Vehicle door and methods for its manufacture

Abstract

The invention relates to a method for manufacturing a vehicle door (100), comprising the steps a. providing a carrier part (102) and equipping the carrier part (102) with at least one installation part (104), b. providing a door panel (112) and at least partially covering the carrier part (102) by means of the door panel (112) to form a door panel assembly (118), c. attaching a primary seal (106) to the door panel assembly (118), d. providing a door blank (110) and joining the primary seal (106) to the door blank (110), thereby at least pre-fixing the door panel assembly (118) formed with the carrier part (102), and e. providing and attaching at least one door panel element (120) to the door panel assembly (118) connected to the door blank (110). The invention also relates to a vehicle door (100).

Description

[0001] The invention relates to a vehicle door and a method for its manufacture.

[0002] WO 2007 / 111 878 A2 discloses a door system which includes a support element that, as its core component, houses some of the components of a vehicle door, such as a window regulator, a lock, a door stay, or even speaker systems. DE 10 2009 040 636 A1 describes a vehicle door system comprising a door frame, a seal, a door panel, and an additional trim panel. The seal is attached to the trim panel and seals against the door frame. DE 10 2004 003 194 A1 also discloses a vehicle door system.

[0003] German patent DE 10 2006 009 701 A1 describes a vehicle door and a method for manufacturing it. This involves a support component that can be fitted with components before being covered with a door panel. The two components are then joined with a door blank.

[0004] The object of the present invention is to provide an improved method for manufacturing a vehicle door and a vehicle door characterized by an increased degree of automation in its manufacture.

[0005] This problem is solved by a method having the features of claim 1 and by a vehicle door having the features of claim 8. Advantageous embodiments with expedient further developments of the invention are specified in the dependent claims.

[0006] The method according to the invention comprises the following steps: a. Providing a carrier part and equipping the carrier part with at least one built-in component, b. Providing a door panel and at least partially covering the support part by means of the door panel to form a door panel assembly, wherein the support part preferably completely covers the support part towards the inside of the passenger cabin, c. Attaching a primary seal to the door panel assembly, d. Providing a door blank and joining the primary seal to the door blank, thereby at least pre-fixing the door trim assembly formed with the support part, and e. Providing and attaching at least one trim element to the door trim assembly connected to the door body.

[0007] This solution makes it possible for all components to be attached to a central support element before it is connected to the door frame.

[0008] The support element is preferably formed as a hollow body and blow-molded in one piece. In a preferred embodiment, however, it is a two-shell hollow body. Preferably, the support element is made of plastic and has a multitude of recesses. These recesses serve to hold or fasten installation components, i.e., the installation parts. If the support element is designed as a hollow body, it can also serve as a sound chamber for a vehicle's sound system. Furthermore, the hollow design of the support element offers the possibility of incorporating reinforcing structures, such as a honeycomb structure within the hollow body of the support element, which increases stability. It is also possible for the support element to be formed with recesses for centering pins (e.g., RPS recesses), and a pocket may also be provided to accommodate, for example, a sturdy steel tube (a so-called "crash tube").Furthermore, the carrier component can be equipped with multiple welding surfaces for additional welding if necessary. The carrier component can also have mounting points for snap connections, such as clip receptacles for clip systems. Additionally, components like a control unit or a window regulator motor can be attached to the carrier component.

[0009] In order to simplify the overall assembly of the vehicle door, it is preferred if, in step a., all door-related installation parts are mounted to or into the carrier part, in particular window regulators, one or more control units, cables or cable harnesses, one or more speakers, one or more crash pads, one or more crash bars, and the like are mounted to or integrated into the carrier part.

[0010] Due to the use of the carrier part, it is advantageously possible that the carrier part can be loaded in step a. both on an inner side facing the driver's cab during normal use and on an outer side facing away from the driver's cab during normal use, preferably robotically. In other words, loading of the carrier part from both sides is possible because it is accessible from both sides.

[0011] Assembly is further simplified by providing a separate door frame trim in step b., and by forming the door panel assembly from the door panel, the door frame trim, and the fitted support component. Using a separate door frame trim from the door panel simplifies handling, especially since the door frame trim can be a delicate component.

[0012] It has proven preferable that, in or during step d. or following step d., the door panel assembly is connected to the door body at at least one position within a crash-relevant area by means of a structurally robust connection, and that the door panel assembly is connected in an area away from the crash-relevant area by a mechanical connection that is weaker than the structurally robust connection. A screw connection, such as a threaded bolt with a nut or a press-fit nut with a screw, is a purely example of a structurally robust connection. A snap connection (e.g., using a clip) is a purely exemplary structurally weaker connection.This ensures increased stiffness in those areas typically subjected to the greatest stress in a side-impact collision, allowing for special occupant protection measures in these areas. Other areas not considered "crash-relevant" in this way can be secured to the door panel assembly with a simple snap-fit ​​connection, such as a clip. For reliable positioning of the door panel assembly, the use of one or more additional centering points (e.g., centering pins, particularly an RPS centering system (RPS for Reference Point Stress)) has proven advantageous.

[0013] Due to the use of the support element, the door panel and frame trim can be designed to be correspondingly slimmer, requiring fewer or reduced stiffeners. The trim itself then acts merely as a kind of cladding for the support element. The door panel and frame trim are preferably designed in two parts to maintain necessary access for assembly. The required stability is then achieved by combining the door panel and frame trim with the support element, meaning that the necessary stability is only present after the components are assembled into the door panel assembly.

[0014] It is further advantageous if a sealing bead surrounding the support element is applied to the support element or to the door frame, which then additionally seals a wet area of ​​the vehicle door against a dry area. Preferably, the sealing bead is attached to the door frame in such a way that it surrounds the support element.

[0015] Typically, a vehicle door also has a window with window regulators, so it is advantageous if at least one window is fitted in step d. or following step d., for which the window is lowered into a window receptacle formed on the door frame until it is automatically locked by a locking device of the door frame.

[0016] The advantages, advantageous designs and effects described above in connection with the inventive method for manufacturing a vehicle door apply in the same way to the vehicle door according to the invention, which is preferably manufactured and / or assembled according to the inventive method.

[0017] The vehicle door comprises a door panel assembly, which includes a support part fitted with at least one component, and a door panel that at least partially covers the support part. The vehicle door also includes a primary seal that is attached circumferentially to the door panel assembly, and a door body component that is joined to the primary seal, thereby at least pre-fixing the door panel assembly formed with the support part. Furthermore, the vehicle door includes at least one door panel element, for example, a fabric panel or other appliqués, which is connected to the door panel assembly connected to the door body component.

[0018] This vehicle door is characterized by the presence of a support structure that already holds many of the door's components, and is therefore only "covered" by the door panel. The primary seal is then attached to the door panel assembly in such a way that it is securely held in place.

[0019] A significant improvement and simplification of the assembly is achieved when all of the door-related installation parts are integrated or mounted to or in the carrier part, including window regulators, one or more control units, cables or cable harnesses, one or more speakers, one or more crash pads, one or more crash bars, or the like, which are integrated or mounted to or in the carrier part.

[0020] Increased stability of the vehicle door with low weight can be achieved by connecting the door panel assembly to the door body at least at one position in a crash-relevant area by means of a screw connection, and by connecting the door panel assembly in an area away from the crash-relevant area by means of at least one snap connection (for example, a clip connection with a clip).

[0021] The features and combinations of features mentioned above in the description, as well as those subsequently mentioned in the figure description and / or shown in the figures alone, can be used not only in the combinations specified, but also in other combinations or on their own, without departing from the scope of the invention. Thus, embodiments that are not explicitly shown or explained in the figures, but which can be derived and generated from the explained embodiments by separate combinations of features, are also to be considered as encompassed and disclosed by the invention.

[0022] Further advantages, features, and details of the invention will become apparent from the claims, the following description of preferred embodiments, and the drawings. These show: Fig. 1 a schematic exploded view of a vehicle door, Fig. 2 a schematic representation of the individual steps for the manufacture / assembly of the vehicle door Fig. 1, Fig. 3 a detailed sectional view through the vehicle door in area A from Fig. 2, and Fig. 4 another detailed view of the vehicle door Fig. 2, from which the arrangement of the door stop becomes apparent.

[0023] In Fig. Figure 1 shows a schematic exploded view of the relevant components of a vehicle door 100, which is characterized by simplified assembly and by an assembly option with a higher degree of automation.

[0024] In its assembled state, the vehicle door 100 comprises a door panel assembly 118, which includes a carrier part 102 fitted with at least one installation part 104. The carrier part 102 itself is formed as a hollow body, for example made of plastic, so that this hollow body can accommodate a variety of installation parts 104; for example, loudspeakers of a sound system, a door control unit, crash structures, cables or cable harnesses, actuators for the window regulators, a crash tube, and the like.

[0025] The hollow body of the support part 102 is formed, for example, from two half-shells, which allows, for example, a built-in part 104 in the form of a door stop 144 to be positioned in a dry area 140 of the vehicle door 100 (see detail according to Fig. 4) A door stop can then, for example, be inserted between the two half-shells. A number of loudspeakers and / or crash pads can be arranged within the volume of the two half-shells or the hollow body. Due to the use of the support element 102 in the form of two half-shells, the wiring can also be routed from both sides. The lock of the vehicle door 100, for example, is located in a wet area 138 of the vehicle door 100.

[0026] In any case, the support part 102 comprises an inner side 122 facing the driver's cab during normal use and an outer side 124 facing away from the driver's cab during normal use, wherein the support part 102 can be fitted with components 104 on both sides. This fitting can then be carried out, for example, using an automated robot. The inner side 122 is covered, in particular completely, by a door panel 112. Furthermore, a primary seal 106 is provided, which is attached circumferentially to the door panel assembly 118. A door blank 110 is provided, which is joined to the primary seal 106, thereby at least pre-fixing the door panel assembly 118 formed with the support part 102. The door panel assembly 118 is fastened to the door blank 110 by means of a structurally robust connection, preferably with a screw connection 130.To ensure precise positioning, the door frame component 110 has centering points 142 to align the door panel assembly 118 with the door frame component 110. Apart from the screw connections 130, there are also inaccessible mechanical connections, preferably snap connections 132, which fix the door panel assembly 118 to the door frame component 110. Finally, there is a door panel element 120 that covers the freely accessible connections. The door panel element 120 is connected to the door panel assembly 118, which is connected to the door frame component 110. The structurally robust connection, for example screw connection 130, of the door panel assembly 118 with the door body 110 is located in a crash-relevant area 126, whereas the non-accessible mechanical connections, for example a snap connection 132, are located in a “crash-irrelevant” area 128.

[0027] The following describes the process for manufacturing vehicle door 100 using the following examples: Fig. 2 explained in more detail (process from left to right).

[0028] First, the carrier part 102 is provided and fitted with all necessary components 104 on both sides (step a.). Then, a door panel 112 and a door frame panel 116 are provided and attached to the inside 122 of the carrier part 102, thus forming a door panel assembly 118 (step b.). Next, the primary seal 106 is attached to the door panel assembly 118. Then, the door blank 110 is provided, and the door panel assembly 118 and the primary seal 106 are joined to the door blank 110 (step d.). In doing so, the door panel assembly 118, formed with the carrier part 102, is at least pre-fixed to the door blank 110, with the centering points 142 ensuring the door panel assembly 118 is aligned with the door blank 110.In the crash-relevant area 126, the door frame component 110 has a structurally robust mechanical connection onto which a nut can be screwed to securely connect the door panel assembly 118 to the door frame component 110 in this area. Outside the crash-relevant area 126, namely in the crash-irrelevant area 128, there are, purely by way of example, several snap connections 132, which are also, purely by way of example, implemented by clips.

[0029] A pane 134 is then provided for a window of the vehicle door 100. The pane 134 is lowered into a pane receptacle formed in the door frame 110 until it is automatically locked by a locking device of the door frame 110. In those areas where the screw connection 130 is located, a cover or panel is subsequently attached; in this case, in the form of at least one door trim element 120, for example, a fabric panel or the like. The door trim element 120 is mounted to the inside of the door trim assembly 118 for this purpose (step e.).

[0030] In Fig. 3 is another sectional view of detail A from Fig.Figure 2 shows that the primary seal 106 is formed with a receptacle 108 into which the support part 102 engages. The primary seal 106 has an additional sealing lip 114 to effectively seal the dry area 140 against the wet area 138 of the vehicle door 100, which is illustrated with dashed lines. Additional sealing of the support part 102 is achieved by the sealing bead 136, which further ensures that the components 104 are predominantly located in the dry area 140 of the vehicle door 100.

[0031] The vehicle door 100 and the method according to the invention are characterized by a high degree of automation, since the carrier part 102 can be fitted with components on both sides and can therefore be robot-assisted with the installation parts 104. The door panel assembly 118, provided with the primary seal 106, can be easily mounted to the door blank 110, with only a final door panel element 120 needing to be mounted. The number of assembly steps is thus significantly reduced compared to conventional door manufacturing methods, which is why assembly is faster and highly automated. REFERENCE MARK LIST: 100 vehicle doors 102 Carrier part 104 Installation part 106 Primary seal 108 recording 110 Door rough-in component 112 Door trim 114 Sealing lip (primary seal) 116 Door frame trim 118 Door panel assembly 120 Door panel element 122 Inside (carrier part) 124 Outer side (carrier part) 126 crash-relevant area (safety area) 128 crash-irrelevant area 130 Screw connection (threaded pins) 132 Snap connections (clips) 134 discs 136 Sealing bead 138 Wet area 140 Dry area 142 Centering point (centering pin / RPS centering) 144 Door stops

Claims

A method for manufacturing a vehicle door (100), comprising the steps: a. providing a carrier part (102) and fitting the carrier part (102) with at least one component (104), b. providing a door panel (112) and at least partially covering the carrier part (102) with the door panel (112) to form a door panel assembly (118), c. attaching a primary seal (106) to the door panel assembly (118), d. providing a door blank (110) and joining the primary seal (106) to the door blank (110), thereby at least pre-fixing the door panel assembly (118) formed with the carrier part (102), and e. providing and attaching at least one door panel element (120) to the door panel assembly (118) connected to the door blank (110). Method according to claim 1, characterized in that in step a. all door-related installation parts (104) are mounted on or into the support part (102). Method according to claim 1, characterized in that the carrier part (102) is fitted in step a. both on an inner side (122) facing the driver's cab in the intended use and on an outer side (124) facing away from the driver's cab in the intended use. Method according to one of claims 1 to 3, characterized in that in step b. a door frame cladding (116) which is separate from the door panel (102) is also provided, and that the door panel assembly (118) is formed from the door panel (112) and the door frame cladding (116) as well as the equipped carrier part (102). Method according to one of claims 1 to 4, characterized in that in step d. or following step d. the door panel assembly (118) is connected to the door body part (110) at at least one position of a crash-relevant area (126) by means of a structurally robust connection, and that the door panel assembly (118) is connected in an area (128) located away from the crash-relevant area (126) by a mechanical connection that is weaker than the structurally robust connection. Method according to one of claims 1 to 5, characterized in that a sealing bead (136) surrounding the carrier part (102) is applied to the carrier part (102) or to the door blank part (110), which additionally seals a wet area (138) of the vehicle door (100) against a dry area (140) of the vehicle door (100). Method according to one of claims 1 to 6, characterized in that at least one disc (134) is mounted in step d. or following step d., for this purpose the disc (134) is lowered into a disc receptacle formed on the door blank (110) until it is automatically locked by a locking device of the door blank (110). Vehicle door (100), comprising: - a door trim assembly (118) comprising a carrier part (102) which is fitted with at least one installation part (104) and which comprises a door trim (112) which covers the carrier part (102) at least partially, - a primary seal (106) which is attached circumferentially to the door trim assembly (118), - a door blank (110) which is joined to the primary seal (106) whereby the door trim assembly (118) formed with the carrier part (102) is at least pre-fixed, and - at least one door trim element (120) which is connected to the door trim assembly (118) connected to the door blank (110). Vehicle door (100) according to claim 8, characterized in that window regulators, one or more control units, cables or cable harnesses, one or more loudspeakers, one or more crash pads, one or more crash bars are mounted on or integrated into the carrier part (102). Vehicle door (100) according to claim 8 or 9, characterized in that the door panel assembly (118) is connected to the door body part (110) at at least one position of a crash-relevant area (126) by means of a structurally robust connection, and that the door panel assembly (118) is connected in an area (128) located away from the crash-relevant area (126) by a mechanical connection that is weaker than the structurally robust connection.

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