Patent Document

BACKGROUND 
     The disclosed subject matter relates to vehicle door assemblies, and methods of use and manufacture thereof. In particular, the disclosed subject matter relates to vehicle door structures that are at least visibly accessible from the vehicle interior, and that include base and exterior surfaces. 
     Many types of vehicles include doors and/or other structures that enable passenger ingress and/or egress. These vehicle doors are typically configured to be actuable (such as via pivoting or rotational movement) between an open position facilitating passenger ingress/egress, and a closed position impeding passenger ingress/egress. These types of vehicle doors in the closed position thereby operate as a barrier between the vehicle exterior and interior passenger compartment. 
     SUMMARY 
     Based on their operation as a barrier, these types of vehicle doors inherently include interior and exterior surfaces. The interior and exterior surfaces perform different functions and are subject to different operational challenges. For example, the exterior surfaces are typically required to be relatively resilient to conditions exterior of the vehicle, which may be intensified when the vehicle is traveling. The interior surfaces need to be resilient to conditions within the vehicle, which are typically less extreme than the exterior conditions. 
     However, the interior surfaces may be subject to other challenges. For example, the interior surfaces may provide various functions, such as providing a support for passenger actuable controls, i.e., raising/lowering a door window, locking/unlocking the door, etc. In addition, the interior surfaces may provide a surface configured for direct contact with a vehicle passenger, such as the case where the surface defines an arm rest. 
     In addition or as an alternative to the above, it may also be beneficial for the interior surfaces to be configured for aesthetics. Aesthetic considerations may be especially significant because these surfaces are proximate to the vehicle passengers and thus subject to relatively significant and close scrutiny. 
     It may therefore be beneficial to configure the vehicle door interior surfaces to enhance aesthetics while at the same time facilitating the functionality discussed above. For example, the orientation(s) of the surfaces can be tailored to interact or complement other surfaces, visually and/or operationally, to enhance aesthetics. In some of these cases, the vehicle door interior surfaces can be configured so as to take into account their visual appearance relative to the associated door belt line, which extends along a bottom surface of the vehicle door window in a longitudinal direction of the vehicle. As one example, it may be beneficial to provide an outboard base defining a relatively planar upper surface that is oriented at an angle relative to the vehicle transverse direction so as to face upwardly toward the vehicle exterior. It may also be beneficial to provide an inboard base defining a relatively planar upper surface that is also oriented at an angle relative to the vehicle transverse direction extending downward toward the vehicle interior. The outboard and inboard bases may be disposed so as to meet and form a common surface or line that extends in the vehicle longitudinal direction and that defines an uppermost surface of the outboard and inboard bases. 
     It may also be beneficial to provide a common exterior layer or topcoat to cover both the outboard and inboard bases. This common exterior layer/topcoat may provide a uniform and smooth appearance for both planar surfaces, thereby enhancing aesthetics. 
     Some embodiments are therefore directed to a door lining assembly for use with a vehicle that defines a vehicle exterior and a vehicle passenger compartment. The door lining assembly can include a base assembly including an outboard base that defines a substantially planar upper surface that extends obliquely relative to a transverse direction of the vehicle so as to face upwardly toward the vehicle exterior. The base assembly can also include an inboard base that defines a substantially planar upper surface that extends obliquely relative to the upper surface of the outboard base downward toward the vehicle passenger compartment. The outboard and inboard bases can be joined together to form a peak that is the vertically highest portion of the base assembly. A unitary topcoat can cover the upper surfaces of the outboard and inboard bases. 
     Some other embodiments are directed to a door assembly for use with a vehicle that defines a vehicle exterior and a vehicle passenger compartment. The door assembly can include a vehicle door, and a door lining assembly. The door lining assembly can include a base assembly including an outboard base that defines a substantially planar upper surface that extends obliquely relative to a transverse direction of the vehicle so as to face upwardly toward the vehicle exterior. The base assembly can also include an inboard base that defines a substantially planar upper surface that extends obliquely relative to the upper surface of the outboard base downward toward the vehicle passenger compartment. The outboard and inboard bases can be joined together to form a peak that is the vertically highest portion of the base assembly. A unitary topcoat can cover the upper surfaces of the outboard and inboard bases. The door assembly can also include an attachment fixture configured to attach the door lining assembly to the door. 
     Still other embodiments are directed to method of manufacturing a door lining assembly for use with a vehicle that defines a vehicle exterior and a vehicle passenger compartment. The method can include: configuring a base assembly to include an outboard base that defines a substantially planar upper surface that extends obliquely relative to a transverse direction of the vehicle so as to face upwardly toward the vehicle exterior; configuring the base assembly to also include an inboard base that defines a substantially planar upper surface that extends obliquely relative to the upper surface of the outboard base downward toward the vehicle passenger compartment; joining the outboard and inboard bases together to form a peak that is the vertically highest portion of the base assembly; and extending a unitary topcoat over the upper surfaces of the outboard and inboard bases. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosed subject matter of the present application will now be described in more detail with reference to exemplary embodiments of the apparatus and method, given by way of example, and with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of an interior side of an exemplary vehicle door in accordance with the disclosed subject matter. 
         FIG. 2  is a partial perspective view of an exterior side of the exemplary vehicle door in accordance with the disclosed subject matter. 
         FIG. 3  is a partial perspective view of the interior side of the exemplary vehicle door in accordance with the disclosed subject matter. 
         FIG. 4  is a cross-sectional perspective view of a part of the exemplary vehicle door in accordance with the disclosed subject matter. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     A few inventive aspects of the disclosed embodiments are explained in detail below with reference to the various figures. Exemplary embodiments are described to illustrate the disclosed subject matter, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations of the various features provided in the description that follows. 
     Certain embodiments of a door lining assembly  20  are disclosed below, and  FIGS. 1-4  illustrate some of these embodiments. However, embodiments are intended to include or otherwise cover many different embodiments and structures for lining a vehicle door. 
     The embodiments are disclosed below and in the context of a front door assembly of an automobile. However, the embodiments are intended to be applicable to any automobile door assembly, any type of automobile, and any type of vehicle, and to further be applicable to non-vehicular doors. 
     Embodiments are also disclosed below in the context of a door lining assembly. However, embodiments are intended to include or otherwise cover any type of lining assembly, including lining assemblies for automobile panels configured without a door, such as panels adjacent window frames of third row seating configurations. 
     I. Vehicle and Door Lining Assembly 
       FIG. 1  is a perspective view of an interior side of an exemplary door  10  of a vehicle in accordance with the disclosed subject matter. The vehicle may be primarily for use on paved roadways, and can be referred to as a passenger vehicle. However, as indicated above, the disclosed door lining assembly  20  can be used with any vehicle that is configured to travel along any one or combination of improved, unimproved, and unmarked roadways and paths constituted by gravel, dirt, sand, etc. For example, embodiments are intended to include or otherwise cover any other type of automobile, including passenger car, truck, ATV, etc. In fact, embodiments are intended to include or otherwise cover configurations of the door lining assembly  20  for use in any other type of vehicle, such as an aircraft, boat, ship, train, spacecraft, etc. Some other embodiments can be used in non-vehicular carrier applications, such as for amusement park rides, gondolas, or any other situation where lining can be applied to a door or window frame. 
     The exemplary door  10  of the vehicle can include a door frame  12  ( FIG. 3 ) surrounding an outer panel (not shown) and an inner panel  13 , and a window opening  14 . The outer panel  11  and the inner panel  13  oppose each other to form a body panel of the door  10 . The window opening  14  is disposed above the body panel formed of the outer and inner panels  13  so as to be proximate a roof of the vehicle. The inner panel  13  of the door  10  may include an armrest having multiple controls disposed therein, including switches for window actuation, door locking, mirror actuation, and any other control to be used by an occupant sitting adjacent the door  10 . The inner panel  13  may also include a multitude of pockets, cupholders, compartments, etc. 
     In the present embodiment, the window opening  14  defines a belt-line  16  of the door  10 , such that the belt-line  16  extends along a lower edge of the window opening  14  from a front portion of the door frame  12  to a rear portion. The window opening  14  can also include a quarter window  18  extending from the front portion of the door frame  12  along a portion of the belt-line  16 , the quarter window  18  extending from the belt-line  16  to an upper edge of the window opening  14 . In some configurations, the quarter window  18  can occupy a relatively small amount of the window opening  14 , while other configurations may feature a relatively large amount of the window opening  14  being occupied by the quarter window  18 . The window opening  14  can also include a quarter window pillar  19  disposed adjacent an edge of the quarter window  18  that extends from the belt-line  16  to the upper edge of the window opening  14 . In some configurations, the window opening  14  may not include the quarter window  18 , or the quarter window pillar  19 . The window opening  14  may additionally include a pillar cover  17  extending along a portion of the window opening  14  adjacent the quarter window  18 . 
     In the present embodiment, the door  10  also includes a door lining assembly  20  that can extend along the belt-line  16  on the inner panel  13 . The door lining assembly  20  may include a topcoat  21  configured to cover base portions of the door lining assembly  20 , which are described below. The topcoat  21  can include an inboard topcoat  22  and an outboard topcoat  24 . The inboard and outboard topcoats  22 ,  24  have approximately planar surfaces extending a length of the door lining assembly  20 . The topcoat  21  can contour closely to the base portions such that the inboard topcoat  22  and the outboard topcoat  24  are formed on either side of a topcoat peak  26 . The inboard topcoat  22  is thereby configured to slant and face inward, towards an interior of the vehicle. On the other hand, the outboard topcoat  24  is configured to slant and face outward, away from the interior of the vehicle. Since the inboard and outboard topcoats  22 ,  24  obliquely intersect at the topcoat peak  26 , the topcoat peak  26  can extend approximately a length of that intersection. 
     In the present embodiment, the topcoat  21  provides for a durable and clean surface finish style on the door lining assembly  20 , and can be formed of fabric or any alternate material. For example, the topcoat  21  can be formed of a natural material (such as leather) or a synthetic material. 
       FIG. 2  is a partial perspective view of an exterior side of the exemplary door  10  in accordance with the disclosed subject matter. In the present embodiment, the lower edge of the window opening  14  defining the belt-line  16  is shown extending along an upper edge of the outer shell  15  of the door  10 . The belt-line  16  can include molding attached to the door  10 , such as a weatherstrip or guard, or may alternatively define an edge between the window opening  14  and the outer shell  15 . 
     Also shown in  FIG. 2 , the pillar cover  17  is visible through the quarter window  18  of the door  10  from the exterior of the vehicle. As described below, the door lining assembly  20  of the present embodiment extends along the belt-line  16  on the inner panel  13 , such that the front portion of the door lining assembly  20  abuts the pillar cover  17 . In other embodiments, the door lining assembly  20  may terminate before the pillar cover  17 , or alternatively extend beyond the pillar cover  17 . 
     In the present embodiment, the door lining assembly  20 , as well as the topcoat  21  that covers the door lining assembly  20 , is configured to extend along the belt-line  16  before deviating upward and away from the belt-line  16  as the door lining assembly  20  approaches the pillar cover  17 . In this manner, the door lining assembly  20  of the present embodiment curves upward away from the belt-line  16  as the door lining assembly  20  extends forward from the rear portion of the door  10  to the front portion. As previously described, the door lining assembly  20  of the present embodiment may curve in a concave manner up from the belt-line  16 , or alternatively, the door lining assembly  20  can simply extend upwards from the belt-line  16  in an approximately straight planar slant. As the door lining assembly  20  deviates upward from the belt-line  16 , the outboard topcoat  24  and the topcoat peak  26  (to which the outboard topcoat  24  extends) are visible from the exterior of the vehicle. Because the pillar cover  17  is disposed fore of at least a portion of the quarter window  18 , as well as the quarter window pillar  19 , in the present embodiment, a portion of the outboard topcoat  24  is visible through the quarter window  18  from the exterior of the vehicle. In embodiments configured without the quarter window  18 , the outboard topcoat  24  may be exposed to the exterior of the vehicle from where it deviates from the belt-line  16  to where it meets the pillar cover  17 . 
       FIG. 3  is a partial perspective view of the interior side of the exemplary door  10  of the vehicle in accordance with the disclosed subject matter. Particularly,  FIG. 3  shows a portion of the door lining assembly  20  that deviates above the belt-line  16  as it approaches the pillar cover  17  proximate a front side of the door frame  12 . Slant angles of the door lining assembly  20  result in the outboard topcoat  24  facing outward and away from the interior of the vehicle, such that the outboard topcoat  24  extends obliquely from the belt-line  16  towards the topcoat peak  26 . Contrarily, the inboard topcoat  22  can face inward and towards the interior of the vehicle, such that the inboard topcoat  22  also extends towards the topcoat peak  26  at an angle relative to the outboard topcoat  24 . The inboard and outboard topcoats  22 ,  24  can be planar, approximately planar, or otherwise contoured. 
     Also shown in  FIG. 3 , the door lining assembly  20  of the present embodiment can include a side edge  28  and a front edge  30 . The side edge  28  can extend along an interior side of the inboard topcoat  22 , and can define a width of the inboard topcoat  22 . The side edge  28  can be rounded, beveled or chamfered, or otherwise planar so as to extend from the inboard topcoat  22  at any angle. The front edge  30  can extend along a front side of the inboard topcoat  22  proximate the front side of the door  10 , thereby defining a length from a back edge of the inboard topcoat  22 . The front edge  30  can be rounded, beveled or chamfered, or otherwise planar so as to extend from the inboard topcoat  22  at any angle. 
       FIG. 4  is a cross-sectional perspective view of a part of the exemplary door  10  of  FIG. 3  in accordance with the disclosed subject matter. The cross-sectional view in  FIG. 4  reveals an inboard base  32  and an outboard base  34  adhered together and then completely enveloped by the topcoat  21  to form the door lining assembly  20 . 
     In the present embodiment, the inboard base  32  has a primary surface disposed adjacent and underneath the inboard topcoat  22 , the inboard topcoat  22  being wrapped to cover and follow the primary surface of the inboard base  32 . The outboard base  34  also has a primary surface disposed adjacent and underneath the outboard topcoat  24 , the outboard topcoat  24  being wrapped to cover and follow the primary surface of the outboard base  34 . The inboard and outboard bases  32 , 34  are joined at overlapping portions to form the topcoat peak  26 , which is described below. 
     The inboard base  32  of the present embodiment can include an inboard overlap  36  having an inboard protrusion  40  disposed thereon, with the inboard protrusion  40  extending along an edge of the inboard base  32  proximate the topcoat peak  26 . The inboard overlap  36  can be configured to overlap with an outboard overlap  38  of the outboard base  34 , which is described below. Specifically, the inboard protrusion  40  can extend downward towards the outboard overlap  38 . In some embodiments, the inboard protrusion  40  is formed as an elongated hook, while in other embodiments the inboard protrusion  40  can be configured as any type of catch for securing the inboard overlap  36  to the outboard overlap  38 . 
     The outboard base  34  of the present embodiment can include the outboard overlap  38  having an outboard channel  42  disposed thereon, with the outboard channel  42  extending along a portion of the outboard base  34  proximate the topcoat peak  26 . The outboard overlap  38  is configured to obliquely extend from the primary surface of the outboard base  34  parallel to the primary surface of the inboard base  32 . Particularly, the outboard overlap  38  extends along the inboard overlap  36  for a sufficient distance to secure the inboard base  32  and the outboard base  34  together. Due to the orientation of the inboard and outboard overlaps  36 , 38 , the inboard protrusion  40  is configured to be inserted within the outboard channel  42 , thereby locking the inboard and outboard bases  32 , 34  together adjacent the topcoat peak  26 . The outboard channel  42  can be configured as a slot, groove, or other recessed portion capable of engagement with the inboard protrusion  40 . Alternatively, the inboard overlap  36  can include a channel to engage a protrusion disposed on the outboard overlap  38 . Furthermore, the engagement between the inboard protrusion  40  and the outboard channel  42  can occur anywhere along the inboard and outboard overlaps  36 , 38 , and is not limited to a portion adjacent the topcoat peak  26 . The inboard and outboard overlaps  36 , 38  can also extend the entire length of the door lining assembly  20 , or a partial length. 
     In the present embodiment, the inboard base  32  is configured to include the primary surface adjacent the inboard topcoat  22 , as well as an inboard edge  49 , an inboard lower side  50 , and an inboard lower portion  44 . The inboard base  32  can be configured such that the inboard edge  49  extends downward from the primary surface, the inboard lower side  50  extends from the inboard edge  49  outward towards the outboard base  34 , and the inboard lower portion  44  extends downward from the inboard lower side  50 . The inboard lower portion  44  can be configured to abut an outboard lower portion  46  of the outboard base  34 , as described below. Furthermore, the topcoat  21  of the present embodiment is wrapped around the primary surface, the inboard edge  49 , the inboard lower side  50 , and the inboard lower portion  44  of the inboard base  32  so as to completely envelop and cover surfaces of the aforementioned elements defining an exterior of the inboard base  32 . Particularly, the topcoat  21  includes an under topcoat  53  and a lower topcoat  54  as portions wrapping around the inboard lower side  50  and the inboard lower portion  44 , respectively. 
     Similarly, the outboard base  34  is configured to include the primary surface adjacent the outboard topcoat  24 , as well as an outboard edge  48 , an outboard lower side  52 , and the outboard lower portion  46 . The outboard base  34  can be configured such that the outboard edge  48  extends downward from the primary surface, the outboard lower side  52  extends from the outboard edge  48  inward towards the inboard base  32 , and the outboard lower portion  46  extends downward from the outboard lower side  52 . As described above, the outboard lower portion  46  can be configured to abut the inboard lower portion  44  of the inboard base  32 , and may have a protruding portion to overlap and/or interlock with the inboard lower portion  44 . In the present embodiment, the topcoat  21  is wrapped around the primary surface of the outboard base  34  from the topcoat peak  26  to an edge of the primary surface from which the outboard edge  48  extends, and which abuts a weather-strip  58  disposed along a base of the quarter window  18 , as described below. The topcoat  21  is thereby configured to completely envelop and cover the primary surface of the outboard base  34 . 
     As described above, the topcoat  21  of the present embodiment wraps around the inboard and outboard bases  32 ,  34  so as to span from the edge of the primary surface which abuts the weather-strip  58 , across the topcoat peak  26  to then cover the above described surfaces defining the exterior of the inboard base  32 . 
     In  FIG. 4 , the weather-strip  58  is shown disposed at the base of the quarter window  18 , with the weather-strip  58  being approximately aligned with the belt-line  16  of the door  10 . The weather-strip  58  can include an interior strip  59  extending upward along an interior side of the base of the quarter window  18 . The interior strip  59  can be configured to abut the outboard base  34  at the outboard edge  48 , as well as a portion of the topcoat  21 , specifically the outboard topcoat  24 , that terminates at the outboard edge  48 . In this manner, the topcoat  21  can be oriented to mate to the interior strip  59  to form a close fit or seal. The weather-strip  58  can be rubber or any other type of semi-pliable material to fit between the quarter window  18  and the edge of the topcoat  21  aligned with the outboard edge  48 . 
     The present embodiment can include an attachment fixture  56  disposed within an interior of the inner panel  13  of the door  10  to attach the door lining assembly  20  to the door  10 . Particularly, the outboard lower portion  46  can include a complementary fixture for attachment to the attachment fixture  56 . The attachment fixture  56  can thereby serve to align and secure the door lining assembly  20  to the door  10 . 
     II. Alternative Embodiments 
     In the disclosed embodiment, various structures are applied to a door lining assembly of a vehicle door. However, the disclosed structures may alternatively be applied to or modified to include or otherwise cover any type of lining assembly, including lining assemblies for automobile panels configured without a door, such as panels adjacent window frames of third row seating configurations. 
     As disclosed above, embodiments are intended to be used with any type of vehicle. The power source of the vehicle can be an internal combustion engine, an electric motor, or a hybrid of an internal combustion engine and an electric motor. The power source configured as an internal combustion engine or a hybrid power source can have the engine output axis oriented in the longitudinal direction or in the traverse direction of the vehicle. The engine can be mounted forward of the front axles, rearward of the rear axles, or intermediate the front and rear axles. 
     In the disclosed exemplary embodiments, the door lining assembly is attached to the front door of the vehicle. However, the lining assembly can be attached to any component of the vehicle where it is desirable to cover or line body panels, such as the dashboard, roofline, pillars, etc. 
     Embodiments are also intended to include or otherwise cover methods of using and methods of manufacturing any or all of the elements disclosed above. The methods of manufacturing include or otherwise cover processors and computer programs implemented by processors used to design various elements of the vehicle door adjuster disclosed above. 
     While the subject matter has been described in detail with reference to exemplary embodiments thereof, it will be apparent to one skilled in the art that various changes can be made, and equivalents employed, without departing from the scope of the invention. All related art references discussed in the above Background section are hereby incorporated by reference in their entirety.

Technology Category: 7