GB2276903A - Motor vehicle window aperture infill arrangement - Google Patents

Abstract

A motor vehicle body part 23 such as a van rear door comprises a window aperture surrounded by a recessed flange 22, a separately produced frame 18 attached to the flange 22 and an infill panel 4 fixed to the frame 18. The infill panel 4 comprises an outer skin 5 and joined thereto an inner stiffening structure including a peripheral portion 31 which is spaced from the outer skin 5 and fixed to the frame 18. The outer surface of the outer skin 5 is substantially aligned with the outer surface of the body part and a gap is provided between an external edge 6 of the panel 4 and an external edge 32 of the flange recess 27 into which is fitted a filler strip 29, 30 eg for weather proofing. The panel 4 and frame 18 may be components of a kit permitting vehicle customer fitment. <IMAGE>

Description

Motor Vehicle Window Aperture Infill Arrangement.

This invention relates to an infill arrangement for a window aperture of a motor vehicle and particularly but not exclusively, a window aperture of a rear door of a commercial vehicle such as a van.

The windows of motor vehicles are vulnerable to being broken by thieves to gain access to the vehicle contents. Vans carrying valuable cargo are a special target and it is therefore sometimes desirable that the cargo compartment of a van does not have windows. On the other hand, some customers for vans prefer to have windows.

Accordingly, motor vehicle manufacturers have sought to meet the requirements of both customers requiring windows and those not, while continuing to maintain an economic manufacturing operation. To this end, motor vehicles, and particularly vans, have been manufactured with window apertures, especially in their rear doors, which may be fitted, in a down-stream manufacturing operation, with either windows or with infill panels of sturdy material such as steel. This manufacturing procedure has provided access through the open apertures in rear doors, before the fitting of windows or infill panels, enabling latches to be adjusted with the doors closed,thus aiding the motor vehicle assembly process.

The fitting of such infill panels has customarily been in a manner whereby the finished structure lacks strength, durability and aesthetic appeal.

According to the present invention there is provided a motor vehicle window aperture infill arrangement comprising a motor vehicle body part having a window aperture therein surrounded by a recessed flange of the body part, a separately produced frame attached to the flange so as to overlap a peripheral portion of the flange and a peripheral portion of the aperture, an infill panel comprising an outer skin and an inner stiffening structure joined thereto, the inner stiffening structure including a peripheral portion spaced from the outer skin and fixed to the frame, the dimensions of the flange recess, the frame, the outer skin and of the spacing of the spaced portion of the stiffening structure being such that the outer surface of the outer skin is substantially aligned with the outer surface of the body part surrounding the flange recess and such as to provide a gap between an external edge of the infill panel and an external edge of the flange recess into which gap is fitted a filler strip.

The present invention provides a motor vehicle window aperture infill arrangement permitting the achievement of strength, durability and aesthetic appeal in the finished structure. The invention also provides a window aperture infill arrangement which permits incorporation of an infill panel in a motor vehicle window aperture during the vehicle manufacture or afterwards for example by way of a replacement of a glazed unit.

The motor vehicle body part may be any body part which may have a window aperture and may be therefore, for example, a body part comprising a side , roof or rear part of the vehicle. However, it is preferred that the body part comprises a rear door of a commercial vehicle and, in particular, of a van. The body part will generally comprise an outer layer of steel, for example, which may be supported and/or strengthened by ribs, channel or box section structures or by merely doubling up the thickness of the material of the outer layer for example, in selected regions.

The window aperture is preferably a window aperture as such but may be any aperture in a vehicle body part. However, the aperture should be located in a recessed portion of the body part so that it is surrounded by a recessed flange. It is preferred that the flange recess is a stepped recess to provide strength. It is preferred that the flange is braced by a surrounding box section and strengthened by a doubling of the outer layer material thickness in the flange itself.

The frame is a separately produced component of the arrangement and preferably has a stepped cross-sectional shape produced by moulding or pressing for example.

It is preferred that the frame is attached to the inner side of the flange.

The frame may be attached to the flange by any means and therefore may be welded, adhesively bonded, bolted, riveted or clamped to the flange or attached by a combination of two or more of these means, for example. However, if the frame is attached after the body part has received any protective coating such as a paint coating, it is preferred that the method of attaching is such as to minimize the exposure of coating-free surfaces. Accordingly, it is preferred that welding, for example,is reserved as a method for use in attaching the frame to the flange in an in-line factory process where suitable protective coating can be subsequently applied. When the frame is attached to the inner side of the flange, it may be attached by clamping effected at the same time as fixing the infill panel to the frame.

The infill panel preferably comprises an outer skin of pressed steel sheet the edges of which are turned over to provide an external smooth edge to the panel to maximize the aesthetics of the panel and minimize the risk of formation of corrosion sites. The inner stiffening structure joined to the outer skin preferably comprises a channel-shaped peripheral portion combined with integral channel-shaped intersecting cross members. The open side of each of the channel-shapes is preferably arranged to face the rear face of outer skin.

The peripheral portion of the inner stiffening structure which is spaced from the outer skin is preferably the base of a channel-shaped portion of the stiffening structure but may be the side of a box, rib or tubular-shaped portion, for example.

The inner stiffening structure may be joined to the outer skin by bonding, welding or riveting, for example, but it is preferably joined by clinching its peripheral edge between the rear surface of the outer skin and a turned-over edge of the outer skin in known manner. Edges of the stiffening structure not clinched may be bonded to the rear surface of the outer skin with mastic or filler,for example.

The peripheral portion of the inner stiffening structure which is spaced from the outer skin, may be fixed to the frame by any means such as welding, adhesive bonding, bolting, riveting, clamping or a combination of two or more such means, for example. However, when the stiffening structure has received a protective coating, for example a paint coating, prior to fixing to the frame, it is preferred that the means is such as to minimise the exposure of coating-free surfaces. Accordingly, it is preferred that fixing by welding, for example, would be reserved for use in an in-line factory process where suitable protective coating can be subsequently applied and that when the structure is pre-coated, alternative adhesive or mechanical means are employed, riveting, especially blind-riveting, being particularly preferred.

The fixing of the stiffening structure to the frame may be such as to simultaneously clamp the frame to the recessed flange of the body part. A means by which this may be achieved will be described below.

It is preferred that the infill panel including stiffening structure is pre-coated with a paint coating, more preferably with a finish paint coating, prior to fixing of the structure to the frame. It is further preferred that the structure is provided with fixing holes prior to the paint being applied. Such pre-formed holes may not only serve to minimise the exposure of uncoated surfaces in fixing but also to provide drainage holes for excess paint after the application of a paint coating.

It is preferred that the frame is likewise pre-coated with a paint coating, more preferably with a finish paint coating, prior to its attachment to the flange and is preferably provided with fixing holes and attaching holes where required, prior to the paint being applied.

The filler strip fitted into the gap between the external edge of the panel and the external edge of the flange recess may be a mastic or other such adhesive filler but is preferably a continuous loop of extrusion moulded plastic filler of such cross-sectional shape as to fit securely in the gap and provide a barrier against the weather gaining access to the flange recess. Separate weather-proofing of the fixing of the stiffening structure to the frame is also preferred and to this end a sealer bead or gasket is preferably applied between the stiffening structure and the frame and/or the flange during the fixing of the structure to the frame.

The invention will now be illustrated by way of example with reference to the accompanying drawings in which: Figure 1 is a sketch of the rear view of a commercial motor vehicle with window aperture infill arrangements according to the invention.

Figure 2 is an enlarged semi-schematic view of a cross section taken through part of one of the infill arrangements shown in Figure 1.

Figure 3 is a sketch of the infill panel part of which is shown in Figure 2.

Figure 4 is a sketch of the frame part of which is shown in Figure 2.

In the drawings in which like numbers correspond, 1 indicates generally a commercial motor vehicle comprising a van having a pair of rear doors 2, each of which has a window aperture infill arrangement indicated generally by 3.

Details of the window aperture infill arrangement are shown in Figures 2, 3 and 4.

The infill panel 4 comprises the outer skin 5 made of sheet metal and having its edges turned over to provide a smooth, durable external edge 6 to the panel 4, and to enable the inner stiffening structure 7, comprising a unitary pressed steel structure to be joined by its peripheral edge 8 to the skin 5 in a clinched joint indicated generally by 9. The stiffening structure 7 comprises the integrally intersecting peripheral, longitudinal and lateral pressed steel channels 10, 11, and 12 having their open sides facing the rear surface of the outer skin 5. In addition to the out-turned peripheral edge 8 of the structure 7, the remaining edges of the channels are likewise out-turned as at the edges 13 and 14. In order to increase the stiffening effect of the structure 7 and reduce vibration, a sealer bead 15 is inserted between the out-turned edge 13 of peripheral channel 10 and the rear surface of the outer skin 5. The depth of the channel 10, and therefore the spacing of the spaced portion 31 of the stiffening structure 7 from the outer skin 5, is related to the depth of the flange recess as will be clarified below.

The stiffening structure 7 is provided with the fixing holes 16 and the breather holes 17 before joining the structure 7 to the outer skin 5. In a painting process to which the panel is subjected following the joining of structure 7 and skin 5 and prior to fixing, the holes permit drainage of excess paint from the channels when the panel is laid flat with the outer skin 5 uppermost.

The infill panel is fixed to the frame 18 by the rivets 19 which pass through the holes 16 in the stiffening structure and the aligned holes 20 provided in the frame 18. The holes 20 are made in the frame 18 prior to the frame being subjected to a painting process.

The frame 18 has a stepped cross-sectional shape as more clearly seen in Figure 2. It will be seen that the outer edge 21 of the frame overlaps the inner side of a peripheral portion of the recessed flange 22 of the body part indicated generally by 23. The frame 18 is attached to the flange 22 by a clamping action effected by securing the rivets 16 against the resilient filler bead 24 placed around the outer side of a peripheral portion of the flange 22 prior to assembly of the infill panel to the frame 18 and flange 22.

This means of attachment of frame 18 to flange 22 aims to minimise the exposure of unpainted surfaces during attachment.

The recessed flange 22 is formed in the body part 23 which surrounds the window aperture in the van rear door 2 and covered by the infill panel 4. The body part 23 of pressed steel comprises outer layer 25 which has an outer surface 26 surrounding a flange recess 27 which recess is stepped as shown in Figure 2 to add strength and has the external edge 32. The outer layer 25 is braced by the inner layer 28 formed generally so as to form a box section around the flange, the shape depending on the position around the flange, but the inner layer 28 and the outer layer 25 each terminating in the recessed flange 22 and in which they are spot-welded together during the manufacture of the rear door 2. After the spot-welding of the flange 22, the body part 23 is painted, the paint being applied before application of the frame 18 and the infill panel 4 with a view to maximising protection against corrosion. The dimensions of the frame 18, of the outer skin 5 and of the spacing of the spaced portion 31 of the stiffening structure 7 from the outer skin 5 are such that the outer surface of outer skin 5 is approximately aligned with the outer surface 26 of the body part 23, thus maintaining the overall contours of the vehicle. The dimensions of the outer skin 5 and of the flange recess 27 are also such as to provide a substantially uniform peripheral gap between the external edge 6 of the panel 4 and the external edge 32 of the of the flange recess 27 and into which is fitted the tongue 29 of filler strip 30. Filler strip 30 comprises a continuous loop formed by joining the ends of a plastics extruded section, which loop neatly fits the peripheral gap between the external edge 6 of the infill panel 4 and the edge 32 of the stepped flange recess 27.

It will be appreciated from the foregoing that the frame and the infill panel, and optionally filler strip, filler and rivets or other fixings may be provided, by the vehicle manufacturer for example, as a kit, preferably wherein the frame and infill panel have finished paint surfaces, for fitment by vehicle franchises or ultimate customers to suit particular requirements. This may involve the removal from the window apertures glazing fitted by the vehicle manufacturer.

Claims (14)

Claims

1. A motor vehicle window aperture infill arrangement comprising a motor vehicle body part having a window aperture therein surrounded by a recessed flange of the body part, a separately produced frame attached to the flange so as to overlap a peripheral portion of the flange and a peripheral portion of the aperture, an infill panel comprising an outer skin and an inner stiffening structure joined thereto, the inner stiffening structure including a peripheral portion spaced from the outer skin and fixed to the frame, the dimensions of the flange recess, the frame, the outer skin and of the spacing of the spaced portion of the stiffening structure being such that the outer surface of the outer skin is substantially aligned with the outer surface of the body part surrounding the flange recess and such as to provide a gap between an external edge of the infill panel and an external edge of the flange recess into which gap is fitted a filler strip.

2. An infill arrangement as claimed in Claim 1 wherein the body part comprises a rear door of a van.

3. An infill arrangement as claimed in either Claim 1 or Claim 2 wherein the window aperture is a window aperture as such.

4. An infill arrangement as claimed in any one of the preceding claims wherein the flange recess is a stepped recess.

5. An infill arrangement as claimed in any one of the preceding claims wherein the flange is braced by a surrounding box section and is strengthened by a doubling of body part outer layer material thickness in the flange.

6. An infill arrangement as claimed in any one of the preceding claims wherein the frame has a stepped crosssectional shape.

7. An infill arrangement as claimed in any one of the preceding claims wherein the frame is attached to the inner side of the flange.

8. An infill arrangement as claimed in Claim 7 wherein the frame is attached to the flange by clamping

9. An infill arrangement as claimed in any one of the preceding claims wherein the inner stiffening structure is joined to the outer skin by clinching its peripheral edge between the rear surface of the outer skin and a turned-over edge of the outer skin.

10. An infill arrangement as claimed in any one of the preceding claims wherein the peripheral portion of the inner stiffening structure which is spaced from the outer skin is fixed to the frame by riveting.

11. An infill arrangement as claimed in any one of the preceding claims wherein the infill panel including stiffening structure is coated with a finish paint coating prior to fixing the structure to the frame.

12. An infill arrangement as claimed in Claim 11 wherein the frame is coated with a finish paint coating prior to fixing the structure to the frame.

13. An infill arrangement as claimed in any one of the preceding claims wherein the infill panel and frame are components of a kit permitting vehicle customer fitment.

14. An infill arrangement substantially as described herein with reference to the drawings.