Description:A DOOR ASSEMBLY IN A PANEL TYPE DOOR FOR A VEHICLE

FIELD OF DISCLOSURE

[0001] The present disclosure in general relates to the field of door panels of an automotive vehicles. In particular, the present disclosure relates to door assembly of a panel type door that offers a continuous glass support throughout the sash span when the glass reached the top dead center (TDC) position to resolve the problems related to glass run sagging and waviness efficiently.

BACKGROUND
[0002] Automotive industry in India is one of the main pillars of the economy. With strong backward and forward linkages, it is a key driver of growth. In addition, automotive industry has always been known to be very competitive as far as its design and material usage are concerned. Therefore, the automotive industry is always facing greater market pressure to develop high quality products more quickly with different variants of a particular vehicle model in order to cater different segments of end users.
[0003] Nowadays, doors of the automotive vehicle are of major concern as the doors are expected to meet one of the toughest sets of requirements among interior car components. In general, doors serve as an interface between the interior of the car and the inner workings of the door, and between vehicle occupants and the door. They are expected to meet a variety of design specifications regarding safety, aesthetics, and functionality.
[0004] Generally, the doors are of two types, the panel type doors and the sash type doors. In panel type doors, the whole panel is made in a single die by forming. However, in sash type door, sash area is made by roll forming and lower panel area is made by forming. The sash and the lower panel area is then joined by welding. The present disclosure is related to the panel type doors. Referring FIGs. 1 and 2, a vehicle door assembly 100 as a whole includes an outer panel 102 and inner panel 104 adapted to be joined together to form the vehicle door. Further, the vehicle door assembly 100 has two sections, the upper section is called as sash area 106, and the lower section is called as lower door panel 108, wherein the sash area 106 is extending above the lower door panel 108.
[0005] In addition, the sash area 106 defines a space in which the glass 112 can move up to a top dead center (TDC) 114. In other words, TDC is the upper position of the glass where it stops. A reinforcement member is generally disposed in the inner panel 104, for providing a support to the glass 112 in the sash region.
[0006] In the existing conventional configuration of the door, there are problems related to part inaccuracy which leads to bulging of the glass run 116 in the local area.
[0007] In order to overcome the problem, different state of arts related to this field of technology has proposed several types of conventional configuration of the door.
[0008] Referring FIGs. 1 and 2A-2C, that illustrates the conventional configuration of the door along with detailed sectional view of sections ‘A-A’ and ‘B-B’, a door assembly 100 comprising two small reinforcements 202,204 that are welded on the door inner panel 104 to stop the glass 112 at top dead center (TDC) 114. The glass 112 in its TDC position 114 is only in contact with these two reinforcements 202,204. Due to the inaccuracies in placement of these two reinforcements 202, 204, the glass 112 contact surface of one of the reinforcements comes down. This pushes the glass run 116 down which in turn leads to the sagging problem of glass run 116 in the local area when viewed from outside.
[0009] Referring to FIG. 3, in another proposed conventional configuration of the door, a single reinforcement 300 having continuous glass support face along the sash span is welded on to the door inner panel 104 to stop the glass 112 at top dead center 114. The glass 112 at the TDC position 114 is in contact with the reinforcement 300 throughout the sash span. This reinforcement configuration 300 is such that it is welded into the inner panel 104 in the top near the hemming edge. Due to the L-shaped structure of the reinforcement, the reinforcement requires larger space in between the inner panel and the outer panel. This leads to increment in the overall section width of the inner panel 104 and the outer panel 102. Hence the overall cost of the reinforcement 300 and door increases.
[0010] Hence, there is an immense need to develop a reinforcement in the door assembly that overcomes the disadvantages associated with the existing reinforcements incorporated in the doors.

OBJECTS OF DISCLOSURE

[0011] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0012] A general or primary object of the present disclosure is to provide a reinforcement in a door assembly that resolves the glass run sagging and waviness problem.
[0013] It is another object of the present disclosure to provide the reinforcement in the door assembly that offers a continuous glass support throughout the sash span when the glass reached the top dead center (TDC) position.
[0014] It is yet another object of the present disclosure to provide the reinforcement in the door assembly having enhanced strength and rigidity.
[0015] It is further object of the present disclosure to provide the reinforcement in the door assembly that is cost-effective in nature.
[0016] It is yet further object of the present disclosure to provide the reinforcement in the door assembly that provides rigidity when welded to the inner panel and eliminates the chances of bending of the reinforcement when load is applied by the glass at the TDC position.
[0017] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.

SUMMARY OF DISCLOSURE
[0018] This summary is provided to introduce concepts related to providing is to provide a reinforcement member in a door assembly that resolves the problem related to glass run sagging and waviness. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0019] In accordance with an embodiment, the present disclosure provides a door assembly for a vehicle, the door assembly comprising an outer panel, and an inner panel surrounding a sash region, and a reinforcement member disposed in between a top dead center of the inner panel and the outer panel. Further, the reinforcement member comprises a first vertical end, and a second vertical end opposite to the first vertical end, a flat surface connecting the base of the first vertical end and the second vertical end, and two brackets joined with the flat surface.
[0020] In accordance with an aspect, the brackets are fixed at two ends of the reinforcement member.
[0021] In accordance with an aspect, the brackets are of z-shaped structure.
[0022] In accordance with an aspect, one of the two brackets comprises a horizontal member, a first end joined with the first vertical end of the reinforcement member, a second end fixed with the flat surface of the reinforcement member, and an aligned member in an inclined position joining the horizontal member and the second end of the bracket.
[0023] In accordance with an aspect, another of the two brackets comprises a horizontal member, a first end joined with the second vertical end of the reinforcement member, a second end fixed with the flat surface of the reinforcement member, and an aligned member in an inclined position joining the horizontal member and the second end of the bracket.
[0024] In accordance with an aspect, the reinforcement member is extending along the vehicle length direction on the top dead center of the inner panel of the vehicle.
[0025] In accordance with an aspect, the first vertical end and the second vertical end of the reinforcement member are configured to be attached with the inner panel.
[0026] In accordance with an aspect, a strengthen bead structure is provided at the entire surface of the horizontal members of the brackets.
[0027] In accordance with an aspect, the brackets form a closed box section with the flat surface.
[0028] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.
[0029] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF DRAWINGS
[0030] The illustrated embodiments of the present disclosure will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the subject matter as claimed herein, wherein:
[0031] FIG.1 illustrates a perspective view of a door assembly in accordance with a prior art;
[0032] FIG.2A-2C illustrate a cross-sectional view of a door assembly including two reinforcements in accordance with the prior art;
[0033] FIG.3 illustrates a cross-sectional view of a door assembly including a single reinforcement having continuous glass support face in accordance with the prior art;
[0034] FIG.4 illustrates an isometric view of a proposed reinforcement in a door assembly in accordance with the present disclosure;
[0035] FIG.5 depicts the installation of the reinforcement on the inner door panel in accordance with the present disclosure;
[0036] FIG.6A depicts the cross-section view of door assembly along with the reinforcement along the section D-D of fig. 5 in accordance with the present disclosure;
[0037] FIG.6B depicts the cross-section view of door assembly along with the reinforcement along the section E-E of fig. 5 in accordance with the present disclosure; and
[0038] FIG.6C depicts the cross-section view of door assembly along with the reinforcement along the section F-F of fig. 5 in accordance with the present disclosure.
[0039] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the assembly as illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF DISCLOSURE
[0040] A few aspects of the present disclosure are explained in detail below with reference to the various figures. Example implementations 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.
[0041] In order to overcome the problems associated with the existing reinforcement, the present disclosure proposed a new reinforcement in the door assembly. FIG.4 illustrates the configuration of the proposed reinforcement 400 placed in between the outer panel 102 and the inner panel 104 of the door assembly 100 surrounding a sash region 106 in accordance with the present disclosure. In addition, the reinforcement member 400 is disposed in between a top dead center 114 of the inner panel 104 and the outer panel 102. The reinforcement member 400 comprises a first vertical end 402, and a second vertical end 404 placed opposite to the first vertical end 402. A flat surface 406 is provided that connects the base of the first vertical end 402 and the second vertical end 404.
[0042] In embodiment of the present disclosure, the reinforcement member 400 further comprises two brackets 408, 410 that are positioned at two ends of the reinforcement member. These two brackets 408,410 are disposed on the flat surface 406 at two ends 402, 404 of the reinforcement member 400 by spot-welding. These two brackets 408,410 are used to increase rigidity of the reinforcement member 400 by forming a closed box section with the flat surface 406. These two brackets 408, 410 are of z-shaped structure that are positioned at two ends of the reinforcement member 400. In addition, each of the two brackets 408,410 comprises some configuration described hereinbelow.
[0043] Here, the configuration of the one bracket 408 is described such that it consists of a horizontal member 408-H, a first end 408-F joined with the first vertical end 402 of the reinforcement member 400, a second end 408-S fixed with the flat surface 406 of the reinforcement member 400, and an aligned member 408-A in an inclined position joining the horizontal member 408-H and the second end 408-S of the bracket 408.
[0044] In addition to this, the configuration of the another bracket 410 is described in such a manner that it includes a horizontal member 410-H, a first end 410-F joined with the second vertical end 404 of the reinforcement member 400. Further, the bracket 410 includes a second end 410-S fixed with the flat surface 406 of the reinforcement member 400, and an aligned member 410-A in an inclined position joining the horizontal member 410-H and the second end 410-S of the bracket 410.
[0045] In an embodiment of the present disclosure, the reinforcement member 400 is extending along the vehicle length direction on the top dead center 114 of the inner panel 104 of the vehicle.
[0046] In an embodiment of the present disclosure, the first vertical end 402 and the second vertical end 404 of the reinforcement 400 are configured to be attached with the inner panel 104.
[0047] In an embodiment of the present disclosure, wherein a strengthen bead structure is provided at the entire surface of horizontal members 408H, 410H of the brackets 408, 410.
[0048] Here, the configuration of the bracket 408 and the bracket 410 is similar to each other.
[0049] Moreover, the flat surface 406 is extending throughout the sash span and the two brackets 408, 410 welded at the two ends 402, 404 of the reinforcement member 400.
[0050] FIG.5 depicts the installation of reinforcement 400 on the inner door panel 104 in accordance with the present disclosure. As mentioned, the reinforcement member 400 is extending along the vehicle length direction of the inner panel 104 of the vehicle. The reinforcement member 400 further comprises first vertical end 402 and the second vertical end 404 that are used to attach the reinforcement member 400 with the inner panel 104.
[0051] FIG.6A depicts the cross-section view of the door assembly 100 along with the reinforcement 400 along the section D-D in accordance with the present disclosure.
[0052] FIG.6B depicts the cross-section view of door assembly 100 along with the reinforcement 400 along the section E-E in accordance with the present disclosure.
[0053] FIG.6C depicts the cross-section view of door assembly 100 along with the reinforcement 400 along the section F-F in accordance with the present disclosure.
[0054] In embodiment of the present disclosure, the reinforcement member 400 is welded with the brackets 408 and 410 at the supplier end creating two box sections at the two ends 402, 404 of the reinforcement member 400. The reinforcement member 400 is then welded onto the inner panel 104 with the help of two spots at the two ends 402, 404.
[0055] In embodiment of the present disclosure, the two brackets form a closed box section with the flat surface of the reinforcement member which provides the rigidity when welded on the inner panel and thus eliminates the bending of the reinforcement member when load is applied by the glass at the TDC.
[0056] The door assembly having the proposed reinforcement member helps in providing a continuous glass support throughout the span of the sash region when the glass is reached at the top dead center that further helps in resolving the glass run sagging and glass waviness problem without increasing the overall cost. In addition, the reinforcement member provides a continuous glass support along the span of the sash region without changing the panel section.

EXEMPLARY IMPLEMENTATIONS AND/OR EMBODIMENTS
[0057] While the present disclosure may be embodied in various forms, there are shown in the drawings, and will hereinafter be described, some exemplary and non-limiting embodiments, with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. Not all of the depicted components described in this disclosure may be required, however, and some implementations may include additional, different, or fewer components from those expressly described in this disclosure. Variations in the arrangement and type of the components may be made without departing from the scope of the claims as set forth herein.
[0058] Through the above proposed configuration of the reinforcement, the problem related to glass run sagging and waviness is solved without increment in the cost.

TECHNICAL ADVANTAGES
[0059] Due to the proposed reinforcement in a door assembly the problem of glass run sagging and waviness is solved. The enhanced features are explained hereinbelow:
[0060] It also offers a continuous glass support throughout the sash span when the glass reached the top dead center (TDC) position.
[0061] It also eliminates the problem of glass run sagging and waviness problem without increasing the overall cost.
[0062] It further enhances strength and rigidity due to configuration of two brackets positioned at two ends of the reinforcement member.
[0063] Due to this rigidity, when the reinforcement member is welded on the inner panel, the bending of the reinforcement member when load is applied by the glass at TDC is fully eliminated.
[0064] It is also simple in configuration and cost-effective in nature.
[0065] It eliminates the glass waviness problem when the door glass is viewed from outside by the user.

EQUIVALENTS
[0066] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0067] Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0068] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[0069] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
, Claims:We Claim:
1. A door assembly (100) for a vehicle, the door assembly (100) comprising:
an outer panel (102);
an inner panel (104) surrounding a sash region (106); and
a reinforcement member (400) disposed in between a top dead center (114) of the inner panel (104) and the outer panel (102), wherein the reinforcement member (400) comprises:
a first vertical end (402);
a second vertical end (404) opposite to the first vertical end (402);
a flat surface (406) connecting the base of the first vertical end (402) and the second vertical end (404); and
two brackets (408, 410) joined with the flat surface (406),
wherein one (408) of the brackets (408,410) is positioned at the first vertical end (402) and another (410) of the brackets (408,410) is positioned at the second vertical end (404) of the reinforcement member (400).
2. The door assembly (100) as claimed in claim 1, wherein the brackets (408,410) are of z-shaped structure.
3. The door assembly (100) as claimed in claim 1, wherein the bracket (408) comprising:
a horizontal member (408-H);
a first end (408-F) joined with the first vertical end (402) of the reinforcement member (400);
a second end (408-S) fixed with the flat surface (406) of the reinforcement member (400); and
an aligned member (408-A) in an inclined position joining the horizontal member (408-H) and the second end (408-S) of the bracket (408).

4. The door assembly (100) as claimed in claim 1, wherein the bracket (410) comprises:
a horizontal member (410-H);
a first end (410-F) joined with the second vertical end (404) of the reinforcement member (400);
a second end (410-S) fixed with the flat surface (406) of the reinforcement member (400); and
an aligned member (410-A) in an inclined position joining the horizontal member 410-H and the second end (410-S) of the bracket (410).
5. The door assembly (100) as claimed in claim 1, wherein the reinforcement member (400) is extending along the vehicle length direction on the top dead center (114) of the inner panel (104) of the vehicle.
6. The door assembly (100) as claimed in claim 1, wherein the first vertical end (402) and the second vertical end (404) of the reinforcement member (400) are configured to be attached with the inner panel (104).
7. The door assembly (100) as claimed in claim 3, wherein a strengthen bead structure is provided at the entire surface of the horizontal member (408H) of the bracket (408).
8. The door assembly (100) as claimed in claim 4, wherein a strengthen bead structure is provided at the entire surface of the horizontal member (410H) of the bracket (410).

9. The door assembly (100) as claimed in claim 1, wherein each of the brackets (408, 410) form a closed box section with the flat surface (406).