Composite vehicle door components formed by sheet molding compound-resin transfer molding assemblies

Abstract

A lightweight and simplified vehicle door assembly is provid- ed with four main components, an upper frame positioned about the window, an inner frame structure, an outer body panel, and a composite reinforcement component. The composite reinforcement component provides an all-in-one solution for a side impact cross beam, as well as an upper door reinforcement, a front door pillar reinforcement, and a rear door pillar reinforcement. The com- posite reinforcement component acts to reinforce the overall door structure, of- fers resistance to a side impact that limits the intrusion into the passenger com- partment, and offers resistance to a frontal impact by maintaining the spacing between the vehicle A and B pillars (for a front door) and pillar C and D for a back door. A coupe vehicle door in which there is no window frame may be reinforced with the composite reinforcement component. The composite rein- forcement component may have continuous or chopped fibers.