[0001] The present disclosure, in general, relates to vehicle side door structure and, more particularly, to reinforcing outside area around outer handle mounted on the vehicle side door.
BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Generally, vehicle side door consists an inner panel and an outer panel that combines with each other to form a box shaped side door. Further, a door opening handle is mounted on the outer panel. The vehicle side door has an opening at upper side for window glass.
[0004] As shown in figure 1, the vehicle side door 100 comprises an inner panel 101 and an outer panel 102. The inner panel 101 and the outer panel 102 joins with each other to form the vehicle side door structure 100. Further, a reinforcement member 103 is disposed between the inner wall and the outer wall. The reinforcement member 103 extends along vehicle length direction to provide support to the vehicle side door during side crash and to avoid thumb impressions.
[0005] Technical problem: To open the door, while operating the Flap type outside handle, user operates the handle by supporting his thumb on the outer panel. Because of his thumb load, there are high chances of thumb impression on the outer panel and as a result of which, permanent dent is formed on the outer panel.

[0006] In the existing solutions for the above technical problem, a longitudinal reinforcement is provided in between the inner panel and the outer panel along vehicle length direction on complete length of the side door. The reinforcement member is spot welded on the inner panel and coupled to the outer panel through a mastic sealant that is provided along vehicle length. The mastic sealant along with the reinforcement member provide strength and stiffness to the outer panel to avoid any impression, such as thumb impression during pulling of door handle.
[0007] As shown in figure 1, the existing solutions uses big size of reinforcement in the side door to avoid permanent dent around handle area of the flap type outer handle. The big size reinforcement bracket is used because there is no other space for spot welding of the reinforcement on the side door except inner panel. If the reinforcement is spot welded on the outer panel, it creates impression of spot welding which is not acceptable for aesthetic point of view.
[0008] Another disadvantage associated with existing solution is the cost of mastic sealer. The mastic sealer is provided along the length of the reinforcement which ultimately increases cost.
[0009] The existing reinforcement is big in size that increases cost and weight of the vehicle. With the increase in cost, there are other impacts, such as fuel efficiency on the vehicle.
[0010] The reinforcement is provided along the length of the side door which creates layout problem with the glass and window regulator. With the reinforcement in the side door, big size glass is required to maintain the clearance between the glass holder and reinforcement.
[0011] Accordingly, there is a need in the state of the art to provide a structure that uses small size of reinforcement on the outer panel of the side door.

OBJECTS OF THE DISCLOSURE
[0012] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed hereinbelow.
[0013] The principal object of the present invention is to provide a side door structure of vehicle with small size reinforcement.
[0014] Another object of the present invention is to provide a reinforcement on the outer panel.
[0015] Another object of the present invention is to provide a reinforcement on inner surface of handle area on outer panel.
[0016] Another object of the present invention is to spot weld the reinforcement on the outer panel in handle area without disturbing aesthetic appearance of the outer panel.
[0017] Another object of the present invention is locally strengthen the outer panel around the handle area to avoid thumb impression.
[0018] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.
SUMMARY
[0019] This summary is provided to introduce concepts related to a vehicle side door structure with reinforcement to avoid thumb impression on outer panel of the side door structure. 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.
[0020] In an embodiment, the present disclosure relates to a vehicle side door structure with reinforcement around handle area to provide local stiffness. The vehicle side door structure includes an inner panel and an outer panel that is

joined with the inner panel to form the vehicle side door structure. The outer panel comprises a handle area to accommodate a handle, specifically Flap type handle to open the side door. The vehicle side door further includes a reinforcement bracket that is provided at upper end and around the handle area from the inner surface to reinforce the outer panel around the handle area. The reinforcement is spot welded on the outer panel of the vehicle side door.
[0021] In an aspect, the reinforcement bracket comprises a first surface and a second surface. The second surface is connected with the first surface through a vertical wall with predefine angle of inclination. The inclination angle or depression of the reinforcement bracket corresponds to protruded inner surface of the handle area. The second surface engages with inner surface of the handle area and the first surface engages with the inner surface of the outer panel at upper side from the handle area.
[0022] Further, the first surface has at least two longitudinal beads in vehicle length direction (X) and a vertical bead in between the two longitudinal beads in vehicle height direction (Y).
[0023] Furthermore, the second surface has a vertical bead in vehicle height direction (Y) at center.
[0024] In an aspect, the vertical bead of the second surface is continuation with a vertical bead of the first surface to allow flow of ED coating and water.
[0025] In an aspect, the second surface comprises a plurality of mounting holes for mounting the outer handle and a plurality of welding spots for spot welding the second surface with the handle area, and a slot for outer handle movement.
[0026] In an aspect, the reinforcement is spot welded on the outer panel, specifically on the protruded portion of the handle area. On the outer side the spot welding points are covered by the flab of the handle.

[0027] 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.
5 BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The illustrated embodiments of the subject matter 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, 10 and methods that are consistent with the subject matter as claimed herein, wherein:
[0029] Fig. 1 illustrates side door structure with reinforcement conventional side door structure;
[0030] Fig. 2, 3, and 4 illustrate structure of reinforcement bracket to be 15 mounted on outer panel of the side door, in accordance with an embodiment of the present disclosure;
[0031] Fig. 5 illustrates assembly of the reinforcement on inner surface of the outer panel, in accordance with an embodiment of the present disclosure;
[0032] Fig. 6 illustrates assembled view of Fig. 5, in accordance with an 20 embodiment of the present disclosure;
[0033] Fig. 7a illustrates assembled view of side door with flap type handle, in accordance with an embodiment of the present disclosure; and
[0034] Fig. 7b and 7c illustrate cross section view along AA of Fig 7a, in accordance with an embodiment of the present disclosure.
25 [0035] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from
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the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein
DETAILED DESCRIPTION
5 [0036] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the
10 contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0037] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of 15 the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0038] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As
20 used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence
25 or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
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[0039] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts 5 involved.
[0040] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should 10 be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0041] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be 15 noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0042] In the subsequent figures arrow X indicates vehicle length direction, 20 arrow Y indicates vehicle height direction, and arrow Z indicates vehicle inner direction from outside.
[0043] As explained above sections, major challenge in front of the inventors is to mount the reinforcement on the outer panel of the vehicle. If reinforcement is directly mounted on the outer panel, it creates spot issues which are clearly visible 25 from outer side on the outer panel. Another major challenge is to provide local stiffness around the handle area to avoid thumb impression on the outer panel. Yet
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another challenge is to minimize the size of the reinforcement so that there is less requirement of sealer.
[0044] First referring figures 5 and 6 to illustrate position of mounting of reinforcement on outer panel. The vehicle side door structure 500 includes an
5 inner panel 501 and an outer panel 502 that is joined with the inner panel 501 to form the vehicle side door structure 500. The outer panel 502 having an inner surface 502a and an outer surface 502b. The inner surface 502a faces the inner panel and the outer surface 502b is visible from outside and creates aesthetic appearance of the vehicle side door. The inner panel 501 and the outer panel 502
10 extend in longitudinal direction X and in vertical direction Y to form the vehicle side door structure 500. The outer panel 502 comprises a handle area 504 to accommodate a handle 504b (referring to Fig. 7a) from the outer surface 502b. The handle 504b may be flap type handle. In vehicle height direction, the handle area 504 may be provided in middle of the vehicle side door structure 500 near B
15 pillar or C pillar. The handle area 504 is depressed toward the inner panel 501 from outer surface 502b. Accordingly, the handle area 504 has protruded inner surface 504a at inner side 502a (inner surface) of the outer panel 502. On outer surface 502b of the outer panel 502, the handle 504b is mounted to latch and unlatch door striker to open the vehicle side door.
20 [0045] In an aspect, a reinforcement bracket 503 is provided only at upper end and around the handle area 504 from the inner surface 502a to reinforce the outer panel 502 locally around the handle area 504. The reinforcement bracket 503 is provided locally around the handle area and spot welded on the handle area 504 of the outer panel. Further, the spot-welding points of the reinforcement bracket 503
25 on the outer panel 502 are hidden by the handle 504b. By this way, the reinforcement bracket is spot welded on the outer panel.
[0046] Returning to figure 2, 3, and 4 that illustrates structure of the reinforcement bracket, in accordance with an embodiment of the present subject
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matter. The reinforcement bracket 200 comprises a first surface 201 and a second surface 202 that is connected with the first surface 201 through a vertical wall 202a with predefined inclination angle. The second surface 202 engages with protruded inner surface 504a of the handle area 504. On the other hand, the first 5 surface 201 engages with the inner surface 502a of the outer panel 502 at upper side from the handle area 504 where there is high possibility of thumb impression.
[0047] In an embodiment, the inclination angle of the vertical wall 202a corresponds to the protruded inner surface 504a of the handle area 504. Further, profile of the second surface 202 of the reinforcement bracket 200 10 corresponds/depends on the protruded inner surface 504a of the handle area 504.
[0048] The first surface 201 includes at least two longitudinal beads 203 in vehicle length direction X. Further, the atleast two longitudinal beads 203 are separated by a vertical bead 204 provided at center in vehicle height direction Y.
[0049] The second surface 202 includes a vertical bead 205 in vehicle height 15 direction Y at center. The vertical bead 205 is continuation with the vertical bead 204 of the first surface 201 to allow flow of ED coating and water to avoid rusting of the reinforcement bracket 200. The second surface 202 further comprise a plurality of mounting holes 207 for mounting the outer handle 504b and a plurality of welding spots 208 for spot welding the second surface 202 with the 20 handle area 504. Further, a slot 206 is provided on the second surface 202 to allow movement of the outer handle 504b. The flap of the outer handle 504b hides the spot welding points on the outer panel therefore, it does not create any aesthetic issue while achieving spot welding of the reinforcement bracket on the outer panel 502.
25 [0050] Referring to figure 7a, 7b, and 7c illustrating cross section view along line AA and flow of ED coating and water in the assembled reinforcement on the outer panel. Fig. 7a illustrates out side view of the outer panel of the side door
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having handle in the handle area. Fig. 7b illustrates cross section view along line AA of fig. 7A. As shown in the figure 7b, mastic sealant 505 is provided in between the atleast two longitudinal beads 203 of the first surface 201 and the inner surface 502a of the outer panel 502. The mastic sealant 505 provides 5 strength to the outer panel 502 in local area to avoid thumb impression. Accordingly, requirement of long reinforcement member has been eliminated on the side door structure by provide local stiffness around the handle area to avoid thumb impressions or dent on the outer panel.
[0051] As shown in figure 7b, the reinforcement bracket 503 is spot welded 10 on the outer panel 502 specifically on the handle area 504. Further, the welding points are covered by the flap of the handle 504b so these welding points are not visible from outside. In this way, the present mounting maintains aesthetic appearance while solving a technical problem.
[0052] As shown in the figure 7c, the reinforcement bracket 503, 200 has 15 continue vertical bead structure 204, 205 that allow movement of water and ED coating. Therefore, present reinforcement bracket structure with mounting on local area around handle area solves all existing technical problems.
[0053] Thus, with the vehicle side door structure 500 proposed in the present disclosure, the reinforcement bracket 200 provide stiffness locally around the 20 handle area to avoid thumb dent on the outer panel.
[0054] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or 25 inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without
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more constraints, preclude the existence of other elements or additional elements in the system or device.
[0055] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended
5 claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such
10 an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation
15 by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds
20 true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or
25 two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include
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but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having
5 skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative
10 terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0056] It will be further appreciated that functions or structures of a plurality
15 of components or steps may be combined into a single component or step, or the
functions or structures of one-step or component may be split among plural steps
or components. The present invention contemplates all of these combinations.
Unless stated otherwise, dimensions and geometries of the various structures
depicted herein are not intended to be restrictive of the invention, and other
20 dimensions or geometries are possible. In addition, while a feature of the present
invention may have been described in the context of only one of the illustrated
embodiments, such feature may be combined with one or more other features of
other embodiments, for any given application. It will also be appreciated from the
above that the fabrication of the unique structures herein and the operation thereof
25 also constitute methods in accordance with the present invention. The present
invention also encompasses intermediate and end products resulting from the
practice of the methods herein. The use of “comprising” or “including” also
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contemplates embodiments that "consist essentially of or "consist of the recited feature.
[0057] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

We claim:

A vehicle side door structure (500) comprising:
an inner panel (501);
an outer panel (502) joined with the inner panel (500) to form the vehicle side door structure (500), the outer panel (502) having an inner surface (502a) and an outer surface (502b), the outer panel (502) comprising:
a handle area (504) to accommodate a handle (504b) from the outer surface (502b); and
characterized in that
a reinforcement bracket (503, 200) provided at upper end and around the handle area (504) from the inner surface (502a) to reinforce the outer panel (502) around the handle area (504).
The vehicle side door structure (500) as claimed in claim 1, wherein the reinforcement bracket (503, 200) comprising:
a first surface (201); and
a second surface (202) connected with the first surface (201) through a vertical wall (202a) with predefined inclination angle, the second surface (202) engages with inner surface (504a) of the handle area (504),
wherein the first surface (201) engages with the inner surface (502a) of the outer panel (502) at upper side from the handle area (504).
The vehicle side door structure (500) as claimed in claim 2, wherein the first surface (201) has at least two longitudinal beads (203) in vehicle length direction (X), wherein the atleast two longitudinal beads (203) separated by a vertical bead (204) provided at center in vehicle height direction (Y).

The vehicle side door structure (500) as claimed in claim 2, wherein the second surface (202) has a vertical bead (205) in vehicle height direction (Y) at center, the vertical bead (205) is continuation with a vertical bead (204) of the first surface (201) to allow flow of ED coating and water.
The vehicle side door structure (500) as claimed in claim 3, wherein mastic sealant (505) provided in between the atleast two longitudinal beads (203) of the first surface (201) and the inner surface (502a) of the outer panel (502).
The vehicle side door structure (500) as claimed in claim 2, wherein the inclination angle of the vertical wall (202a) corresponds to the inner surface (504a) of the handle area (504).
The vehicle side door structure (500) as claimed in claim 2, wherein the second surface (202) of the reinforcement bracket (200) corresponds to the inner protruded surface (504a) of the handle area (504).
The vehicle side door structure (500) as claimed in claim 2, wherein the second surface (202) comprises:
a plurality of mounting holes (207) for mounting the outer handle;
a plurality of welding spots (208) for spot welding the second surface (202) with the handle area (504); and
a slot (206) for outer handle movement.
The vehicle side door structure (500) as claimed in claim 8, wherein the plurality of welding spots (208) hidden behind flap of the handle (504b).