Description:FIELD OF THE INVENTION
[001] The present invention relates to a sash frame for a side door of a vehicle.

BACKGROUND OF THE INVENTION
[002] Consumer expectations for improved vehicle aesthetics and performance necessitates continuous innovation in design and construction of various vehicle parts including side doors. Packaging of components in side doors can be varied to provide a unique user experience. To improve aesthetics and user experience of a vehicle, side doors having a scoop handle provided at an upper portion of the door adjacent to a C-pillar of the vehicle is known in the art.
[003] In the prior art, the side doors having scoop handle at the upper portion adjacent to the C-pillar of the vehicle are implemented in full inner panel side doors. In a full inner panel side door 10 as shown in figure 1, an additional panel 14 must be attached to the upper portion of a full inner panel 12 to accommodate the scoop handle. The additional panel 14 adds to the weight of the side door and leads to wastage of material. Further, in the full inner panel side door 10 provided with the additional panel 14, a run channel for a glass window of the side door 10 is not formed. In the full inner panel side door 10, the run channel is provided by additional plastic parts assembled on the side door. The assembly of additional plastic parts increases the possibility of variations in the run channel and lead to obstructions for the raising and lowering of the glass window.
[004] To provide a stable run channel integrally formed in the side door, sash frame doors are provided in the prior art. Sash frame doors have a sash structure at a top portion. The sash structure is a continuous rolled frame. The sash structure provides an integral run channel for the glass window. However, the sash structure being a rolled section, variation in cross section is not possible in the upper portion of the side door. Therefore, a scoop handle cannot be accommodated in the conventional sash frame door.
[005] Hence there is a need in the art for a sash frame for a side door which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[006] Accordingly, the present invention in one aspect provides a sash frame for a side door of a vehicle. The sash frame includes a bottom frame member mounted to a lower section of the side door and a top frame member positioned above the bottom frame member. The top frame member extending from a rear end to a front end and the top frame member being a roll-formed sheet metal having a top channel along the top frame member. The sash frame further includes a front frame member extending between the front end of the top frame member and a front end of the bottom frame member, the front frame member being a roll-formed sheet metal having a front channel along the front frame member. The sash frame further includes a rear frame member extending between the rear end of the top frame member and a rear end of the bottom frame member. The rear frame member comprising an outer panel, an inner panel, and a rear channel provided between the outer panel and the inner panel. The rear frame member coupled with the top frame member and the top frame member coupled with the front frame member, whereby the rear channel, the top channel and front channel are interconnected forming a continuous run channel for guiding and supporting a glass window of the side door, and each of the inner panel and the outer panel being a stamped sheet metal panel configured to accommodate a scoop handle of the vehicle.
[007] In an embodiment of the invention, the outer panel and the inner panel are welded with the rear channel.
[008] In another embodiment of the invention, the outer panel and the inner panel are hemmed and welded to each other along the edge opposing the rear channel.
[009] In another embodiment of the invention, the top frame member comprises of a mounting portion disposed opposite to the top channel, a tubular section disposed towards the interior of the vehicle and a flat section disposed towards the exterior of the vehicle. The mounting portion being configured for mounting of a side door top sealing member.
[010] In another embodiment of the invention, the front frame member comprises of a mounting portion disposed opposite to the front channel, a tubular section disposed towards the interior of the vehicle and a flat section disposed towards the exterior of the vehicle. The mounting portion being configured for mounting of a side door front sealing member.
[011] In another embodiment of the invention, a top front edge of the rear frame member and the rear end of the top frame member are having matching cross-sectional profiles configured to be welded with each other.
[012] In another embodiment of the invention, the inner panel has a bulged section adjacent the top front edge, the bulged section and the tubular section of the top frame member having a minimum width of 18 mm.
[013] In another embodiment of the invention, the top front edge has an angle in the range of 35° to 45° with respect to the horizontal and the rear end of the top frame member has a corresponding angle to the horizontal as the top front edge.
[014] In another embodiment of the invention, the outer panel has one or more mounting provisions for the scoop handle.
[015] In another embodiment of the invention, the inner panel has mounting provisions for door seal members.

BRIEF DESCRIPTION OF THE DRAWINGS
[016] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a side view of a side door of the prior art.
Figure 2 illustrates a side view of a side door, in accordance with an embodiment of the invention.
Figure 3 illustrates views of the side door with a scoop handle, in accordance with an embodiment of the invention.
Figure 4 illustrates an exploded view of the sash frame for the side door, in accordance with an embodiment of the invention.
Figure 5 illustrates an exploded view of a rear frame member of the sash frame for the side door, in accordance with an embodiment of the invention.
Figure 6 illustrates a side view of a portion of the sash frame for the side door, in accordance with an embodiment of the invention.
Figure 7 illustrates a cross-sectional view of the rear frame member of the sash frame for the side door, in accordance with an embodiment of the invention.
Figure 8 illustrates a cross-sectional perspective view of a top frame member of the sash frame for the side door, in accordance with an embodiment of the invention.
Figure 9 illustrates a cross-sectional perspective view of a front frame member of the sash frame for the side door, in accordance with an embodiment of the invention.
Figure 10 illustrates a perspective view of a top front edge of the rear frame member of the sash frame for the side door, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[017] The present invention is directed towards a sash frame for a rear side door of a vehicle. The sash frame of the present invention provides for accommodation of a scoop handle on the rear side door adjacent to a C-pillar of the vehicle. Such scoop handle is a stylistic and functional feature which is not possible to be accommodated on conventional sash frame side doors.
[018] Figure 2 shows a side view of a side door 100 of a vehicle in accordance with the present invention. The side door 100 of the present invention is a rear door having a sash frame 200 and a lower section 100b. The lower section 100b of the side door 100 has an outer panel and a spaced apart inner panel forming an enclosed space for accommodating various subsystems such as the entertainment system, power window assembly etc. Further, cut outs/openings are provided on the inner panel for accessing such subsystems. The sash frame 200 is mounted above the lower section 100b of the side door 100 and forms the upper portion of the side door 100. The sash frame 200 has an opening (O) at the upper portion of the side door 100. The opening (O) accommodates a glass window of the side door 100. Figure 3 shows the fully assembled side door 100 having a scoop handle 210 provided on the side door 100 adjacent to C-pillar of the vehicle. The scoop handle 210 is provided for opening and closing the side door 100 and enables the locking and unlocking of the side door 100.
[019] As shown in figure 4, the sash frame 200 of the present invention comprises of a bottom frame member 206, a top frame member 202, a front frame member 208 and a rear frame member 204. The top frame member 202 extends between a rear end 202d and a front end and is disposed at a top portion of the sash frame 200 of the side door 100. The front frame member 208 extends between a front end of the top frame member 202 and a front end of the bottom frame member 206.
[020] The top frame member 202 and the front frame member 208 are roll-formed sheet metal members. The roll forming process of the top frame member 202 and front frame member 208 involves feeding a sheet of metal between several rollers which have profiles corresponding to the desired cross-section for these members. The roll forming process of the top frame member 202 and front frame member 208 may be executed in several steps by rollers of varying profiles till the desired cross-section is achieved for the top frame member 202 and front frame member 208.
[021] Figure 8 shows a cross-sectional perspective view of the top frame member 202. A top channel (CT) is provided along the length of the top frame member 202. The top channel (CT) in the side door 100 is adapted to mount rubber sealing and guiding members for the glass window of the side door 100. Further, the top frame member 202 has a mounting portion 202b for a side door top sealing member which is disposed on the opposite side of the top channel (CT). The top frame member 202 has a tubular section 202c extending along the length of the top frame member 202 and having a width (W). The tubular section 202c is disposed towards the interior of the vehicle and provides stiffness to the sash frame 200. The top frame member 202 has a flat section 202a extending along the length of the top frame member 202. The flat section 202a is disposed opposite the tubular section 202c towards the exterior of the vehicle.
[022] Figure 9 shows a cross-sectional perspective view of the front frame member 208. A front channel (CF) is provided along the length of the front frame member 208. The front channel (CF) in the side door 100 is adapted to mount rubber sealing and guiding members for the glass window of the side door 100. Further, the rolled profile of the front frame member 208 has a mounting portion 208b for a side door front sealing member which is disposed on the opposite side of the front channel (CF). The front frame member 208 has a tubular section 208c extending along the length of the front frame member 208 and having a width (W). The tubular section 208c is disposed towards the interior of the vehicle and provides stiffness to the sash frame 200. The front frame member 208 has a flat section 208a extending along the length of the front member 208. The flat section 208a is disposed opposite the tubular section 208c towards the exterior of the vehicle.
[023] The bottom frame member 206 is a stamped sheet metal member which extends between the front frame member 208 and the rear frame member 204 at a bottom portion of the upper section of the side door 100 and the bottom frame member 206 is mounted to the lower section 100b of the side door 100. The bottom frame member 206 acts as a reinforcement member connecting the front frame member 208 and the rear frame member 204. The rear frame member 204 extends between the rear end of the bottom frame member 206 and the rear end 202d of the top frame member 202.
[024] As shown in figure 5, the rear frame member 204 comprises of an outer panel 204b, an inner panel 204a and a rear channel (CR). The rear channel (CR) is disposed between the outer panel 204b and the inner panel 204a. The outer panel 204b and the inner panel 204a are stamped sheet metal panels. In an embodiment, as shown in figure 7, the outer panel 204b and the inner panel 204a are welded to the rear channel (CR) in a front portion of the rear frame member 204. In another embodiment, as shown in figure 7, the outer panel 204b and the inner panel 204a are hemmed and welded to each other along the edge opposing the rear channel (CR). The welding process adds strength to the joining portion of the outer panel 204b and the inner panel 204a and the hemming process prevents corrosion of the panels. Accordingly, the inner panel 204a and the outer panel 204b are spaced apart by the rear channel (CR) and joined along the edge opposing the rear channel (CR) forming a structure providing reinforcement and stiffness required for the sash frame 200 as well as the scoop handle 210.
[025] As shown in figures 4, 5 and 6, the outer panel 204b of the rear frame member 204 is configured to accommodate the scoop handle 210. The provision for accommodating scoop handle 210 adjacent to the C-pillar on the side door 100 is enabled through the incorporation of the rear frame member 204 in the sash frame 200.
[026] In an embodiment of the invention, the outer panel 204b and the inner panel 204a are stamped sheet metal panels having corresponding depressed portions with one or more mounting provisions for the scoop handle 210. The scoop handle 210 is a plastic or metallic member which is mounted in the depression provided in the outer panel 204b. The scoop handle 210 is mounted on the outer panel 204b by screws or through snap fit. Further, the inner panel 204a has mounting provisions for door seal members. The door seal members are mounted on the inner panel 204a by screws or through snap fit.
[027] In the sash frame 200 of the present invention, the rear frame member 204 is coupled with the top frame member 202 and the top frame member 202 is coupled with the front frame member 208 such that the rear channel (CR), the top channel (CT) and the front channel (CF) are interconnected to form a continuous run channel surrounding the opening (O). The continues run channel is configured to guide and support the glass window of the side door 100. The continuous metallic run channel for the glass window ensures that there are no distortions or variations in the path of the glass window. The continuous run channel ensures that the raising and lowering of the glass window is smooth and efficient.
[028] Figure 6 shows a portion of the side door 100 where the top frame member 202 and the rear frame member 204 are coupled to each other. As shown, the top front edge 204c of the rear frame member 204 is provided at an angle (?) to the horizontal. In an embodiment of the invention, the top front edge 204c has an angle (?) in the range of 35° to 45° with respect to the horizontal. For coupling the rear frame member 204 with the top frame member 202, the rear end 202d of the top frame member 202 is to be provided with a corresponding angle to the horizontal as the top front edge 204c. Accordingly, the top frame member 202 is terminated at the rear end 202d of the top frame member 202 at an angle (?) to the horizontal.
[029] In an embodiment, the top front edge 204c of the rear frame member 204 and the rear end 202d of the top frame member 202 are having matching cross-sectional profiles. As shown in figure 10, adjacent to the top front edge 204c of the rear frame member 204, the inner panel 204a has a bulged section 204d having a width (W). To provide the matching cross-sectional profiles, the width (W) of the bulged section 204d is kept same as the width (W) of the tubular section 202c of the top frame member 202. In an embodiment, the bulged section 204d and the tubular section 202c are having a minimum width (W) of 18 mm. The minimum width (W) of 18 mm is necessary for the stamping operation of the rear frame member 204.
[030] Further, the outer panel 204b of the rear frame member 204 and the flat section 202a of the top frame member 202 are joined coplanar such that a continuous sash frame 200 is seen from the exterior of the vehicle. In an embodiment of the invention, the top front edge 204c of the rear frame member 204 and the rear end 202d of the top frame member 202 are configured to be welded to each other. In an embodiment, the top front edge 204c of the rear frame member 204 and the rear end 202d of the top frame member 202 are welded by carbon dioxide welding. The matching cross-sectional profiles of top front edge 204c of the rear frame member 204 and the rear end 202d of the top frame member 202 enable proper alignment and attachment of these members.
[031] Advantageously, the present invention enables the integration of the scoop handle on the sash frame type side door adjacent to the C-pillar of a vehicle. The present invention negates the requirement of having a full inner panel type side door for integration of the scoop handle. The disadvantages of the full inner panel side door such as higher material use, material wastage and increased weight are prevented by the present invention. The sash frame of the present invention results in less usage of material and hence is cost effective. Further, the present invention provides a continuous run channel for the glass window which is provide with the sash frame and thereby ensure stable raising and lowering of the glass window.
[032] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
, Claims:1. A sash frame (200) for a side door (100) of a vehicle, the sash frame (200) comprising:
a bottom frame member (206) mounted to a lower section (100b) of the side door (100);
a top frame member (202) positioned above the bottom frame member (206), the top frame member (202) extending from a rear end (202d) to a front end, the top frame member (202) being a roll-formed sheet metal having a top channel (CT) along the top frame member (202);
a front frame member (208) extending between the front end of the top frame member (202) and a front end of the bottom frame member (206), the front frame member (208) being a roll-formed sheet metal having a front channel (CF) along the front frame member (208);
a rear frame member (204) extending between the rear end (202d) of the top frame member (202) and a rear end of the bottom frame member (206), the rear frame member (204) comprising an outer panel (204b), an inner panel (204a), and a rear channel (CR) provided between the outer panel (204b) and the inner panel (204a), the rear frame member (204) coupled with the top frame member (202) and the top frame member (202) coupled with the front frame member (208), whereby the rear channel (CR), the top channel (CT) and front channel (CF) are interconnected forming a continuous run channel for guiding and supporting a glass window of the side door (100), and each of the inner panel (204a) and the outer panel (204b) being a stamped sheet metal panel configured to accommodate a scoop handle (210) of the vehicle.

2. The sash frame (200) as claimed in claim 1, wherein the outer panel (204b) and the inner panel (204a) are welded with the rear channel (CR).

3. The sash frame (200) as claimed in claim 1, wherein the outer panel (204b) and the inner panel (204a) are hemmed and welded to each other along the edge opposing the rear channel (CR).

4. The sash frame (200) as claimed in claim 1, wherein the top frame member (202) comprises of:

a mounting portion (202b) disposed opposite to the top channel (CT), the mounting portion (202b) being configured for mounting of a side door top sealing member;
a tubular section (202c) disposed towards the interior of the vehicle; and
a flat section (202a) disposed towards the exterior of the vehicle.

5. The sash frame (200) as claimed in claim 1, wherein the front frame member (208) comprises of:

a mounting portion (208b) disposed opposite to the front channel (CF), the mounting portion (208b) being configured for mounting of a side door front sealing member;
a tubular section (208c) disposed towards the interior of the vehicle; and
a flat section (208a) disposed towards the exterior of the vehicle.

6. The sash frame (200) as claimed in claim 1, wherein a top front edge (204c) of the rear frame member (204) and the rear end (202d) of the top frame member (202) are having matching cross-sectional profiles configured to be welded with each other.

7. The sash frame (200) as claimed in claim 4 and 6, wherein the inner panel (204a) has a bulged section (204d) adjacent the top front edge (204c), the bulged section (204d) and the tubular section (202c) of the top frame member (202) having a minimum width (W) of 18 mm.

8. The sash frame (200) as claimed in claim 6, wherein the top front edge (204c) has an angle (?) in the range of 35° to 45° with respect to the horizontal and the rear end (202d) of the top frame member (202) has a corresponding angle to the horizontal as the top front edge (204c).

9. The sash frame (200) as claimed in claim 1, wherein the outer panel (204b) has one or more mounting provisions for the scoop handle (210).

10. The sash frame (200) as claimed in claim 1, wherein the inner panel (204a) has mounting provisions for door seal members (504).