the tab  48  into the channel  46  of the frame member  42  and then sliding the module  22  back into the door housing  16 . Moreover, although the channel  46  and tab  48  may be reversed such that the tab  48  is on the frame members  42  and the channel is provided on the top intrusion beam  20  of the module  22 . Additionally, other structures of the module  22  could include a feature matting to the features of door housing  16 . Furthermore, although a channel and tab are illustrated, other mating structures and shapes that provide relative alignment between relative sliding parts could also be utilized within the contemplation of this disclosure. 
     Referring to  FIG. 8  with continued reference to  FIGS. 6 and 7 , a method of converting the door  12  for the vehicle  10  to a skeleton door assembly  30  is schematically shown at  50  and includes the initial step  52  of removing the module  22  from the door  12 . Once the module  22  is removed from the door  12 , assembly steps are undertaken to install a hinge  24  and latch  26 . The hinges  24  and latches  26  can be stored within the vehicle  10  and are separately assembled to the module  22  once it is removed from the door. Attachment of the latch  26  is schematically indicated at  54  and is provided by use of threaded fasteners or other mechanical connection techniques that are known. Moreover, assembly of the hinges  24  as indicated at  56  is also provided by way of threaded fasteners or other mechanical linkage configurations and systems as are known. 
     The door  12  is removed from the vehicle  10  as is indicated at  58  and stored in a safe location to prevent damage. It should be appreciated that the door  12  may be removed at any time once the module  22  is removed from the door housing  16 . Moreover, it is also possible to remove the module  22  from the door  12  once the door  12  is removed from the vehicle. 
     With the door  12  removed, the vehicle  10  includes an axis opening  14  into which the skeleton door assembly  30  is assembled as is schematically shown at  60 . Assembly of the skeleton door assembly  30  includes attachment of the hinges  56  to the vehicle  10  and alignment of the latch  26  with the corresponding features on the vehicle  10 . 
     Accordingly, once the skeleton door assembly  30  is assembled to the vehicle, the vehicle will include the door bars  22  extending across the access opening  14  to provide some protection. Moreover, the open skeleton door assembly  30  provides an open environment preferred by some operators during off-road or other desired driving conditions. The structure of the skeleton door  30  can be of any shape or size that provides the desired protection as well as a desired aesthetic appearance. 
     Accordingly, the example convertible door  12  includes features that are removable and usable as a skeleton door without requiring an entirely different structure. Moreover, the module  22  is removed from the door  12  and assembled to hinges  56  and latches  26  that may be carried with the vehicle. Carrying all structures for assembly of the skeleton door assembly  30  within the vehicle enables conversion from the normal door  12  at any time and also reduces the need to store separate doors. 
     Although the different non-limiting embodiments are illustrated as having specific components or steps, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments. 
     It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure. 
     The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.