GB2378727A

GB2378727A - A door, door assembly method and elongate strip

Info

Publication number: GB2378727A
Application number: GB0119725A
Authority: GB
Inventors: Simon Blair Dobson; Jurgen Moser
Original assignee: ArvinMeritor Light Vehicle Systems France SA; Meritor Light Vehicle Systems France
Current assignee: Inteva Products France SAS
Priority date: 2001-08-13
Filing date: 2001-08-13
Publication date: 2003-02-19
Anticipated expiration: 2021-08-13
Also published as: GB0119725D0; GB2378727B

Abstract

A door 10 for a vehicle comprising an inner portion 12 and an outer portion 14, the portions comprising overlapping peripheral regions (fig. 2) with expandable compression means arranged therebetween. The expandable compression means comprises an elongate strip 16 through which a flexible rod (25 fig 4b) is inserted, on inserting the rod (25 fig 4b) the elongate strip expands exerting a force between the overlapping peripheral regions (fig. 2) securing the portions 12 and 14 of the door together.

Description

A Door, Door Assembly Method And Elongate Strip The present invention relates to a door, a method of assembling a door and an elongate 0 strip. More particularly, the present invention relates to a vehicle door, a method of assembling a vehicle door, and an expandable elongate strip for a door.

Known car doors are typically assembled by welding various strengthening and reinforcement elements to an inner portion (normally an inner panel) and then attaching an outer portion (normally an outer skin) to the subassembly by a hemming technique.

This bare door is then allocated to a car body along with other bare doors and a bare bonnet (hood) and a bare boot (trunk) and this set of components is then painted together to provide the final exterior colour for the vehicle- However, doors assembled by this method suffer from the disadvantage that should the outer skin of the door become damaged to an extent that respraying and/or dent removal is not possible, the entire door must be replaced due to the irreversible nature of welding one part to another.

A further disadvantage is that this assembly method is not well suited to the use of different materials for the inner and outer portions (e. g. a plastics outer skin and a steel inner panel).

Numerous prior art methods have been proposed by which an outer door skin may be secured to an inner door panel. These methods include gluing or bonding, bolting, screwing, or using other fasteners. However, known methods suffer from a number of disadvantages such as the difficulty of removing the fixing once assembled or the complexity of the fixing process, for example.

The present invention seeks to overcome or at least mitigate the problems of the prior art.

Accordingly, one aspect of the present invention provides a door for a vehicle comprising an inner portion and an outer portion, the portions comprising overlapping peripheral regions with compression means arranged therebetween, the compression

means exerting a force between the regions so as to secure the portions together. el n A second aspect of the present invention provides a method of assembling a door for a vehicle comprising the steps of : providing a door inner portion, a door outer portion and compression means ; positioning the inner portion and the outer portion such that peripheral regions of the portions overlap and have compression means arranged therebetween ; expanding the compression means so as to secure the outer portion to the inner portion.

A third aspect of the present invention provides an expandable elongate strip for use in securing together inner and outer portions of a door for a vehicle, the strip comprising first and second sections arranged such that, in use, the insertion of an expansion member therebetween causes expansion to occur.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which :- Figure lA is an exploded perspective view of a door according to one embodiment of the present invention ; Figure 1B is a perspective view of an assembled door of Figure 1 A ; Figure 2 is a cross sectional view along the axis x-x of Figure 1B ; Figures 3A and 3B illustrate an alternative embodiment of an elongate strip for use with the door of the present invention; Figure 4A is an exploded perspective view of a door according to another embodiment of the present invention, and

Figure 4B is a perspective view of the assembled door of Figure 4A.

Referring to Figures 1A and IB a door 10 is disclosed comprising an inner portion 12 and an outer portion 14 (the terms outer and inner designating the relative positions of the portions in respect of the inside and outside of a vehicle in which the door is installed). In this embodiment the inner portion 12 comprises structural elements of the door namely a window frame 15, peripheral frame members 17a, b and c, as well as a waist member 19. The outer portion 14 comprises the exterior skin of the door The door additionally comprises a perimeter strip 16 which is arranged between the inner and outer portions 12,14 to facilitate attachment of the portions together.

As can be seen most clearly from Figure 2, the inner portion 12 comprises a peripheral flange 18 extending around frame members 17a, b and c. An inwardly folded flange 20 is provided on the outer portion 14 so as to form a channel 21 around the outer portion.

It can be seen that the planes of flanges 18 and 20 are arranged substantially parallel to a longitudinal axis of the door.

Considering the construction of the strip 16 in more detail, it is preferably injection or extrusion moulded and is formed from plastics material that is flexible but which has low compressibility characteristics. Examples of suitable material are acetal, ABS thermoplastic polyesters, and medium density polyethylene (MDPE). The material should preferably exhibit low creep at maximum operating temperatures, toughness and a low, or at least stable friction coefficient. Thus, other crystalline type plastics materials may also be suitable.

The strip 16 comprises in this embodiment two sections 26 and 30 with a gap 28 therebetween. Approximately midway along each section are provided elongate substantially semi-circular recesses which together form. a bore 24. In this embodiment the bore 24 is provided with internal threads. The strip preferably also comprises a spacer region 32 arranged so as to prevent contact between the edge of flange 20 and the inner portion 12 and the edge of flange 18 and the outer portion 14, which could

otherwise result in rattling or the scraping of paintwork from the portions, in use. The strip constitutes part of the aforesaid compression means.

Referring to Figures 1B and 2, the strip 16 is first fitted into the channel 21 formed by the outer skin 14 and flange 20 along the bottom, front and rear edges of the outer portion. The outer portion 14 is then slid over the flange 18 of the inner portion 12.

Mastic type non-hardening sealant 22 is then advantageously injected between flange 18 and the outer portion 14 to provide a water seal and to assist further in the prevention of rattles.

In alternative embodiments, the mastic 22 may be replaced by adhesive tape (not shown) having high adherence characteristics on one side and lower adherence on the other, thereby permitting easier disassembly and allowing for differential expansion of the inner and outer portions. In order to ensure that the tape fills the gap between the inner and outer portions 12 and 14, a low modulus of elasticity closed cell foam layer is preferably included in the tape.

Subsequently, in order to secure the outer portion 14 to the inner portion 12, a flexible rod 25 is inserted into the bore 24 in direction Y, the diameter of the rod being such that sections 26 and 30 of the strip 16 are forced apart so as to bear against flanges 18 and 20. Preferably, the rod is threaded so as to co-operate with the internal threads on the bore 24, thereby enabling the rod to be screwed into position as indicated by auow W so as to extend around the front, bottom and rear of the door 10. In a particularly preferred embodiment, the rod may be a"Golde"-type cable comprising a heavy weight stranded core with a helically wound steel wire outer that forms the thread. When the rod 25 is installed, the otherwise visible end thereof may be covered by the wing mirror trim of the door (not shown). The rod constitutes another part of the compression means.

If it is necessary to access the interior of the door (eg to service or replace a component mounted therein) or if the outer portion becomes damaged (due to an impact, for

example) it is then simply a case of unscrewing the rod 25 to gain access to the door interior or to enable the outer portion 14 to be replaced.

Figures 3A and 3B illustrate an alternative embodiment of the strip designated 116. It can be seen from figure 3A that the sections 126 and 130 are moulded in an"opened out"position in which they are connected by a relatively thin flexible strip of material enabling the sections to be folded together to form the finished strip 116. One advantage of this embodiment is that the screw thread in particular can be more easily formed in the bore 24 using an injection moulding process.

A second embodiment of the door is shown in Figures 4A and 4B and where possible like numerals have been used for like parts.

The door of this embodiment differs from that of Figures J A and 1B in that three separate strips 16a, 16b and 16c are provided and three separate rods 25a, 25b and 25c are inserted into the bores 24 of the strips in directions Y ;, Y2 and Y3 respectively to secure the outer portion in place. One advantage of this embodiment is that the rods and strips need not be as flexible as in the first embodiment.

It should be noted that the amount of overlap between flanges 18 and 20, and the longitudinal thickness of the spacer regions 32, 132 may be adjusted so as to enable the outer portion to be mounted on the inner by"clipping"one of the front or rear flange portions 20 behind flange IS, then"clipping"the other of the front/rear flange portions 20 in place before inserting the strip 25.

It will be appreciated that a door according to the present invention has numerous of advantages over the prior art: it enables access to be gained to internal components of the door (eg window regulator devices) from the outer face of the door both during and after the door assembly process-This means that the door inner portion requires fewer and smaller apertures to install and access the internal door components (eg just holes for fixing components such as loudspeakers may be needed). This in turn obviates the need for a waterproof layer on the inside of the door between the inner portion and an

interior mm panel, thereby reducing manufacturing costs and improving the crash and NVH (noise, vibration, harshness) performance of the door. Additionally, the strip is not visible or accessible when the door is closed, the strip provides a secure and substantially rattle-free connection between the inner and outer portions, only the outer portion needs to be painted the same colour as the rest of the car ; the strip is easily removable to enable the outer portion to be replaced with the minimum of labour required ; and the strip permits the inner and outer portions to be fitted together without damaging the painted surfaces thereof.

It will be understood that numerous changes may be made within the scope of the present invention. For example, suitable alternative compression means may be used such as fluids or gels introduced under pressure into a envelope located between the flanges, and subsequently sealed to provide for sufficient compression. The

compression means may be fitted between the outer portion 14 and flange 18 with the sealant being provided between flanges 18 and 20. The rod may be a push-fit in the bore. The outer portion may comprise the structural elements of the door, with the inner portion comprising the interior trim, for example. The strip and rod may be provided along two edges of the door only. Part or all of the compression means may be moulded or cast integrally with either the inner or outer portion. As well as providing

for the securement of the inner and outer portions, the compression means may enable the relative portions of the portions to be adjusted as desired in the direction of X, Y and Z axes, as well as rotationally.

Claims

Claims 1. A door for a vehicle comprising an inner portion and an outer portion, the portions comprising overlapping peripheral regions with compression means arranged therebetween, the compression means exemg a force between the regions so as to secure the portions together.
2. A door according to claim 1 wherein the peripheral regions comprise first and

second flanges of the inner and outer portion respectively.

0
3. A door according to claim 2 wherein respective planes defined by the first and second flanges are arranged substantially parallel to the longitadina ! axis of the door.
4. A door according to claim 2 or claim 3 wherein the second flange is arranged inwardly of the first.
5. A door according to any preceding claim wherein the compression means comprises an expandable elongate strip.
6. A door according to claim 5 wherein the compression means further comprises an expansion member wherein, in use, the strip is expanded by the insertion of the expansion member into a cavity provided in the elongate strip.
7. A door according to claim 6 wherein the expansion member is an elongate rod arranged so as to fit in an elongate bore provided in the strip and thereby cause the

strip to expand.
8. A door according to claim 6 or claim 7 wherein the member is push-fitted into the cavity.
9. A door according to claim 7 wherein the member is screw-fitted into the bore.

9. A door according to claim 7 wherein the member is screw-fitted into the bore.

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10. A door according to any one of claims 6 to 9 wherein the strip comprises two sections arranged such that insertion of the member causes the spacing between the sections to increase.

11. A door according to any one of claims 5 to 10 wherein at least one elongate strip extends around at least two edges of the door.

12. A door according to claim 11 wherein at least one elongate member extends around three edges of the door.

13. A door according to claim 11 or claim 12 wherein one elongate member extends around at least two edges of the door.

14. A door according to claim 11 or claim 12 wherein one elongate member is provided so as to extend along each one of said at least two edges of the door respectively.

15. A door according to any preceding claim wherein sealing means is further provided between the inner and outer portions.

16. A door according to claim 15 wherein the sealing means comprises mastic.

17. A door according to any preceding claim wherein the outer portion is a door skin.

18. A door according to any preceding claim wherein the inner portion is a door structural member.

19. A method of assembling a door for a vehicle comprising the steps of- i) providing a door inner portion, a door outer portion and compression means ; ii) positioning the inner portion and the outer portion such that peripheral regions of the portions overlap and have compression means arranged therebetween ;

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iii) expanding the compression means so as to secure the outer portion to the inner portion.

20. A method according to claim 19 wherein the compression means comprises an expandable elongate strip and an expansion member, the expansion being achieved by the insertion of the expansion member into the strip.

21. An expandable elongate strip for use in securing together inner and outer portions of a door for a vehicle, the strip comprising first and second sections arranged such that, in use, the insertion of an expansion member therebetween causes expansion to occur.

22. A door or a method or an expandable elongate strip substantially as hereinbefore described.

23. A door or a method or an expandable elongate strip substantially as hereinbefore described-with reference to, or as illustrated by figures lA, 1B, 2 or 3A, 3B or 4A and 4B of the drawings.

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Amendments to the claims have been filed as follows 1. A door for a vehicle comprising an inner portion and an outer portion, the portions comprising overlapping peripheral regions with expandable compression means arranged therebetween, the compression means exerting a force between the regions so as to secure the portions together.

2. A door according to claim 1 wherein the peripheral regions comprise first and second flanges of the inner and outer portion respectively.

3. A door according to claim 2 wherein respective planes defined by the first and second flanges are arranged substantially parallel to the longitudinal axis of the door.

4. A door according to claim 2 or claim 3 wherein the second flange is arranged inwardly of the first.

5. A door according to any preceding claim wherein the compression means comprises an expandable elongate strip.

6. A door according to claim 5 wherein the compression means further comprises an expansion member wherein, in use, the strip is expanded by the insertion of the expansion member into a cavity provided in the elongate strip.

7. A door according to claim 6 wherein the expansion member is an elongate rod arranged so as to fit in an elongate bore provided in the strip and thereby cause the strip to expand.

8. A door according to claim 6 or claim 7 wherein the member is push-fitted into the cavity.