Doors for vehicles

Abstract

The vehicle door according to the exemplary embodiment has improved coupling strength through structural coupling by molding a window frame of a door module assembled between a door trim and a door panel with a separate aluminum injection molding product and inserting a coupling portion of the window frame into a module body by injection molding, and a groove is formed along the coupling portion of the window frame coupled to the module body to easily identify the various components and to achieve sealing during injection molding.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of Korean Patent Application No. 10-2020-0002683 filed in the Korean Intellectual Property Office on January 8, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to a vehicle door. More specifically, the present disclosure relates to a vehicle door in which a window frame of a door module assembled between a door trim and a door panel is formed as a separate aluminum injection-molded product, and a coupling portion of the window frame is insert-injection-molded to a module body to improve coupling strength through structural coupling. Background Art

[0004] Generally, a door for a vehicle is provided with a door glass to improve ventilation, occupant visibility, and riding quality within a vehicle cabin interior, and is made of a steel material or an aluminum material in consideration of collision safety.

[0005] The door outer panel and the door inner panel formed of such a steel or aluminum material are coupled to each other to form a door frame, so that a door panel is formed, and the window frame is coupled to the door panel.

[0006] A glass module in which a guide, an actuator, etc. for raising and lowering a door glass are installed is embedded in an interior space formed by coupling a door outer panel and a door inner panel.

[0007] In addition, a door trim in which a door latch, a window switch, etc. are installed is coupled to the door inner panel, and an anti-collision beam is installed corresponding to the door outer panel to increase the side impact strength of the door.

[0008] Since the window frame and glass module guide assembled to the door inner panel are made of steel, the conventional vehicle door constructed in this manner increases the weight of the entire door, and has the disadvantage of increasing production work and the number of parts since the window frame and glass module are manufactured separately.

[0009] On the other hand, in recent years, more innovative vehicle doors are being developed through a reduction in the number of components of the door and a reduction in the weight of the material.

[0010] The vehicle door disclosed in Korean Patent Publication No. 10-2019-0068672 published on June 19, 2019 can reduce the number of parts of the door by modularizing multiple parts, and can reduce weight by using relatively lightweight materials instead of steel to manufacture some door modules.

[0011] In addition, the prior art is intended to help reduce the number and cost of assembly work steps, and therefore includes a first door module formed by a door outer panel, a door inner panel, a door frame and an anti-collision beam, a second door module formed of a lightweight material, and a door trim as a third door module.

[0012] The door outer panel is disposed outside the vehicle cabin and is formed into a complete panel shape considering door strength and appearance, while the door inner panel is disposed inside the vehicle cabin and has an opening in the center to reduce weight and cost.

[0013] The second door module is formed of a relatively lightweight material (eg, plastic material) compared to the first door module, and a module body having a panel shape and a window frame portion forming a door window are integrally formed.

[0014] However, in the above-mentioned prior art vehicle door, the window frame portion as the door window portion is formed of a lightweight plastic composite material together with the module body, and therefore, a reinforcing bracket (such as steel or other non-ferrous metal) needs to be insert-molded for strength reinforcement.

[0015] Therefore, due to heterogeneity between the materials, the bonding force between the window frame portion formed of the composite material and the reinforcing bracket formed of steel or non-ferrous metal is reduced.

[0016] Specifically, when a twisting force or a bending force due to an external force acts on the window frame portion, the reinforcement bracket insert-molded in the window frame portion is separated or separated from the window frame portion.

[0017] Furthermore, since the reinforcing bracket is exposed to the outside, the appearance quality is deteriorated.

[0018] The above information disclosed in this Background section is only for enhancement of understanding of the background of the disclosure and therefore it may not contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art. Summary of the Invention

[0019] An exemplary embodiment of the present disclosure provides a vehicle door, wherein a window frame of a door module assembled between a door trim and a door panel is molded as a separate aluminum injection-molded product, and a coupling portion of the window frame is insert-molded into a module body so that coupling strength can be improved through structural coupling.

[0020] In an exemplary embodiment of the present disclosure, a groove is formed along a coupling portion of a window frame coupled to a module body so that respective components can be easily distinguished and used to achieve sealing during injection molding.

[0021] To achieve such an object, a vehicle door according to an exemplary embodiment of the present disclosure includes: a door panel formed by combining a door outer panel and a door inner panel; a door module formed by a module body and a window frame, and the door module is coupled to the inner side of the door inner panel; and a door trim coupled to the inner side of the door module, wherein the window frame is integrally formed by aluminum injection molding and is formed with a coupling portion, in which a plurality of perforations are formed at uniform intervals along a lower end portion coupled to the module body, and in injection molding of plastic resin, the coupling portion of the module body is insert-injection-molded into the module body, so that the plastic resin is structurally coupled by being solidified while being introduced through the plurality of perforations formed in the coupling portion.

[0022] A groove having a constant shape may be formed along a length direction of the coupling portion in the vehicle window frame.

[0023] A plurality of perforations may be formed along the interior surface of the slot.

[0024] The plurality of perforations may be formed in a quadrilateral shape.

[0025] The inner surface and the outer surface of the coupling portion of the window frame may be inserted between the inner end portion and the outer end portion injection-molded at the upper end portion of the module body.

[0026] In injection molding, a stopper hole for insertion of a stopper of each mold may be formed in each of the inner and outer ends of the module body to support coupling on opposite sides.

[0027] The stopper hole may be formed in each of an inner end portion of the module body corresponding to a lower portion of each through-hole formed in the coupling portion and an outer end portion of the module body corresponding to a lower portion between corresponding holes of the coupling portion.

[0028] The inner front end portion may be formed in an inner surface of a groove formed in the coupling portion, and the outer end portion may be formed to surround an outer surface of the groove formed in the coupling portion.

[0029] A connection portion connecting the inner end portion and the outer end portion through a through-hole formed in the groove may be formed in the module body.

[0030] The vehicle door according to the exemplary embodiment of the present disclosure improves the coupling strength by structural coupling by molding the window frame of the door module assembled between the door trim and the door panel as a separate aluminum injection molding product and inserting the coupling part of the window frame into the module body by injection molding, so that the weight can be reduced compared with the existing technology and the rigidity of the window frame can be improved.

[0031] Furthermore, according to the present disclosure, in injection molding of the module body, the coupling strength of the window frame and the module body can be improved by structural coupling in which plastic resin is introduced through perforations formed along the coupling portion of the window frame and then cured.

[0032] Furthermore, according to the present disclosure, a groove is formed along a coupling portion of the window frame to the module body, so that it can be easily distinguished from the module body and can serve as a seal during injection molding. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 is a perspective view of a vehicle door according to an exemplary embodiment of the present disclosure.

[0034] Figure 2 is an exploded perspective view of a vehicle door according to an exemplary embodiment of the present disclosure.

[0035] Figure 3 is an enlarged view of a window frame applied to a vehicle door according to an exemplary embodiment of the present disclosure.

[0036] Figure 4 is a perspective view of a door module applied to a vehicle door according to an exemplary embodiment of the present disclosure.

[0037] Figure 5 It is along Figure 4 A cross-sectional view taken along line AA.

[0038] Figure 6 It is along Figure 4 A cross-sectional view taken along line BB. DETAILED DESCRIPTION

[0039] The present disclosure will be described more fully hereinafter with reference to the accompanying drawings showing exemplary embodiments of the present disclosure. As those skilled in the art will appreciate, all disclosed embodiments can be modified in various different ways without departing from the spirit and scope of the present disclosure.

[0040] The drawings and description are to be regarded as illustrative in nature and not restrictive. Throughout the specification, like reference numerals refer to like elements.

[0041] However, in order to clearly describe the exemplary embodiments of the present disclosure, parts irrelevant to the description will be omitted, and the same reference numerals refer to the same or similar elements throughout the specification.

[0042] In the following description, since the names of components are the same as each other, the names of the components are divided into first, second, etc. to divide the names, and the order thereof is not particularly limited.

[0043] In addition, unless explicitly described to the contrary, the word “comprise” and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of stated elements but not the exclusion of any other elements.

[0044] Figure 1 is a perspective view of a vehicle door according to an exemplary embodiment of the present disclosure, Figure 2 is an exploded perspective view of a vehicle door according to an exemplary embodiment of the present disclosure, Figure 3 is an enlarged view of a window frame applied to a vehicle door according to an exemplary embodiment of the present disclosure, and Figure 4 is a perspective view of a door module applied to a vehicle door according to an exemplary embodiment of the present disclosure.

[0045] refer to Figures 1 to 4 , a vehicle door according to an exemplary embodiment of the present disclosure includes a door panel 10 , a door module 20 and a door trim 30 .

[0046] The door panel 10 is formed of a door outer panel 11 , a door inner panel 13 , and an impact beam 15 .

[0047] The door outer panel 11 is provided outside the vehicle body and is formed into a complete panel shape in consideration of the strength and appearance of the door. The door inner panel 13 is provided inside the vehicle cabin and has an opening 13a formed in its center to reduce weight and cost.

[0048] For example, the door outer panel 11 and the door inner panel 13 may be formed of a metal material such as steel.

[0049] The anti-collision beam 15 is provided corresponding to the door outer panel 11, and its opposite ends are coupled to the door inner panel 13. Such an anti-collision beam 15 can protect the occupants in the vehicle cabin by absorbing the impact at the time of the side collision of the vehicle.

[0050] As described, the edges of the door inner panel 13 and the door outer panel 11 are respectively coupled by a process such as hemming, while the opposite ends of the impact beam 15 are joined to the door inner panel 13 , so that the door panel 10 may be completed.

[0051] The door module 20 is formed of a module body 21 and a window frame 23 .

[0052] The module body 21 may be formed by injection molding a composite material including a lightweight plastic resin.

[0053] The window frame 23 may be manufactured as an aluminum injection molded product integrally formed by injection molding a lightweight material of an aluminum alloy material.

[0054] Such a door module 20 is coupled to the inner panel 13 of the door panel 10 .

[0055] Elements such as a raising and lowering unit (not shown) for the door glass, an actuator (not shown), wires (not shown), guides (not shown), etc. are formed in the inner space formed between the door module 20 and the door inner panel 13 to enable the door glass (not shown) to be opened and closed relative to the window frame.

[0056] The window frame 23 is integrally formed by aluminum injection molding, and can ensure strength and reduce weight by reducing its thickness compared to a conventional window frame in which a reinforcing bracket is insert-injection-molded with a plastic resin.

[0057] refer to Figure 2 The door trim 30 is coupled to the door module 20 through a coupling unit, and may play the role of sound insulation, sound absorption, occupant protection in the event of a collision, and interior decoration.

[0058] Furthermore, the door trim 30 is configured to have convenience items such as a door lock 31 , a window switch 33 , a speaker 35 , and an armrest 37 which may be integrally molded.

[0059] refer to Figure 3 , in the vehicle door according to the exemplary embodiment of the present disclosure, the window frame 23 is manufactured as an aluminum injection molded product that is integrally formed by aluminum injection molding using an aluminum alloy.

[0060] A coupling portion 25 coupled to the module body 21 , in which a plurality of penetration holes H are formed at even intervals along a lower end portion, is insert-molded into the window frame 23 .

[0061] Furthermore, a groove G formed in a constant shape is formed along the length direction of the coupling portion 25 in the window frame 23 .

[0062] That is, the groove G is formed as a groove having a certain width and a certain depth, and at the same time, the groove has a certain distance along the molding line at the lower end of the coupling portion 25 of the window frame 23 .

[0063] Here, the groove G may serve as a boundary between the window frame 23 and the module body 21 to separate the window frame from the module body.

[0064] Furthermore, the groove G may function as a seal in response to injection pressure of a plastic resin during injection molding of the module body 21 so that the coupling portion 25 of the window frame 23 is inserted at the upper end of the module body 21 .

[0065] A plurality of through-holes H may be formed along the lower side of the groove G at even intervals.

[0066] Meanwhile, in the exemplary embodiment of the present disclosure, the penetration hole H is formed in a quadrangular shape, but the present disclosure is not limited thereto and may have various shapes that enable the plastic resin to flow in and solidify in the insert injection molding of the module body 21 .

[0067] refer to Figure 4 , in the injection molding of the plastic resin, the coupling portion 25 of the window frame 23 is insert injection-molded into the upper end portion of the module body 21 .

[0068] Here, the window frame 23 may be substantially coupled to the upper end portion of the module body 21 without an additional coupling member because the plastic resin is solidified while being introduced through the plurality of penetration holes H formed in the coupling portion 25 .

[0069] Figure 5 and Figure 6 It is along Figure 4 A cross-sectional view taken along line AA and line BB.

[0070] refer to Figure 5 and Figure 6 , the window frame 23 is injection molded while the inner surface F1 and the outer surface F2 of the coupling portion 24 are interposed between the inner end portion 27 and the outer end portion 29 of the upper end of the module 21 .

[0071] In this case, in the injection molding of the plastic resin, a stopper hole SH may be formed in the inner end portion 27 and the outer end portion 29 of the upper end to support the coupling portion 25 of the window frame 23 on the opposite side, and a stopper (not shown) provided in the upper mold (not shown) and the lower mold (not shown) of each mold is inserted into the stopper hole.

[0072] Here, the stopper hole SH is formed in each of the inner end portion 27 of the module body 21 corresponding to the lower portion of each through hole H of the coupling portion and the outer end portion 29 of the module body 21 corresponding to the lower portion between the corresponding through holes H of the coupling portion 25.

[0073] That is, the stopper hole SH may be formed across each of the inner end portion 27 and the outer end portion 29 of the module body 21 along the coupling portion 25 of the window frame 23 , respectively.

[0074] Furthermore, the top end of the inner end portion 27 in the module body 21 is formed to contact the inner surface of the groove G formed in the coupling portion 25. Furthermore, the outer end portion 29 is formed to surround the outer surface of the groove G formed in the coupling portion 25.

[0075] Here, a connection portion C connecting the inner end portion 27 to the outer end portion 29 through a through hole H formed in the groove G may be formed in the module body 21 .

[0076] That is, the connection portion C is formed during injection molding of the module body 21 while the plastic resin introduced through the penetration hole H of the coupling portion 25 is solidified.

[0077] As described, the vehicle door having the structure as described above according to the exemplary embodiment of the present disclosure is manufactured by molding the window frame 23 included in the door module 20 into a separate aluminum injection molded product, and therefore, the weight can be reduced and the strength of the window frame 23 can be enhanced compared to the existing vehicle door.

[0078] In addition, when the coupling portion 25 coupled to the module body 21 is integrally formed in the lower portion of the window frame 23, and the coupling portion 25 is insert-molded into the module body 21, the coupling strength of the window frame 23 and the module body 21 can be enhanced by structural coupling in which plastic resin is introduced into the coupling portion 23 through a plurality of perforations H and solidified.

[0079] In addition, the groove G is formed along the coupling portion 25 coupled to the module body 21, and therefore, the module body 21 can be easily identified, and the groove G can play a sealing role corresponding to the injection pressure of the plastic resin in the injection molding of the module body 21.

[0080] As described, in the vehicle door according to the exemplary embodiment of the present disclosure, the window frame 23 is formed integrally from an aluminum injection molded product, so that the bending and torsional strength can be enhanced while reducing the thickness compared to the prior art, thereby preventing deformation due to external force without additional reinforcing members.

[0081] Furthermore, in the present disclosure, the coupling strength of the window frame 23 and the module body 21 may be increased by the perforations H and the grooves G, so that the window frame 23 may be prevented from being separated or separated from the module body 21 .

[0082] While the present disclosure has been described in conjunction with what are presently considered to be practical exemplary embodiments, it is to be understood that the present disclosure is not limited to the disclosed embodiments, but is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A vehicle door, comprising: a door panel formed by combining an outer door panel with an inner door panel; a door module comprising a module body and a window frame, wherein the door module is coupled to an inner side of the door inner panel; as well as a door trim coupled to an inner side of the door module, wherein the window frame is integrally formed by aluminum injection molding, and the window frame is formed with a coupling portion in which a plurality of perforations are formed at uniform intervals along a lower end portion coupled to the module body, and During injection molding of a plastic resin, the coupling portion of the window frame is insert-injection-molded to the module body so that the plastic resin is structurally coupled by solidifying while being introduced through the plurality of perforations formed in the coupling portion, Wherein, in the vehicle window frame, a groove of a constant shape is formed along the length direction of the coupling portion.

2. The vehicle door according to claim 1, wherein: A plurality of the through holes are formed along the inner surface of the groove.

3. The vehicle door according to claim 2, wherein: The plurality of through holes are formed in a quadrilateral shape.

4. The vehicle door according to claim 2, wherein: An inner surface and an outer surface of the coupling portion of the window frame are insert-molded between an inner end portion and an outer end portion at an upper end portion of the module body.

5. The vehicle door according to claim 4, wherein: During injection molding, a stopper hole for insertion of a stopper of each mold is formed in each of the inner end portion and the outer end portion of the module body to support coupling on opposite sides.

6. The vehicle door according to claim 5, wherein: The stopper hole is formed in each of an inner end portion of the module body corresponding to a lower portion of each of the through holes formed in the coupling portion and an outer end portion of the module body corresponding to a lower portion between the corresponding holes of the coupling portion.

7. The vehicle door according to claim 4, wherein: A tip end of the inner end portion is formed to contact an inner surface of the groove formed in the coupling portion, and the outer end portion is formed to surround an outer surface of the groove formed in the coupling portion.

8. The vehicle door according to claim 4, wherein: A connection portion is formed in the module body, the connection portion connecting the inner end portion and the outer end portion through the through hole formed in the groove.

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