Description:
FORM 2
THE PATENTS ACT 1970
39 OF 1970
&
THE PATENT RULES 2003
COMPLETE SPECIFICATION
(SEE SECTIONS 10 & RULE 13)
1. TITLE OF THE INVENTION

A DOOR ASSEMBLY OF A VEHICLE FOR GLASS RUN SUPPORT
2. APPLICANT (S)
NAME NATIONALITY ADDRESS

MARUTI SUZUKI INDIA LIMITED

Indian
Maruti Suzuki India Limited
1, Nelson Mandela Road, Vasant Kunj,
New Delhi - 110070
India
3. PREAMBLE TO THE DESCRIPTION

COMPLETE SPECIFICATION

The following specification particularly describes the invention and the manner in which it is to be performed.

A DOOR ASSEMBLY OF A VEHICLE FOR GLASS RUN SUPPORT

FIELD OF DISCLOSURE

[001] 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 that offers a continuous glass support throughout the sash span when the glass reached the top dead center (TDC) position to resolve problems related to glass run sagging and waviness.

BACKGROUND
[002] 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.
[003] 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 an interior of the car and the inner workings of the door, and also between vehicle occupants and the door as well. They are expected to meet a variety of design specifications regarding safety, aesthetics, and functionality.
[004] Generally, the doors are of two types, the panel type doors and the sash type doors. In the panel type doors, the whole panel is made in a single die by forming. However, in the sash type doors, sash area is made by roll forming and a 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 a sash area (106), and the lower section is called as a lower door panel (108), wherein the sash area (106) is extending above the lower door panel (108).
[005] 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, the TDC (114) 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.
[006] In the existing conventional configuration of the door, there are problems related to part inaccuracy which leads to bulging of a glass run (116) in the local area.
[007] 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.
[008] Referring FIGs. 1 and 2A-2C, that illustrates the conventional configuration of the door along with detailed sectional view of sections ‘A-A’ (as shown in FIG. 2B) and ‘B-B’ (as shown in FIG. 2C), 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 the top dead center (TDC) (114). The glass (112) in the TDC position (114) is only in contact with these two reinforcements (202, 204). Due to 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 the glass run (116) in the local area when viewed from outside.
[009] Referring to FIG. 3A-3B, 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 overall cost of the reinforcement (300) and door increases.
[010] Therefore, it is evident that there is a pressing 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

[011] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[012] It is an object of the present subject matter to overcome the aforementioned and other drawbacks existing in the prior art systems and methods.
[013] It is 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.
[014] 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.
[015] It is yet another object of the present disclosure to provide the reinforcement in the door assembly having enhanced strength and rigidity.
[016] It is still another object of the present disclosure to provide the reinforcement in the door assembly that is cost-effective in nature.
[017] It is even another 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.
[018] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.

SUMMARY OF DISCLOSURE

[019] This summary is provided to introduce concepts related to providing a reinforcement in a panel type door assembly of a vehicle that resolves difficulties faced due 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.
[020] According to an embodiment of the present disclosure, there is provided a door assembly for a vehicle. The door assembly is implemented to support a glass run. The door assembly comprises an outer panel, 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.
[021] In an aspect, the reinforcement member comprises a first vertical end, a second vertical end situated opposite to the first vertical end, a flat surface connecting base of the first vertical end and the second vertical end.
[022] In an aspect, the flat surface is provided with two hat shaped regions positioned at a distance from each other.
[023] In an aspect, two brackets are joined with the two hat shaped regions at bottom, respectively.
[024] In an aspect, each of the two hat shaped regions comprises of two aligned members, respectively, for connecting top surface of the two hat shaped regions with the flat surface.
[025] In an aspect, in the door assembly, the two hat shaped regions are adapted to support the reinforcement member by connecting the reinforcement member with the inner panel.
[026] In an aspect, the two hat shaped regions are having a flat profile at top.
[027] In an aspect, in the door assembly, the two aligned members of the two hat shaped regions, respectively, is provided with upward flanges on both sides.
[028] In an aspect, in the door assembly, each of the two hat shaped regions comprises two or more cut-outs provided on the respective aligned member.
[029] In an aspect, in the door assembly, each of the two brackets of the reinforcement member comprises a hole.
[030] In an aspect, in the door assembly, each of the two hat shaped regions has a step like profile at bottom, wherein the two brackets are welded with the two hat shaped regions at the bottom to provide a flat region.
[031] In an aspect, in the door assembly, the first vertical end and the second vertical end of the reinforcement are configured to be attached with the inner panel.
[032] In an aspect, in the door assembly, the two hat shaped regions of the reinforcement member are configured to be attached with the inner panel through spot welding.
[033] 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.
[034] 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

[035] 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:
[036] FIG. 1 illustrates a perspective view of a door assembly in accordance with a prior art;
[037] FIG. 2A-2C illustrate a cross-sectional view of a door assembly including two reinforcements in accordance with the prior art;
[038] FIG. 3A-3B illustrates a cross-sectional view of a door assembly including a single reinforcement having continuous glass support face in accordance with the prior art;
[039] FIG. 4 illustrates an isometric view of a proposed reinforcement in a door assembly in accordance with an embodiment of the present disclosure;
[040] FIG. 5 illustrates a process to connect the proposed reinforcement member in a door assembly in accordance with an embodiment of the present disclosure; and
[041] FIG. 6 (A-B) depicts a cross-section view of door assembly along with the reinforcement along a section ‘D-D’ and ‘E-E’ in accordance with an embodiment of the present disclosure.
[042] 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

[043] A few aspects of a 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.
[044] In order to overcome the problems associated with the existing reinforcement, the present disclosure proposed a new reinforcement member in a door assembly. FIG. 4 illustrates configuration of the proposed reinforcement member (400) placed in between an outer panel (102) and an inner panel (104) of the door assembly (100) surrounding a sash region (106) in accordance with the present disclosure. It is to be mentioned here in that this type of reinforcement member (400) is suitable for panel type doors of a vehicle.
[045] In an aspect, the reinforcement member (400) is disposed in between a top dead center (114) of the inner panel (104) and the outer panel (102) of the door assembly (100).
[046] In an aspect, the reinforcement member (400) comprises of a first vertical end (402), a second vertical end (404). The second vertical end (404) is situated opposite to the first vertical end (402). Additionally, base of the first vertical end (402) and the second vertical end (404) are connected by a flat surface (406). Herein, the flat surface (406) is provided with two hat shaped regions (408, 410) positioned at a distance from each other.
[047] In an aspect, each end of the hat shaped regions (408, 410) comprises of aligned members (412-A1, 412-A2) and (414-A1, 414-A2), respectively, for connecting with the flat surface (406).
[048] In an aspect, the two aligned members (412-A1, 412-A2) and (414-A1, 414-A2) of the two hat shaped regions (408, 410), respectively, are provided with a plurality of upward flanges on both the sides.
[049] In an aspect, there are provided two brackets (412, 414) that are connected with the two hat shaped regions (408, 410), respectively, at bottom. These two hat shaped regions (408, 410) are having a flat profile at top and are adapted to support the reinforcement member (400) by connecting the reinforcement member (400) with the inner panel (104).
[050] In an aspect, each of the two hat shaped regions (408, 410) has a step like profile at bottom. The two brackets (412, 414) are welded with the two hat shaped regions (408, 410) at the bottom to provide a flat region. The resulting flat region provides a continuous support to the glass run (116) when the glass moves to TDC (114). This continuous support for the glass run (116) helps in preventing movement of the glass run (116) which in turn resolves the glass run waviness issues as discussed in the previous sections.
[051] In an aspect, each of the two hat shaped regions (408, 410) includes two or more cut-outs (416) provided on the respective aligned member (412-A1, 412-A2) and (414-A1, 414-A2).
[052] FIG. 5 illustrates a process to connect the proposed reinforcement member (400) in a door assembly in accordance with an embodiment of the present disclosure. Herein, the reinforcement member (400) is extending along the vehicle length direction of the inner panel (104) of the door of the vehicle. Moreover, each of the two brackets (412, 414) of the reinforcement member (400) comprises a hole (418). The hole (418) provides weld gun accessibility for welding the two hat shaped regions (408, 410) with the inner panel (104) of the door of the vehicle through spot welding. Furthermore, the first vertical end (402) and the second vertical end (404) of the reinforcement member (400) are used to attach the reinforcement member (400) with the inner panel (104).
[053] FIG. 6(A-B) depict cross-section views of the door assembly 100 along with the reinforcement (400) along a section ‘D-D’ and ‘E-E’ , respectively, in accordance with the present disclosure.
[054] In an aspect, the reinforcement member (400) is extending along length of the vehicle on the top dead center (114) of the inner panel (104) of the vehicle (as shown in FIG. 5). Herein, 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). Further, the structure of the reinforcement member (400) is so designed that the two hat shaped regions (408, 410) of the flat surface (406) are also configured to be welded to the inner panel (104). This provides an enhanced rigidity to the entire structure of the reinforcement member (400) along with the two brackets (412, 414).
[055] Additionally, the ‘D-D’ and ‘E-E’ sections, as depicted in FIG. 6A and FIG. 6B, respectively, after assembly following the process discussed with reference to FIG. 4 and FIG. 5, the proposed reinforcement member (400) helps in providing a continuous glass support throughout the span of the sash region when the glass is reached at the top dead center (114) that further helps in resolving the glass run sagging and glass waviness problem without increasing overall cost. In addition, the reinforcement member (400) provides a continuous glass support along the span of the sash region without changing the panel section.

Exemplary Implementations and/or Embodiments

[056] 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.
[057] Through the above proposed configuration of the reinforcement, the problem related to glass run sagging and waviness is solved without increment in the cost.

Advantages

All in all, the proposed reinforcement in the door assembly s having the following advantages:
i) Issues related to glass sagging and waviness is resolved unlike the existing arrangement
ii) Continuous glass support is achieved when the glass reaches the top dead center position
iii) The two brackets being flat in shape, helps in maintaining surface of the reinforcement member flat in nature
iv) The two brackets, being flat in shape, also helps in providing flexibility to change design of the reinforcement member as required, for enhanced of rigidity and robustness of the overall structure
v) The proposed structure helps in providing an enhanced rigidity
vi) The proposed structure reduces bending of the reinforcement under loaded condition
vii) The proposed reinforcement in the door assembly makes the overall arrangement cost effective
Equivalents
[058] 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.
[059] 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.
[060] 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.
[061] 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 to support a glass run (116), 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) situated opposite to the first vertical end (402);
a flat surface (406) connecting base of the first vertical end (402) and the second vertical end (404) with the flat surface (406) provided with two hat shaped regions (408, 410) positioned at a distance from each other; and
two brackets (412, 414) joined with the two hat shaped regions (408, 410) at bottom, respectively.

2. The door assembly (100) as claimed in claim 1, wherein each of the two hat shaped regions (408, 410) comprises of two aligned members (412-A1, 412-A2) and (414-A1, 414-A2), respectively, for connecting top surface of the two hat shaped regions (408, 410) with the flat surface (406).

3. The door assembly (100) as claimed in claim 1, wherein the two hat shaped regions (408, 410) are having a flat profile at top.

4. The door assembly (100) as claimed in claim 1, wherein the two hat shaped regions (408, 410) are adapted to support the reinforcement member (400) by connecting the reinforcement member (400) with the inner panel (104).

5. The door assembly (100) as claimed in claim 2, wherein the two aligned members (412-A1, 412-A2) and (414-A1, 414-A2) of the two hat shaped regions (408, 410), respectively, are provided with upward flanges on both sides.

6. The door assembly (100) as claimed in claim 1, wherein each of the two hat shaped regions (408, 410) comprises two or more cut-outs (416) provided on the respective aligned members (412-A1, 412-A2, 414-A1, 414-A2).

7. The door assembly (100) as claimed in claim 1, wherein each of the two brackets (412, 414) of the reinforcement member (400) comprises a hole (418).

8. The door assembly (100) as claimed in claim 1, wherein each of the two hat shaped regions (408, 410) has a step like profile at bottom, wherein the two brackets (412, 414) are welded with the two hat shaped regions (408, 410) at the bottom to provide a flat region.

9. The door assembly (100) as claimed in claim 1, wherein 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).

10. The door assembly (100) as claimed in claim 1, wherein the two hat shaped regions (408, 410) of the reinforcement member (400) are configured to be attached with the inner panel (104) through spot welding.
Dated this 19th day of July, 2022

AMIT JAIN
PATENT AGENT
IN/PA – 2189
OF L. S. DAVAR & CO.