Automatic side door structure

Abstract

A door structure system for a vehicle includes an inner panel, an outer panel, and an outer belt reinforcement. The outer belt reinforcement extends in a front-to-rear direction of the door structure. The outer belt reinforcement makes an overlap joint with a hem flange portion of the inner panel. The outer belt reinforcement includes a kiss feature that extends toward the inner panel and contacts a stepped-down support surface of the inner panel relative to the hem flange portion. Both the overlap joint and the kiss feature contribute to increasing an upper frame rigidity of the door structure and improving a sealing performance between the door structure and a vehicle body structure.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This PCT International Patent Application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 048,332 and titled “Automotive Side Door Structure” filed on July 6, 2020, the entire disclosure of which is incorporated herein by reference. TECHNICAL FIELD

[0003] The present disclosure relates to automotive vehicle structures. More particularly, the present disclosure relates to side door vehicle structures. BACKGROUND

[0004] Automotive vehicles, including but not limited to electric vehicles, hybrid vehicles, and other passenger vehicles, include various components that are assembled together to define the overall shape and functionality of the vehicle. For example, a vehicle subframe provides support for an engine and a vehicle body that extends upwardly from the subframe.

[0005] The vehicle body can include a front portion, a side portion, a rear portion, a floor portion, and a roof portion disposed above the subframe. Generally, the vehicle body can include a frame portion that includes various sections and pillars that define the shape of the vehicle and provide stiffness to the vehicle, allow for further structural assembly to the vehicle, and also protect the vehicle occupants from external factors and collisions, in accordance with various standards.

[0006] The vehicle body defines an interior of the vehicle in which a passenger can operate and sit within the vehicle. A door, such as a side door, provides access into the vehicle through an opening defined by the vehicle structure and particularly between the A-pillar, B-pillar, and C-pillar of the upper vehicle body.

[0007] Upper frame stiffness is an issue in many vehicles, which can be addressed using a vehicle side door. The stiffness provided by the side door is a target value for each vehicle. When the stiffness is higher, the door can provide better sealing performance against the upper frame of the vehicle, thereby reducing wind noise and water leakage.

[0008] In some cases, less than optimal frame dimensions can occur during manufacturing. As a result, it can be difficult to achieve sealing when the side door is assembled with the vehicle structure. One aspect in this case is the use of a flexible grommet type material disposed between the door structure and the frame structure. However, this material has a lower stiffness accordingly, such that the material can fill the variable space between the side door and the frame. This reduced stiffness can result in an increase in wind noise and water leakage.

[0009] In view of the above, improvements can be made to increase the stiffness of the vehicle side door structure to match the vehicle structure. SUMMARY

[0010] In one aspect, a door panel structure system includes: an inner panel having a front portion, a rear portion, an upper portion, and a lower portion; an outer panel sized and arranged to mate with the inner panel to define a door structure having a first stiffness and an internal cavity; an outer belt reinforcement extending between the front portion and the rear portion of the inner panel and disposed vertically between the upper portion and the lower portion and laterally between the outer panel and the inner panel; wherein the outer belt reinforcement and a crimped flange portion of the inner panel define a lap joint, wherein the crimped flange portion is disposed on the rear portion of the inner panel; a kiss member extending inwardly from the outer belt reinforcement into contact with a bearing surface of the inner panel; and wherein the lap joint and the contact with the bearing surface combine to define a second stiffness greater than the first stiffness.

[0011] In one aspect, the crimped flange portion of the inner panel is disposed at a rear edge of the inner panel, wherein the outer panel overlaps the lap joint and wraps around the rear edge of the inner panel to define the crimped flange.

[0012] In one aspect, the kiss member is integrally formed with the outer belt reinforcement.

[0013] In one aspect, the inner panel defines a stepped portion recessed relative to the crimped flange portion, wherein the kiss portion contacts a bearing surface of the stepped portion.

[0014] In one aspect, the crimped flange portion of the inner panel is stepped down relative to an adjacent section of the rear portion of the inner panel, such that the outer belt reinforcement and the adjacent section are generally continuous and define a common plane for mounting the outer panel.

[0015] In one aspect, the system includes at least one reinforcement member attached to the inner panel.

[0016] In one aspect, the at least one reinforcement member includes a window frame reinforcement member.

[0017] In one aspect, a lower portion of the window frame reinforcement member is disposed laterally between the inner panel and the outer belt reinforcement.

[0018] In one aspect, a lower portion of the window frame reinforcement member has a contour corresponding to an inner surface of the inner panel, and wherein the outer belt reinforcement is spaced apart from the window frame reinforcement member.

[0019] In one aspect, the kiss member and the window frame reinforcement member each directly contact the inner surface of the inner panel.

[0020] In one aspect, the outer belt reinforcement member defines a through opening at a rear portion thereof, wherein the strike member is disposed adjacent the through opening.

[0021] In one aspect, the system includes an impact beam extending within the interior cavity in the front-to-rear direction and secured to the door structure, wherein the impact beam provides additional stiffness to the door structure.

[0022] In another aspect, a method of increasing the stiffness of a door panel structure system is provided, the method comprising: providing an inner panel having a front portion, a rear portion, an upper portion, and a lower portion; attaching an outer belt reinforcement member to the inner panel, wherein the outer belt reinforcement member extends in a front-to-rear direction of the door panel structure; creating a lap joint between a rear end of the outer belt reinforcement member and a crimped flange portion of the inner panel; bringing a strike member of the outer belt reinforcement member into contact with a support surface of the inner panel, wherein the support surface is stepped down relative to the lap joint; and attaching an outer panel to the inner panel, wherein the outer panel covers the outer belt reinforcement member and defines an interior cavity with the inner panel.

[0023] In one aspect, the method includes wrapping a rear edge of the outer panel around the lap joint and defining a crimped flange around the rear end of the outer belt reinforcement member and the crimped flange portion of the inner panel.

[0024] In one aspect, the method includes attaching a window frame reinforcement member to the inner panel and attaching the outer belt reinforcement member to the inner panel over a lower portion of the window frame reinforcement member, wherein the outer belt reinforcement member is spaced apart from the lower portion of the window frame reinforcement member to define an open space between the outer belt reinforcement member and the lower portion of the window frame reinforcement member. BRIEF DESCRIPTION OF DRAWINGS

[0025] Other advantages of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0026] Figure 1 is an exploded view of a door structure system for a vehicle, the door structure system including an inner panel, an outer panel, a window frame reinforcement, a latch reinforcement, a check arm link reinforcement, a lower hinge reinforcement, an impact beam, and an outer belt reinforcement member;

[0027] Figure 2 is an assembled view of the door structure system, wherein the outer panel is illustrated removed for clarity;

[0028] Figure 3 is an enlarged view of the outer belt reinforcement member illustrating a lap joint with a crimped flange portion of the inner panel; and

[0029] Figure 4is an enlarged view of the outer belt reinforcement showing the strike feature extending into engagement with the surface of the inner panel. DETAILED DESCRIPTION

[0030] Referring to Figure 1 The vehicle structural system 10 is illustrated in exploded view. The system 10 is shown generally in a "white body" state, or more specifically in a "white door" state in Figure 1 which the structural components have been brought together, but prior to painting and assembly of various components carried on the structural components, such as window regulator mechanisms or latch mechanisms. Of course, since Figure 1 is an exploded view, the various structural components of the system 10 are not shown as "assembled." The corresponding assembled system 10 is shown generally in Figure 1 which, for clarity, some components are not shown, as will be further described below. Figure 2

[0031] With continued reference to Figure 1 , the system 10 is illustrated as a front side door, such as a door mounted on the front half of a four-door sedan-type vehicle. It will be appreciated that aspects of the system 10 disclosed herein can be applied to a rear side door or other door types, including doors with side hinges, doors with upper hinges, sliding doors, etc. Figure 1 More specifically, the right or passenger side (U.S. convention) door is illustrated. For purposes of discussion, the illustrated side door will be discussed herein, but it will be appreciated that aspects of the present disclosure are not necessarily limited to such a door.

[0032] The system 10 includes an inner panel 12 to which various door components and other structural components that make up the overall door structure of the system 10 can be attached. The inner panel includes a front portion 12a, a rear portion 12b, an upper portion 12c, and a lower portion 12d. The front portion 12a is generally the portion that is contiguous with the door hinge, and the rear portion 12b is generally the portion that has the door latch that engages a striker on the vehicle body. The inner panel 12 is configured to partially define an interior cavity of the door that can house various interior door components, such as a window regulator, a latch mechanism, a window glass in a down position, etc. Various types of component mounting methods and mechanisms can be used with the inner panel 12, and the inner panel 12 can have different shapes and sizes corresponding to such mounting methods and mechanisms, so long as such modifications do not hinder aspects of the present disclosure.

[0033] ​The upper portion 12c can be in the form of a curved bar or the like that extends upward and rearward from the front portion 12a and toward the rear portion 12b. The shape of the upper portion 12c can generally correspond to the shape of the A-pillar of the vehicle body structure and the roof line of the vehicle. Thus, different vehicle body shapes will have a corresponding different shape or curve of the upper portion 12c.

[0034] The rear portion 12b extends downward from the rear end of the upper portion 12c in a generally vertical manner, thereby defining a rear edge of the inner panel 12. The rear portion 12b is generally sized and arranged to correspond with the location of the B-pillar of the vehicle body structure. The rear portion 12b can include provisions for a latching structure, such as a latching system having a ratchet, that is configured to capture a striker mounted to the vehicle body structure. For example, the rear portion 12b can define an opening that can receive the striker such that the striker can engage with the latching mechanism of the door. Of course, the latching mechanism can be mounted at other locations and can have other arrangements.

[0035] The lower portion 12d extends from a lower end of the rear portion 12b toward a lower end of the front portion 12a and generally defines a bottom edge of the door and generally corresponds to the bottom edge of the vehicle.

[0036] The front portion 12a extends upward from a front end of the lower portion 12d and toward a front end / lower end of the upper portion 12c. The front portion 12a can be the portion to which a hinge structure can be attached and can be the portion of the door that pivots relative to the vehicle body and supports the door when the door is in the open position.

[0037] The inner door panel 12 includes an inner surface 14 and an outer surface 16. The inner surface 14 generally faces the interior of the door that is partially defined by the inner door panel 12. The outer surface 16 generally faces the interior of the vehicle and is the surface that faces the occupant. Thus, the inner surface 14 of the inner door panel 12 is generally outwardly facing relative to the passenger compartment.

[0038] The system 10 also includes an outer panel 18, which can also be referred to as the door exterior, with the inner panel 12 being referred to as the door interior. The outer panel 18 can be sized and arranged to match the inner panel 12 and together with the inner panel 12 define the interior space of the door.

[0039] The outer panel 18 accordingly includes an inner surface 20 that faces the inner surface of the inner panel 12 and an outer surface 22 that outwardly faces and away from the vehicle. The outer panel 18 can have a curvature that corresponds to the exterior body style of the vehicle and can also match the correspondingly outwardly facing edges and surfaces of the inner panel 12 that the outer panel 18 matches.

[0040] As in Figure 1As shown in FIG. 1, inner panel 12 can have a stamped shape, defining a plurality of sidewall portions about its periphery. These sidewall portions generally define the shape of the interior cavity or space of the door. As shown in Figure 1 As shown in FIG. 1, outer panel 18 has a generally sheet-like shape, which can serve as a cover to substantially enclose the interior cavity or space defined by the sidewalls of inner panel 12.

[0041] Outer panel 18 can be attached to inner panel 12 via a hem flange, in which the edge of outer panel 18 is bent over and around the edge of inner panel 12. Accordingly, system 10 can include a plurality of hem flange adhesives 24, which have a counterpart shape to the hem flange connection between outer panel 18 and inner panel 12.

[0042] Outer panel 18 generally covers the lower half of inner panel 12, defining the interior space within the door with inner panel 12. System 10 can also include a window frame reinforcement 26 disposed above outer panel 18. Window frame reinforcement 26 has a curved profile corresponding to the upper portion 12c of inner panel 12. Window frame reinforcement 26 can be in the form of a panel covering the upper inner surface of inner panel 12. Thus, window frame reinforcement 26 has an inner surface disposed against the inner surface of inner panel 12 and an outer surface facing outward from the vehicle. Figure 1 Window frame reinforcement 26 is shown in an exploded view disposed on the inner side of inner panel 12, but when assembled, window frame reinforcement 26 covers the outwardly facing surface of inner panel (on the same side of inner panel 12 on which outer panel 18 is disposed). Figure 2 Window frame reinforcement 26 is shown on this side of inner panel 12.

[0043] System 10 also includes a latch reinforcement panel 28 disposed on the inner surface of inner panel 12. In other words, latch reinforcement panel 28 can be disposed within the interior cavity defined by inner panel 12 (similar to window frame reinforcement 26, latch reinforcement panel 28 is disposed on the right side of inner panel 12 in the exploded view of FIG. 1). Figure 1 More specifically, latch reinforcement panel 28 can be disposed at the rear portion 12b of inner panel 12 at an area corresponding to the location of the latch mechanism. The latch reinforcement can provide additional stiffness to the door at the location of the door to support the latch mechanism. The latch mechanism generally experiences increased loads, such as opening loads when the door remains latched, or impact loads when the door is closed from an open position, such that latch reinforcement panel 28 can provide additional strength to the door in this location of increased load.

[0044] In addition, the system 10 can also include a striker link reinforcement 30 and a lower hinge reinforcement 32, each in the form of a panel applied to the interior surface of the inner panel 12 along the front portion 12a. Like the above-described reinforcements, these reinforcements 30 and 32 provide additional strength in areas of increased loading. Figure 2 The striker link reinforcement 30 and the lower hinge reinforcement 32 are shown in

[0045] The above-described reinforcement panels 26, 28, 30, and 32 can be joined with the inner panel 12 via structural adhesives 34 disposed along the overlap area between the inner panel 12 and the reinforcement panels.

[0046] The system 10 can also include an impact beam 40 extending in the fore-aft direction of the vehicle and between the front portion 12a and the rear portion 12b of the inner panel 12. The impact beam 40 provides structural reinforcement to the door in the impact area of the door. In Figure 2 The impact beam 40, shown in Figure 2 The impact beam 40 can be disposed (in the stacking direction) on top of the striker reinforcement panel 28 and the lower hinge reinforcement 28, as shown in

[0047] The system 10 also includes an outband reinforcement member 50. The outband reinforcement member 50 is attached to the inner door panel 12 generally at the junction between the window frame reinforcement 26 and the outer panel 18. Like the impact beam 40, the outband reinforcement member 50 extends in the fore-aft direction between the front portion 12a and the rear portion 12b of the door panel 12. The outband reinforcement member 50 is disposed higher on the door relative to the impact beam 40. As shown in Figures 2 to 4 The outband reinforcement member 50 is disposed on top of the window frame reinforcement in the stacking direction, as shown in

[0048] Referring to Figure 2 The outband reinforcement member 50 includes an upper portion 52 and a lower portion 54. The upper portion 52 is disposed adjacent to the window opening, and the lower portion 54 is disposed inside the door cavity defined by the inner panel 12 and the outer panel 18.

[0049] The upper portion 52 can be slightly curved relative to the lower portion 54, such that the upper portion can follow the contour of the inner panel 12 to extend toward the window opening. The upper portion 52 and the lower portion 54 can combine to define a through opening 56 disposed adjacent to the rear end of the outband reinforcement member 50. The opening 56 extends into both the upper portion 52 and the lower portion 54. As shown inFigure 2 As shown in

[0050] As shown in Figure 3 The outer strap reinforcement member 50 includes a rear flange 58 extending in a generally vertical direction along the rear edge of the door. The rear flange 58 is arranged to overlap a hem flange portion 60 of the inner panel 12. The hem flange portion 60 of the inner panel 12 also extends along the rear edge of the inner panel 12. Figure 4 Further illustrating the rear flange 58 covering the hem flange portion 60 of the inner panel.

[0051] When the outer panel 18 is joined with the inner panel 12 to form a hem flange at the rear edge of the door, the outer panel 18 can be wrapped around the outer strap reinforcement 50 at the rear flange 58 and the hem flange portion 60 of the inner panel 12. Thus, the rear flange 58 can be sandwiched between the hem flange portion 60 of the inner panel 12 and the outer panel 18. Similarly, the hem flange portion 60 can be sandwiched between the rear edge 58 of the outer strap reinforcement 50 and the rear portion of the outer panel 18 that has been wrapped around the rear edge 58 and the hem flange portion 60.

[0052] The inner panel 12 can also include a stepped portion 62 that steps down from the rear flange portion 60. The stepped portion 62 can define a support surface 66 that faces outward relative to the inner panel 12, where the support surface 66 faces the outer strap reinforcement 50. The support surface 66 can be configured to interact with and bear against the outer strap reinforcement member 50, as will be further described below.

[0053] As shown in Figure 4 The stepped portion 64 can further support the attachment of the window frame reinforcement 26 to the inner panel, and can define an open space between the window frame reinforcement member 26 and the outer strap reinforcement 50. The window frame reinforcement member 26 can thus have a shape that corresponds to the shape of the inner panel 12 including the stepped portion 62.

[0054] In Figure 4As shown in one aspect, the outer strap reinforcement 50 may include a contact member 68 extending from the outer strap reinforcement 50 toward the inner panel 12. The contact member 68 may also be referred to as a protrusion or leg. More specifically, the contact member 68 may extend toward and abut against a support surface 66 defined by a stepped portion 62 of the inner panel 12. In one aspect, the contact member 68 may define a hollow cavity having an outwardly facing opening that closes at its inner end, wherein the inner end abuts against the support surface 66. The hollow contact member 68 may have a sidewall thickness that is substantially constant around its periphery and is approximately the same as the remainder of the outer strap reinforcement.

[0055] Figure 4 The diagram also illustrates a contact member 68 that contacts the support surface 66 at a position adjacent to the lower edge of the window frame reinforcement 26. The contact member 68 is also disposed between the window frame reinforcement 26 and the latch reinforcement 28. The window frame reinforcement 26 and the latch reinforcement 28 are positioned on the inner panel 12 to contact the stepped portion 62. (As shown in...) Figure 4 As shown, the contact member is in direct contact with the inner door panel 12, just as the window frame reinforcement 26 and the latch reinforcement 28 are also in direct contact with the inner door panel 12. It will be understood that direct contact is intended to include an arrangement in which adhesives or the like may be provided between adjacent panels / reinforcements.

[0056] As in Figure 4 As shown, the outer reinforcement 50 can be positioned above the window frame reinforcement 26 in the stacking direction, but can be spaced apart from the window frame reinforcement 26. (As shown in...) Figure 4 As shown, in addition to the direct contact between the contact member 68 and the step portion 62, the outer reinforcement 50 can directly abut against the rolled edge flange portion 60 of the inner door panel. The rolled edge flange portion 60 against which the outer reinforcement 50 abuts can be slightly recessed or stepped down, so that the rear edge of the inner panel 12 transitions to the outer reinforcement 50 when the outer reinforcement 50 is placed on the inner door panel 12. The combined thickness of the outer reinforcement 50 and the inner panel 12 at the location of the rolled edge flange portion 60 can be greater than the adjacent thickness of the inner panel 12. In other words, the thickness of the inner panel along its rear edge can be approximately constant, resulting in a greater overall thickness at the overlap with other components.

[0057] As in Figure 2 As shown, system 10 may further include vibration-damping material 70 that can be applied to the external reinforcing member 50. Vibration-damping material 70 may also be applied to the impact beam 40, such as... Figure 4Anti-vibration material 70 can be provided along other sections of the panel or other sheet material to reduce vibrations as determined by modeling and other analysis. Both the impact beam 40 and the outer belt reinforcement member are generally spaced apart from the inner panel 12, spanning an interior cavity or space defined by the inner panel 12, and thus can be more susceptible to vibrations than various reinforcement panels that are applied directly to the surface of the inner panel 12 and match the shape and contour of the inner panel 12.

[0058] Figures 2 to 4 The system 10 is illustrated in a generally assembled state with the outer panel 18 removed for clarity, and the inner panel 12 is illustrated in mounting relationship with various reinforcements attached to the inner panel 12. It will be appreciated that the inner panel 12 can have various support surfaces formed thereon against which respective reinforcement panels can be seated. The inner panel 12 can be formed of a stamped metal material, such as a cold formed sheet metal material or a heat treated material. The inner panel 12 can also be formed of a layered composite material.

[0059] Similarly, the various reinforcements described herein can be formed of stamped sheet metal or composite materials. In addition to the impact beam 40 and the outer belt reinforcement member 50, the reinforcement members described herein can have substantially the same shape and contour as the inner panel 12 in the locations where they are mounted.

[0060] In one aspect, the outer belt reinforcement 50 can be formed of a laminated carbon fiber RTM material. The latch reinforcement 28 can be an aluminum stamping (AL5032H32). The window frame reinforcement 26 can be a chopped fiber SMC material. The impact beam 40 can be a 2.5 mm thick, heat formed aluminum material (AL7075). The outer panel 18 can be a 1.0 mm thick, heat formed magnesium. The check link reinforcement 30 and the lower hinge reinforcement 30, 32 can be aluminum extrusions (AL6062-T6). The above arrangement of materials provides one example of a beneficial combination of components and materials. However, it will be appreciated that alternative materials can be used for each of these components depending on the particular needs of the vehicle and door. Various shapes and thicknesses can also be used.

[0061] The outer belt reinforcement member 50, as well as the lap joint formed with the crimped flange portion 60 of the inner panel 12, helps to provide a higher upper frame stiffness for the side door structure of the system 10. In addition, the crash touch member 68 provides additional higher upper frame stiffness in the side door structure of the system 10. Both of these features help to provide upper frame stiffness. In addition, both of these features can be used in structures of various materials, including metals, composites, and the like.

[0062] By including these features on a representative composite side door structure, higher than target stiffness values are achieved. Composite materials have lower modulus compared to metal materials, which can increase the challenge of achieving upper frame stiffness targets, and still achieve higher than target values. Therefore, these features can be applied to higher modulus metal materials, and will also result in high stiffness values higher than target, resulting in optimal sealing performance. Therefore, with a vehicle door structure having higher than target stiffness values, the vehicle door can withstand greater sealing loads and / or provide greater compression to the door seal, thereby reducing wind noise, etc., which is common with softer sealing materials and reduced sealing loads.

[0063] Further, by allowing less material to be used in areas of lower load or stiffness requirements, the use of an inner door panel 12 with corresponding reinforcement members can reduce the weight of the door. Areas of increased load can be established and reinforced via reinforcement members for bearing typical loads, such as at the hinges or latches, or at the window opening. The impact beam 40 and outer belt reinforcement members 50 provide additional structural support for safety.

[0064] Obviously, many modifications and variations of the present application are possible in light of the above teachings, and the appended claims can be practiced in a variety of ways, which are different from those specifically described. These prior recitations should be construed in breadth in accordance with the scope of the present application.

Claims

1. A door panel structure system, the system comprising: An inner panel having a front portion, a rear portion, an upper portion, and a lower portion; An outer panel, which is sized and arranged to match the inner panel to define a door structure having a first rigidity and an internal cavity; An external reinforcing member extends between the front and rear portions of the inner panel, is vertically disposed between the upper and lower portions, and is laterally disposed between the outer panel and the inner panel. The outer reinforcing member and the rolled edge flange portion of the inner panel define an overlapping joint, wherein the rolled edge flange portion is disposed on the rear portion of the inner panel; A contact member extending inward from the outer reinforcing member to contact the support surface of the inner panel; and The lap joint and its contact with the supporting surface combine to define a second stiffness greater than the first stiffness.

2. The system according to claim 1, wherein, The rolled edge flange portion of the inner panel is disposed at the rear edge of the inner panel, wherein the outer panel overlaps the lap joint and is rolled around the rear edge of the inner panel to define the rolled edge flange.

3. The system according to claim 1, wherein, The contact member and the outer reinforcing member are integrally formed.

4. The system according to claim 1, wherein, The inner panel defines a stepped portion that is recessed relative to the rolled flange portion, wherein the contact portion contacts the supporting surface of the stepped portion.

5. The system according to claim 1, wherein, The rolled flange portion of the inner panel descends in a stepped manner relative to the adjacent segment of the rear portion of the inner panel, such that the outer reinforcing member and the adjacent segment are substantially continuous and define a common plane for mounting the outer panel.

6. The system of claim 1, further comprising at least one reinforcing member attached to the inner panel.

7. The system according to claim 6, wherein, The at least one reinforcing member includes a window frame reinforcing member.

8. The system according to claim 7, wherein, The lower portion of the window frame reinforcing member is laterally disposed between the inner panel and the outer reinforcing member.

9. The system according to claim 8, wherein, The lower portion of the window frame reinforcing member has a profile corresponding to the inner surface of the inner panel, and wherein the outer reinforcing member is spaced apart from the window frame reinforcing member.

10. The system according to claim 9, wherein, The contact member and the window frame reinforcement member each directly contact the inner surface of the inner panel.

11. The system according to claim 1, wherein, The outer reinforcing member defines a through opening at the rear portion of the outer reinforcing member, wherein the contacting member is positioned adjacent to the through opening.

12. The system of claim 1, further comprising an impact beam extending in the front-rear direction within the internal cavity and fixed to the door structure, wherein, The impact beam provides additional stiffness to the door structure.

13. A method for increasing the stiffness of a door panel structure system, the method comprising: An inner panel is provided, comprising a front portion, a rear portion, an upper portion, and a lower portion; An external reinforcing member is attached to the inner panel, wherein the external reinforcing member extends along the front-rear direction of the door panel structure; An overlapping joint is formed between the rear end of the outer reinforcing member and the rolled flange portion of the inner panel. The contact member of the outer reinforcing member is brought into contact with the supporting surface of the inner panel, wherein the supporting surface is stepped down relative to the lap joint; An outer panel is attached to the inner panel, wherein the outer panel covers the outer reinforcing member and defines an internal cavity and a door structure having a first rigidity with the inner panel. The lap joint and its contact with the supporting surface combine to define a second stiffness greater than the first stiffness.

14. The method of claim 13, further comprising wrapping the rear edge of the outer panel around the lap joint and defining a rolled flange around the rear end of the outer reinforcing member and the rolled flange portion of the inner panel.

15. The method of claim 13, further comprising attaching a window frame reinforcement member to the inner panel and attaching the outer reinforcement member to the inner panel above a lower portion of the window frame reinforcement member, wherein, The outer reinforcing member is spaced apart from the lower portion of the window frame reinforcing member to define an open space between the outer reinforcing member and the lower portion of the window frame reinforcing member.

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