Modular vehicle door individually operable

Abstract

A vehicle door system includes a door having a door module attached to a hinge module that is attached to a vehicle body. The door module includes a latch mechanism configured to engage a striker of the vehicle body, the latch mechanism having a pawl that pivots to accommodate misalignment with the striker during a door closing operation, wherein the latch mechanism is displaced after engagement with the striker. A door check mechanism includes a permanent magnet and a steel plate. Activation of the permanent magnet displaces the steel plate from a closed position to an open position, allowing the hinge module to move from a locked position. An interface between the doors includes a primary seal and a secondary seal each having a constant cross section, wherein a filler is disposed between the door and the secondary seal along a portion of the interface.

Description

[0001] Cross-references to related applications

[0002] This PCT international patent application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 123,059, filed on December 9, 2020, entitled “Modular Individually Operable Vehicle Door,” the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure relates to doors in passenger vehicles. More specifically, this disclosure relates to individually operable modular doors for passenger vehicles. Background Technology

[0004] Passenger vehicles, such as conventional motor vehicles and electric vehicles, consist of various vehicle components assembled together. The body is typically constructed to define the passenger compartment in which the vehicle's passengers and driver will sit during the vehicle's operation. The body usually includes multiple doors that allow passengers to enter and exit as needed.

[0005] The vehicle body is designed to support various internal components and is supported by a vehicle chassis located beneath the body. This chassis supports various other vehicle components, which, when integrated with the body and interior, define the entire vehicle assembly. Various safety standards and requirements necessitate that the assembled vehicle components withstand impacts and typical vehicle use to adequately protect the occupants of the vehicle and the vehicle itself from substantial damage in response to a collision.

[0006] A traditional vehicle body may include sections commonly referred to as A-pillars, B-pillars, and C-pillars. These pillars are structural parts of the vehicle body that typically define openings through which passengers can enter and exit the vehicle via installed doors. The A-pillars are located at the front of the vehicle, with the windshield extending laterally between them. The C-pillars are located at the rear of the vehicle, with the rear window extending laterally between them. The B-pillars are located longitudinally in the center of the vehicle, between the A-pillars and C-pillars.

[0007] In a typical four-door passenger vehicle, the front doors are supported by the A-pillar via multiple hinges, and the front doors pivot about an axis located near the A-pillar. The front doors may also include a latching mechanism that engages with a corresponding structure located at the B-pillar. The rear doors are typically supported by the B-pillar via multiple hinges, and the rear doors pivot about an axis located near the B-pillar. The rear doors typically include a latching mechanism that engages with a corresponding structure located at the C-pillar.

[0008] When the door is open, the door is cantilevered supported from the pillar to which the door is attached via a hinge. When the door is closed, the door is additionally supported by a latching mechanism that cooperates with the corresponding pillar.

[0009] In some vehicles, such as passenger vans, multiple doors are provided at a single opening. In these vehicles, the rear door can alternatively be supported by a pillar provided rearward of the door. The front and rear doors of such a dual door arrangement can cooperate with one another, wherein one of the doors includes a portion of the latching mechanism and the other of the doors includes the remaining portion of the latching mechanism. This type of arrangement can be undesirable because this type of arrangement can require both doors to be precisely aligned so that the corresponding latching structures of both doors can operate as intended.

[0010] Dual door arrangements are not limited to van vehicles, such arrangements can also be used in vehicles that do not include a B-pillar. Dual door arrangements can be desirable in some cases to provide a greater overall opening, to make it easier for passengers to enter and exit, and also to allow greater cargo to be placed within the vehicle. However, dual door arrangements typically require one of the doors to be opened first and then the other door is opened. Likewise, when closing the doors, one of the doors must be closed before the other. This can lead to undesirable results, in that a passenger can not be able to exit the vehicle independently, or this can result in damage to the vehicle in the event that the wrong door is closed first, causing the structure of the rear door to impact the previously closed door.

[0011] In view of the foregoing, there remains a need for improvements to passenger vehicle door systems. SUMMARY

[0012] A system for opening and closing a door relative to a vehicle body is provided. The system includes a first door and a second door, each of the first and second doors including a hinge module configured to be mounted to the vehicle body and a door module configured to be mounted to the hinge module and further configured to close a door opening defined by the vehicle body. The door module includes an embedded pillar structure provided at a front or rear edge of the door module.

[0013] The hinge module includes a hinge bracket configured to be mounted to the vehicle body and an arm pivotally attached to the hinge bracket. The hinge module further includes a support pivotally attached to the arm, wherein the support is movable between a closed position and an open position in response to movement of the arm relative to the hinge bracket.

[0014] The door module is attached to the support via a plurality of corresponding attachment points between the cross support and the door module. The door module includes a latching mechanism configured to latch with the vehicle body.

[0015] The first door cooperates with the second door and defines an interface therebetween. The embedded post of the first door and the embedded post of the second door are disposed adjacent to one another at the interface. Each of the first and second doors is individually operable relative to one another such that the first or second door can be opened and closed while the other remains latched to the vehicle body.

[0016] In one aspect, the door modules are not directly hinged to the vehicle body.

[0017] In one aspect, the arm of the hinge module includes an upper arm and a lower arm, each having a first end and a second end, each of the upper and lower arms being pivotally attached at the first end to the hinge bracket and at the second end to the support.

[0018] In one aspect, when the door modules are in the closed position, the first end of the upper arm is offset from the first end of the lower arm in a first direction and the second end of the upper arm is offset from the lower arm in a second direction.

[0019] In one aspect, the first arm is generally straight and extends in the first direction and the second arm is curved and includes an upper portion, an angled portion, and a lower portion, wherein the angled portion is disposed at an oblique angle relative to the upper arm.

[0020] In one aspect, the latching mechanism is disposed at a bottom edge of each of the door modules.

[0021] In one aspect, the first and second doors do not latch to one another when the first and second doors are in the closed position.

[0022] In one aspect, the support is in the form of a cross support or an I-shaped support.

[0023] In one aspect, the system further includes at least one of: an electric actuator operatively coupled to each of the doors and configured to automatically open each of the doors; a cinching mechanism operatively coupled to each of the doors and configured to cinch the doors to the closed position; and a latching mechanism associated with each of the doors and configured to hold the doors in the open position.

[0024] In one aspect, the embedded post is defined by an outer curved portion attached to an inner curved portion.

[0025] In one aspect, the embedded post is disposed inwardly relative to an outer sheet of the door panel and outwardly relative to an inner sheet of the door panel.

[0026] In one aspect, the outer sheet defines a rolled edge flange disposed at the interface between the first and second doors, wherein the rolled edge flange is joined to the embedded post.

[0027] In one aspect, the inner curved portion is wrapped around the outer curved portion, wherein the outer curved portion is disposed inward from the inner curved portion relative to the interface, wherein the crimped flange is bonded to the inner curved portion.

[0028] In one aspect, the system further comprises a sealing system disposed between the first door and the second door, wherein the sealing system is attached to only one of the first door and the second door.

[0029] In another aspect, a method for installing vehicle doors is provided. The method includes the steps of attaching a first hinge module and a second hinge module to a vehicle body, the hinge modules each comprising a hinge bracket, an arm extending from and pivotally attached to the hinge bracket, and a support pivotally attached to the arm, wherein the hinge bracket is attached to the vehicle body.

[0030] The method further includes attaching a first door module to the first hinge module and a second door module to the second hinge bracket, wherein each of the door modules includes a plurality of attachment points and the plurality of attachment points are attached to the support of the first hinge module or the second hinge module. Each of the door modules includes an embedded pillar structure at a front edge or a rear edge of the door module. Each of the door modules includes a latching mechanism and the latching mechanism engages the vehicle body when the door is installed in a closed position.

[0031] The method further includes opening and closing the first door module while the second door module remains in a latched position with the vehicle body, and opening and closing the second door module while the first door module remains in a latched position with the vehicle body.

[0032] In one aspect, the method includes latching the first door module to the vehicle body and latching the second door module to the vehicle without latching the first door module to the second door module.

[0033] In one aspect, the embedded pillar is defined by a curved inner portion and a curved outer portion, wherein the curved inner portion is wrapped around the curved outer portion such that the curved inner portion is disposed closer to the interface than the curved outer portion, wherein the embedded pillar is disposed between inner and outer skins of the corresponding first and second door modules.

[0034] In another aspect, a system for opening and closing a door relative to a vehicle body is provided. The system includes: a first door and a second door, each of the first and second doors including: a hinge module configured to be mounted to the vehicle body; a door module configured to be mounted to the hinge module and further configured to close a door opening defined by the vehicle body, wherein the door module includes an embedded post structure disposed at a front or rear edge of the door module; a latch mechanism disposed on the door module and configured to engage a striker that protrudes from the vehicle body, the latch mechanism including: a mounting plate configured to be attached to the post structure; a pawl pivotally attached to the mounting plate and pivotable about a pivot axis; a compression spring attached to opposite sides of the pawl, the compression spring biasing the pawl to a nominal closed position; wherein misalignment of the striker into causes the pawl to pivot about the pivot axis from the nominal position to a displaced position, and upon insertion of the striker, the pawl returns to the nominal position and the mounting plate is displaced relative to the post structure.

[0035] In one aspect, the pawl includes a first portion and a second portion that are pivotable outward about the pivot axis in response to insertion of the striker.

[0036] In one aspect, the compression spring is attached to each of the first and second portions of the pawl and biases the first and second portions into the closed position.

[0037] In one aspect, the secondary latch mechanism is releasable by an electric power actuator and a cam that opens the pawl.

[0038] In one aspect, the secondary latch mechanism is releasable by a mechanical back-up lever that moves the cam that opens the pawl.

[0039] In one aspect, the mounting plate or the post structure includes an oversized mounting hole that allows the mounting plate to be displaced relative to the post structure.

[0040] In one aspect, a door opener mechanism is disposed between the vehicle body and the door.

[0041] In another aspect, a system for opening and closing a door relative to a vehicle body includes: a first door and a second door, each of the first and second doors including: a hinge module configured to be mounted to the vehicle body; a door module configured to be mounted to the hinge module and further configured to close a door opening defined by the vehicle body, wherein the door module includes an embedded post structure provided at a front or rear edge of the door module; wherein the door module includes a latch mechanism configured to latch with the vehicle body; wherein the first door cooperates with the second door and defines an interface therebetween, wherein the embedded post of the first door and the embedded post of the second door are provided adjacent to each other at the interface; wherein the interface includes a sealing arrangement including a primary seal provided at an inner side of the interface and a secondary seal provided at an outer side of the interface, wherein the primary and secondary seals have a constant cross section extending substantially entirely along the interface.

[0042] In one aspect, at the location of the secondary seal, a lower portion of the interface is wider than an upper portion, and wherein a filler is provided in the lower portion between the secondary seal and the door module.

[0043] In one aspect, the primary and secondary seals are attached to a single door.

[0044] In another aspect, a system for opening and closing a door relative to a vehicle body includes: a first door and a second door, each of the first and second doors including: a hinge module configured to be mounted to the vehicle body; a door module configured to be mounted to the hinge module and further configured to close a door opening defined by the vehicle body, wherein the door module includes an embedded post structure provided at a front or rear edge of the door module; wherein the door module includes a latch mechanism configured to latch with the vehicle body; wherein the hinge module includes a first hinge lever and a second hinge lever, the first and second hinge levers being pivotable relative to each other during a door opening operation; a hinge pin extending between the first and second hinge levers, the hinge lever being fixed to the first hinge lever; a permanent magnet fixed to the lower hinge lever; a ring-shaped bracket fixed to the permanent magnet; a steel plate biased towards the permanent magnet, wherein the steel plate is locked with the ring-shaped bracket when adjacent to the permanent magnet in a closed position, and wherein the steel plate is rotatable relative to the ring-shaped bracket when distanced from the permanent magnet in an open position; wherein exciting the permanent magnet displaces the steel plate from the closed position to the open position, thereby allowing relative movement between the first and second hinge levers.

[0045] In one aspect, the steel plate is mounted to the hinge pin and slidably attached to the hinge pin.

[0046] In one aspect, the steel plate is fixed in rotation to the hinge pin.

[0047] In one aspect, the first hinge rod is an upper hinge rod attached to the door module and the second hinge rod is a lower hinge rod pivotably attached to the vehicle body.

[0048] In one aspect, the ring bracket comprises axially protruding teeth and the steel plate comprises corresponding notches for receiving the teeth in the closed position. BRIEF DESCRIPTION OF DRAWINGS

[0049] Other advantages of the present invention 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:

[0050] Figure 1 is a perspective view of a vehicle door system illustrating a hinge module and a door module, wherein the door module can be attached to the hinge module;

[0051] Figure 2 is an exploded perspective view of a second vehicle door illustrating alternative supports joining the hinge module to the door structure;

[0052] Figure 3 is a perspective view of a second vehicle door illustrating the supports and the door structure in an assembled state;

[0053] Figure 4 is a partial cross-sectional perspective view illustrating the reinforcement structure at the interface location between the doors;

[0054] Figure 5 is a cross-sectional plan view illustrating the reinforcement structure and the door structure at the interface;

[0055] Figure 6 is a perspective view illustrating two vehicle doors in a closed position;

[0056] Figure 7 is another perspective view illustrating two vehicle doors in a closed position;

[0057] Figure 8 is Figure 7 a perspective view of one of the two vehicle doors of

[0058] Figure 9 is a cross-sectional view illustrating the sealing mechanism disposed between the two vehicle doors;

[0059] Figure 10 is another cross-sectional view illustrating the sealing mechanism disposed between the two vehicle doors;

[0060] Figure 11 is a perspective view illustrating two door modules, two hinge modules, a door check mechanism, a door opener, a primary latch mechanism, and a secondary latch mechanism in a closed position of the door according to an aspect of the present disclosure;

[0061] Figure 12 is another view of the vehicle door according to an aspect of the present disclosure illustrating the position of the secondary latch mechanism, the door check mechanism, and the door opener;

[0062] Figure 13 is a perspective view of the secondary latch mechanism mounted to the B-pillar of the vehicle door according to an aspect of the present disclosure;

[0063] Figure 14 is a front view of the secondary latch mechanism;

[0064] Figure 15 is a rear view of the secondary latch mechanism illustrating oversized mounting holes of the latch mounting surface for X-axis and Z-axis adjustment;

[0065] Figure 16 is a perspective view illustrating Y-axis adjustment of the striker for the secondary latch mechanism;

[0066] Figure 17 illustrates a misaligned secondary latch mechanism and a pivoting pawl to accommodate the misalignment;

[0067] Figure 18 illustrates the secondary latch mechanism after latching following the misalignment of Figure 17 ;

[0068] Figure 19 is a perspective view of the door check mechanism between the upper hinge bar and the lower hinge bar of the hinge module;

[0069] Figure 20 is a cross-sectional view of the door check mechanism;

[0070] Figure 21 is a perspective view of the door opener with the pawl in a closed position;

[0071] Figure 22 is another perspective view of the door opener with the pawl in an open position;

[0072] Figure 23 is a perspective view of two vehicle doors in a sealed arrangement;

[0073] Figure 24 illustrates a primary seal and a secondary seal provided on only one of the two doors;

[0074] Figure 25 is a cross-sectional view illustrating a sealing member in an upper portion of the sealing device; and

[0075] Figure 26 is a cross-sectional view illustrating a sealing member in a lower portion of the sealing arrangement and including a filler between the door and the secondary seal. DETAILED DESCRIPTION

[0076] Referring to Figure 1 , a vehicle door system 10 is provided. The system 10 is configured to be attached to a vehicle body (not shown), and the system 10 includes a door module 12 and a hinge module 14. The hinge module 14 is configured to be attached to the vehicle body and the door module 12, wherein the hinge module 14 is manipulated to effect corresponding movement of the door module 12 relative to the vehicle body. The door module 12 is fixed to the hinge module 14 and is movable between an engaged position / closed position relative to the vehicle body and a disengaged position / opened position relative to the vehicle body.

[0077] When the door module 12 is in the opened position, the door module 12 does not remain engaged with a portion of the vehicle body as in a traditional hinged connection between a vehicle door and a vehicle body pillar. Rather, the door module 12 can effectively be completely separated from the vehicle body when opened. It will be understood that the door module 12 is ultimately still coupled to the vehicle body via the hinge module 14, but the door module 12 does not pivot about an axis proximate to one of the vehicle body pillars as in a traditional hinged vehicle door design. Further, it will be understood that the traditional hinged vehicle door design referred to is one in which the door is attached to the vehicle body via a simple hinge arrangement and the door can not directly contact the vehicle body when opened. The present system 10 differs from this traditional arrangement, which will be described in further detail below.

[0078] With further reference to the door module 12 shown in Figure 1 , the door module 12 can include a plurality of components that can be assembled prior to installation to the hinge module 14 and ultimately to the remainder of the vehicle. The door module 14 can include a door panel 16 that generally defines the outer profile and overall shape of the door module 12. The door panel can have an inner portion 16a and an outer portion 16b. The outer portion 16b is the portion of the door panel 16 that faces outwardly toward the vehicle body, while the inner portion 16a is the portion that faces inwardly toward the vehicle interior. The inner portion 16a and the outer portion 16b can be fixed to one another in a known manner, such as via welding, fasteners, adhesives, or a combination of these attachment mechanisms. The inner portion 16a and the outer portion 16b are preferably fixed in place relative to one another.

[0079] The inner portion 16a and the outer portion 16b can combine to define an internal cavity 18 between the inner portion 16a and the outer portion 16b. The internal cavity 18 can include additional structures that can be mounted to the door panel 16 via the inner portion 16a, the outer portion 16b, or both the inner portion 16a and the outer portion 16b. The internal cavity 18 can also include wiring harness components that provide power and communication to internally mounted components.

[0080] The door module 12 can include a plurality of window components that can be in the form of power operated window components or manually operated window components. For purposes of discussion, power window components will be described. The door module 12 can include a window glass 20 that can be disposed within the cavity 18 when the window is in a position and that can extend out of the cavity when the window is in a closed position, with the glass 20 having intermediate positions between a fully open position and a fully closed position.

[0081] The glass 20 is supported for movement by guide channels 22 that can be disposed on opposite sides of the glass 20. The channels 22 are disposed within the cavity 18 and are attached to the door panel 16 in a generally fixed position. When the window is operated, the glass 20 will move relative to the channels 22, which allow the glass 20 to move in opposite directions generally along one axis of movement, depending on whether the window is being opened or closed. The channels 22 can have a U-shape, with the base of the "U" receiving the edge of the glass 20.

[0082] The door module 12 can also include a window regulator 24 that is part of an overall window regulator assembly that also includes pulleys, regulator cables, regulator carriers, regulator tracks, motors, and drive mechanisms. The window regulator 24 and associated system can be a conventional system in which the window glass 20 is attached to a carrier portion and actuation of the regulator 24 will drive the window glass 20 between open and closed positions by actuating various interconnected elements.

[0083] The door module 12 can also include a latch mechanism 26 that can be a power latch, a manual latch, or both a power latch and a manual latch. The latch mechanism 26 is configured to receive an electronic or manual signal that will actuate the latch mechanism 26 to open the latch and allow the latch to move relative to a corresponding latch structure. The latch mechanism 26 can be partially or completely disposed within the cavity 18, with a portion of the latch mechanism 26 exposed from the door panel 16 via an opening in the panel that provides access to the cavity, or via an extension of the latch mechanism that extends out of the cavity 18.

[0084] A latch mechanism can be provided at the bottom portion 12a of the door module 12. The door module 12 can also include a top portion 12b, a front portion 12c, and a rear portion 12d. Each of these portions can include a corresponding edge that defines the outer profile of the door module 12. The door module 12 described herein is in relation to a “front” door of a vehicle. The description herein applies equally to a “rear” door of a vehicle (meaning a door that is typically rearward of and adjacent to a “front” door of a vehicle, and not a rear hatch or the like). It will be understood, however, that the functionality and structure of the disclosed door module 12 can also be used for a cargo door or “rear” door, such as a door at the rear of a van or the like. In other words, the disclosed structure can be used as one half in a twin door arrangement, with the other door having similar or identical structural features mirrored across the mating plane between the twin doors, or the structure can be used as a single door.

[0085] Each edge or portion of the door module 12 is configured to mate with a corresponding structure, and can include a sealing member or the like along the edge to limit ingress of intruders or water or debris into the vehicle cabin when the door module 12 is in the closed position. The front edge and the top edge of the door module 12 can be configured to mate with corresponding edges of the vehicle body, and no other mounting structure or hardware is interposed between the vehicle body and the edges of the door module 12. This is different from conventional door modules, in which the front edge of the door will typically include a connector that connects with a hinge mechanism mounted to the vehicle body, with the hinge mechanism being directly attached between the vehicle body and the front edge of the door.

[0086] The bottom edge has a latch mechanism 26, which can be provided at an intermediate region of the bottom edge. The latch mechanism 26 is configured to mate with a corresponding structure provided on the bottom edge of the door opening defined by the vehicle body.

[0087] The rear edge can be configured to mate with the front edge portion of the “rear” configuration of the door module 12. As described above, the “rear” configuration can be identical or similar to the door module 12 described, but mirrored. One alternative embodiment of the door module 112 and hinge module 114 is described in further detail below, and is illustrated as a “rear” configuration. The features of the door module 112 and hinge module 114 discussed below can also apply to the “front” configuration. Thus, the features of the door module 12 and hinge module 14 described herein can also apply to a corresponding second door, and the features of the door module 112 and hinge module 114 can equally apply to a second door. Thus, the rear edge of the rear configuration mates with the vehicle body, while the front edge of the rear configuration mates with the rear edge of the door module 12 described and illustrated. The “front” configuration shown and previously described will continue to be described herein.

[0088] The rear edge of the door module 12 can include a sealing structure 700 (atFigures 8 to 10 are shown in detail and with reference to Figures 8 to 10 The seal structure 700 is configured to cooperate with another door rather than with the structure of the vehicle body (as discussed further below). The seal structure can be in the form of a flexible and resilient lip that can be configured to flex inwardly or outwardly in response to inward or outward forces. The seal structure can also take other forms. The seal structure is preferably configured to allow the door modules 12 to be independently opened or closed regardless of the open / closed state of the other door with which the seal structure can cooperate. Such independent operation of the door modules 12 is possible because the latch mechanism 26 is disposed on the bottom edge of the door module 12 such that the latch mechanism does not cooperate with the other door (as in a conventional dual door arrangement). The unique manner in which the seal is between the front and rear doors at the B-pillar also enables independent operation of the doors. Thus, either door module 12 can be opened while the other remains closed, or both can be opened and closed in any order.

[0089] The door module 12 can also include attachment points 30 for attaching the hinge module 14 to the door module 12. The door module 12 can include four attachment points 30, with two of the attachment points disposed at upper locations and two of the attachment points disposed at lower locations. The upper attachment points 30 can be disposed at approximately the same height on the door panel 16 and spaced longitudinally along the door panel 16. The attachment points 30 can be in the form of reinforced rigid structures, such as threaded bushings or other fasteners. The lower attachment points 30 can also be disposed at approximately the same height on the door panel 16 and spaced longitudinally along the door panel 16. Of course, it will be understood that the locations of the attachment points 30 can vary so long as the spacing of the hinge module 14 matches the spacing on the door module 12 and such spacing is sufficient to support the weight of the door module 12.

[0090] The spacing between the lower attachment points 30 can be different than the spacing between the upper attachment points 30. For example, the spacing between the upper attachment points 30 can be greater than the spacing between the lower attachment points 30. The upper and lower attachment points 30 can be longitudinally offset relative to one another such that no two attachment points 30 are disposed at the same longitudinal location. For example, the front upper attachment points 30 can be forward from the front lower attachment points 30, and the rear upper attachment points 30 can be forward from the rear lower attachment points 30. However, it will be understood that other distributions of attachment points capable of sufficient cooperation with corresponding structures of the hinge module 14 can also be used.

[0091] Turning now to the hinge module 14, the hinge module can include a plurality of interconnected components that allow the hinge module 14 to be displaced and pivoted relative to an attachment of the hinge module 14 to the vehicle body. The hinge module 14 can include a hinge bracket 40 configured to be mounted to the vehicle body. The hinge bracket 40 can be configured to support an upper arm 42 and a lower arm 44 that are pivotable relative to the hinge bracket 40. The hinge module 14 can also include a cross brace 46 that is pivotably attached to the arms 42 and 44. The cross brace 46 is configured to be attached to the door module 12. The cross brace 46 is one embodiment of a brace that can be used as part of the hinge module 14. An alternative I-shaped brace 146 is described with reference to the hinge module 114 and can also be used with the hinge module 14. Features of the cross brace 46 and the hinge module 14 that are independent of the shape of the cross brace 46 can also apply to the I-shaped brace 146.

[0092] The hinge bracket 40 can include an upper pivot pin 48 and a lower pivot pin 50, where the upper pivot pin 48 joins the upper arm 42 to the hinge bracket 40 and the lower pivot pin 50 joins the lower arm 44 to the hinge bracket 40. The upper pivot pin 48 can be disposed at a rearward longitudinal position relative to the lower pivot pin 50. Thus, the arms 42 and 44 are mounted to pivot relative to the hinge bracket 40. It will be appreciated that other types of pivot connections can be used between the hinge bracket 40 and the arms 42 and 44.

[0093] The upper arm 42 can have a generally straight shape so as to extend longitudinally from the hinge bracket 40 when the hinge module 14 is in a closed position corresponding to the door module 12 being closed. The lower arm 44 can have a curved shape having a first portion that extends longitudinally from the hinge bracket 40 and then curves downwardly and extends rearwardly and downwardly, and the curve is relatively upwardly to extend in the longitudinal direction. The lower arm 44 can be described as having a flattened S-shape or Z-shape. Thus, the lower arm 44 can be considered to include an angled portion that is disposed at an oblique angle relative to the upper arm 42.

[0094] The upper arm 42 can extend to a rearward longitudinal position relative to the end of the lower arm 44 when the hinge module 14 is in the closed position. The upper arm 42 also begins from a rearward longitudinal position relative to the lower arm 44. Thus, the longitudinal distance between the ends of the upper arm 42 can be approximately the same as the longitudinal distance between the ends of the lower arm 44.

[0095] Given the curved shape of the lower arm 44 and the straight shape of the upper arm 42, the vertical distance between the ends of arms 42 and 44 at the hinge bracket 40 is smaller than the vertical distance between the ends of arms 42 and 44 opposite to the hinge bracket 40. Therefore, the ends of arms 42 and 44 are spaced apart to provide sufficient support for the cross support 46 attached to the door module 12.

[0096] The cross support 46 can be attached to arms 42 and 44 via bracket 54. Bracket 54 can be fixedly mounted to the cross support 46 and can extend over the ends of arms 42 and 44. Bracket 54 can be attached to the ends of arms 42 and 44 via pin 54a, which extends through the structural members of arms 42 and 44. Therefore, bracket 54 is pivotally rotatable relative to arms 42 and 44. Thus, the cross support 46 is pivotally rotatable relative to arms 42 and 44. The lower bracket 54 is forward-positioned relative to the upper bracket 54, similar to how the lower pin 50 of the hinge bracket 40 is forward-positioned relative to the upper pin 50.

[0097] The cross support 46 may have a generally X-shaped form with arms 58 extending outward from the central hub portion 59 in four directions. Arms 58 may include a front upper arm 58a, a front lower arm 58b, a rear upper arm 58c, and a rear lower arm 58d. Each of the arms 56 extends a different distance from the central hub portion 59. The front upper arm 58a extends in generally opposite directions to the rear lower arm 58d, and the front lower arm 58b extends in generally opposite directions to the rear upper arm 58c. The front upper arm 58a may extend further forward than the front lower arm 58b. The rear lower arm 58d may extend further rearward than the rear upper arm 58c.

[0098] The cross support 46 accordingly has four ends 60, which can be attached to four attachment points 30 of the door module 16. The four ends 60 include fastening structures spaced apart in a manner corresponding to the spacing of the attachment points 30 on the door module. The fastening structures may be in the form of through holes or similar openings that can receive fasteners that engage with the ends 60 of the cross support 46 and the attachment points 30 of the door module 12. It will be understood that the cross support 46 can have other shapes with additional attachment points 30 or fewer attachment points 30.

[0099] The hinge module 14 is movable between a closed position and an open position, in which the supported door module 12 is in a closed position against the vehicle body, and in the open position, the door module 12 is positioned away from the vehicle body and disconnected from it. Figure 1 The closed position of hinge module 14 is shown in the figure.

[0100] To move from the closed position toward the open position, the arms 42 and 44 can pivot relative to the hinge bracket 40. The outer ends of the arms 42 and 44 will move outwardly along an arcuate path corresponding to the radius defined between the pivot point on the hinge bracket 40 and the pivot point at the cross support 46. Based on the same approximate longitudinal distance between the respective pivot points at the opposite ends of the arms 42 and 44, the radius of curvature of each of the outer ends of the arms 42 and 44 is approximately the same.

[0101] However, due to the offset of the pivot points at the hinge bracket 40, the outer ends of the arms 42 and 44 will move relatively closer to each other as the arms 42 and 44 pivot away from the closed position, and will become vertically aligned at the point of radius intersection. Based on the attachment between the door panel 16 and the cross support 46, the door module 12 will open in accordance with the movement of the cross support 46.

[0102] Turning now to Figure 2 , the door module 112 and the hinge module 114 are illustrated. Features of the door module 112 and the hinge module 114 can also apply to the door module 12 and the hinge module 14, unless otherwise noted. In particular, the I-shaped support 146 can be used with the door module 12, and Figure 2 The structural reinforcement of the door module 112 illustrated in

[0103] The door module 112 and the hinge module 114 are illustrated in a "rear" configuration. Thus, the door module 12 and the door module 112 can mate with each other at the interface 100, which is disposed at the rear of the front door and the front of the rear door. The interface 100 is arranged to allow the front door or the rear door to be independently operated and opened relative to the other.

[0104] The hinge module 114 can include an I-shaped support 146 that operates similarly to the cross support 46, as the I-shaped support 146 is attached to the arms 42 and 44, which are attached to the bracket 40, which is attached to the vehicle body. The I-shaped support includes an upper rail 148 and a lower rail 150, each of which is pivotally attached to a corresponding arm 42 and 44, similar to the hinge module 14. The upper rail 148 and the lower rail 150 extend generally horizontally and parallel to each other, and can have approximately the same length.

[0105] The upper rail 148 is attached to the lower rail via a connector plate 152. The connector plate 152 extends generally vertically between the upper rail 148 and the lower rail 150. In the "rear" configuration, the connector plate 152 is disposed forward relative to the pivotal connection of the arms 42, 44. The upper and lower ends of the connector plate 152 can be attached to the upper rail 148 and the lower rail 150 in a manner known in the art, such as via fasteners, welding, or other robust joining methods.

[0106] The upper rail 148 and the lower rail 150 can have a square cross-section or a U-shaped cross-section. The connector plate 152 can have a generally flat cross-section. Thus, the upper rail 148 and the lower rail 150 and the connector plate 152 can combine to define a robust unit in the form of the I-shaped support 146 that can be attached to the door module 12 in a robust and rigid manner, as shown in Figure 3 .

[0107] The upper rail 148 is disposed above the upper arm 42, and the lower rail 150 is disposed below the lower arm 44. Thus, the arms 42, 44 can pivot relative to the I-shaped support 146 without interfering with the upper rail 148 and the lower rail 150, then the door module 12 is opened and the arms 42, 44 are pivoted relative to the bracket 40.

[0108] The I-shaped support 146 has been shown and described with reference to Figure 2 and Figure 3 , but it will be understood that the I-shaped support 146 is a related structure that can also be used with the door module 12 shown in Figure 1 .

[0109] Figure 2 and Figure 3 The door module 112 shown in also includes an additional reinforcing support structure relative to a conventional door or closure panel. In particular, the door module 112 includes an embedded pillar 160 disposed at the front edge of the illustrated "rear" configuration of the door module 112. In the absence of a conventional B-pillar, which is typically disposed at the front of a rear door, the embedded pillar 160 provides additional support to the door module 112. The embedded pillar 160 can similarly be disposed at the rear edge of a front door. In other words, the embedded pillar 160 is disposed at the interface 100 of both the front and rear doors of a pair of doors incorporating the disclosed system 10. Incorporating the embedded pillar 160 allows the exclusion of a pillar structure on the vehicle body, thereby creating a greater overall door opening when the door is open. The embedded pillar 160 provides rigidity to the vehicle against impact and other loads when the door is closed.

[0110] The embedded pillar 160 is disposed at Figure 4 and Figure 5The door module 112 can include an outer sheet 162 that defines an outward facing surface of the door module 112. The outer sheet 162 is disposed outwardly relative to the embedded post 160. The outer sheet 162 will generally wrinkle in response to an impact, as in a typical vehicle door. Figure 4 and Figure 5 Also shown in the cross-section is an inner sheet 164 that is disposed on the inner side of the embedded post 160. The outer sheet 162 and the inner sheet 164 do not substantially fold over the lateral edges (front or rear, depending on the door).

[0111] As shown in the cross-section, the outer sheet 162 defines a folded-over hem flange 162a at the edge. The hem flange 162 is defined by the folded-over edge of the sheet 162. The inner surface of the hem flange 162 can be attached to the embedded post 160 via structural adhesive or single-sided welding to join the embedded post 160 with the outer sheet 162. Figure 4 and Figure 5 The embedded post 160 can be defined by combining a curved outer portion 160a with a curved inner portion 160b. The inner portion 160a and the outer portion 160b can combine to define a closed cross-section, defining an inner cavity 160c. The inner portion 160b can be wrapped around the outer portion 160a, and the inner portion 160b can be the portion that joins with the folded-over hem flange 162a of the outer sheet 162. Thus, as the inner portion 160b is wrapped around the outer portion 160a, the inner portion 160b can be disposed closer to the interface 100 than the outer portion 160a. The inner cavity 160c can include a wide portion 160d at the front and a narrow portion 160e at the rear that extends rearward from the wide portion 160d. It will be understood that “front” and “rear” can be reversed for the opposite configuration of the door. Additional door panel sheeting or structure can be attached to the embedded post 160 and / or the outer sheet 162 and the inner sheet 164 to define an overall door structure, to mount additional structure to the overall door structure.

[0112] The outer portion 160a and the inner portion 160b can be attached to one another by a MIG welding process. Of course, other joining methods sufficient to join the parts securely together and withstand vehicle side impact can be used. Additional door structure can be attached to the embedded post 160 by welding, riveting, bonding, adhesive, etc. The embedded post 160 can be made of steel or a similar material with similar strength characteristics. The additional sheeting attached to the embedded post can be aluminum or the like.

[0113] The outer portion 160a and the inner portion 160b can be attached to one another by a MIG welding process. Of course, other joining methods sufficient to join the parts securely together and withstand vehicle side impact can be used. Additional door structure can be attached to the embedded post 160 by welding, riveting, bonding, adhesive, etc. The embedded post 160 can be made of steel or a similar material with similar strength characteristics. The additional sheeting attached to the embedded post can be aluminum or the like.

[0114] Accordingly, the use of the embedded pillar 160 enables the door module 12 or 112 to meet the side intrusion requirements of a passenger vehicle even without the use of a traditional B-pillar in the vehicle body. The use of the embedded pillar 160 allows the door module 12 or 112 to be paired with an opposite configuration such that a front door and a rear door are provided. The interface 100 between the front door and the rear door allows the doors to be able to operate independently of one another without a B-pillar or latch structure disposed between the front door and the rear door.

[0115] As previously described, although the embedded pillar 160 is described with reference to the door module 12, Figures 2 to 5 it can also be included in the door module 12 shown in Figure 1 .

[0116] The system 10 described above allows the doors having the system 10 to be independently operated in that the front and rear doors latch to the vehicle body rather than to another door. The front and rear doors using the system 10 can seal against one another at the interface 100 without a B-pillar. The doors using the system 10 can meet side impact requirements based on structural and safety interlocks with the vehicle body.

[0117] To assemble the system 10 with the vehicle body, first, the hinge module 14 / 114 can be installed to the vehicle using the fastening provisions and utilizing the planes of slippage in the fore-aft and up-down directions. Then, the door module 12 / 112 can be installed to the hinge module using the fastening provisions and utilizing the planes of slippage in the fore-aft and up-down directions.

[0118] The modular aspects of the hinge module 14 and the modular aspects of the door module 12 / 112 allow different door modules 12 / 112 to be paired with a previously installed hinge module 14. Accordingly, a variety of different door module types can be designed for use with a common hinge module 14.

[0119] Additional aspects of the system 10 are shown with reference to Figures 6 to 10 . With reference to Figure 6 , both the front door module 212a and the rear door module 212b are shown in a closed position with the corresponding front hinge module 214a and rear hinge module 214b shown coupled to the door modules 212a, 212b. Unless otherwise noted, the above-described features and functions of the door modules 12, 112 and the hinge module 14 can apply to the door modules 212a and 212b and the hinge modules 214a and 214b. Similarly, unless otherwise noted, features and functions of other components described with respect to the door modules 212a and 212b and the hinge modules 214a and 214b can apply to the previously described door modules 12, 112 and the hinge module 14.

[0120] Figure 6The door modules 212a and 212b are shown in a closed position, providing a sealed engagement between the door modules 212a and 212b. The system 10 can also include front and rear power actuators 280 configured to provide powered opening and closing of the doors. The actuators 280 can be in the form of linear actuators and can be pivotally secured at each end. One end of the actuator 280 can be attached to the hinge bracket 40 and the opposite end can be attached to the upper arm 42 or the lower arm 44. Upon actuation and extension of the actuator 280, the hinge module 214 can be caused to move open and the door modules 212a, 212b can be caused to open from their closed position. Similarly, upon actuation and retraction of the actuator 280, the door modules 212a, 212b can be caused to close from their open position. The actuators 280 can be included in a pre-assembled state on the door modules 212a, 212b or the hinge modules 214a, 214b. In another aspect, the actuators 280 can be provided as separate components.

[0121] In one aspect, the system 10 can include a cinching mechanism 282 for both the front door module 212a and the rear door module 212b. In one aspect, a front cinching mechanism 282a can be provided at a front portion of the front door module 212a proximate the hinge bracket 40. A central cinching mechanism 282b can be provided at the top of the front door module 212a and the rear door module 212b. The cinching mechanism 28 is operable to pull the door modules 212a and 212b closed fully after the latch mechanism 26 provided on the bottom of the door is engaged. The central cinching mechanism 282b can be configured to cinch the doors together and the front cinching mechanism 282a can be configured to cinch and pull the doors to the body.

[0122] In one aspect, the system 10 can include a latch mechanism 284 associated with each of the actuators 280. The latch mechanism 284 can be configured to lock when the door modules 212a, 212b are in an open position, thereby prohibiting the door modules 212a, 212b from closing and / or moving to prevent contact with other areas of the vehicle when the door modules 212a, 212b are in an open position. The latch mechanism 284 can be configured to lock after the power actuator 280 has caused the door to open and can also be configured to disengage before the actuator 280 is actuated to cause the door to close.

[0123] The actuators 280, the cinching mechanisms 282 and the latch mechanisms 284 can each be operatively connected to a controller or the like configured to send signals for operating each of these components to cause the doors to automatically open, lock in place and close in response to a corresponding associated command signal.

[0124] Turning now to Figures 7 to 10A seal mechanism 700 is illustrated with respect to the door modules 212a, 212b. In one aspect, the seal mechanism 700 can be provided on only one of the doors 212a or 212b, with the opposite door configured to engage the seal mechanism 700 when closed.

[0125] In one aspect, the seal mechanism can include a first sealing member 702 that extends generally vertically along substantially the entire height of the inter-door interface. The seal mechanism 700 can also include a second sealing member 704 and a third sealing member 706 that combine to extend vertically along substantially the entire height of the inter-door interface. The first sealing member 702 can be provided on an inboard portion of the interface, and the second and third sealing members 704, 706 can be provided on outboard sides of the sealing interface. Thus, at almost any vertical location along the interface, two sealing members are provided in the direction of the vehicle interior, providing redundancy.

[0126] The first sealing member 702 can have a box-like cross-section, and have an elongated cavity that extends substantially the entire length of the sealing member 702. Thus, in response to a force applied on the sealing member, the sealing member 702 can flex in a responsive manner. The sealing member 702 can be made of a flexible and resilient material, such as rubber.

[0127] The second and third sealing members 704, 706 can have a fin-like shape or a lip-like shape. The second sealing member 704 can be provided above the third sealing member 706, and can be provided along a portion of the door that defines a window opening. The second sealing member can have a curved shape to define a loop, and the second sealing member can be provided between a pair of inwardly extending flanges of the door structure.

[0128] The third sealing member 706 can be provided along a lower portion of the door below the window opening. The third sealing member 706 can have an L-shaped shape or the like, and can extend between the doors such that the third sealing member 706 spans the opening between the opposing rolled flanges of the door modules 212a, 212b. When one of the doors is opened, the seal mechanism 700 will remain in place or move with the opening door. When the doors are returned together, the seal mechanism 700 will re-engage the opposite doors.

[0129] Turning now to Figure 11 In another aspect, a modular door system 800 is illustrated. The system 800 includes many of the same aspects and advantages as described above, and can include any of the above aspects not expressly discussed herein with respect to the system 800.

[0130] System 800 includes door modules 812a and 812b. As previously described, each door module 812a, 812b is pivotable about a front hinge structure or a rear hinge structure. As described above, door modules 812a, 812b are sealed together at the central B-pillar location.

[0131] Door module 812a includes a main door latch 813a disposed at its bottom edge. The main door latch 813a is configured to interact with the vehicle body, particularly the bottom edge of the vehicle body, which defines an opening within the vehicle body for passenger access. Door module 812b similarly includes a main door latch 813b disposed at its bottom edge, which operates similarly to the main door latch 813a of door module 812a.

[0132] System 800 also includes auxiliary latching mechanisms 815a, 815b, and 815c. The first auxiliary latching mechanism 815a is located at the top of the B-pillar of door module 812a. The second auxiliary latching mechanism 815b is located at the top of the B-pillar of door module 812b. Therefore, the first and second auxiliary latching mechanisms 815a and 815b are arranged adjacent to each other when door modules 812a and 812b are in the closed position. The third auxiliary latching mechanism 815c is located in the front hinge area (front A-pillar area) of door module 812a.

[0133] As described above, hinge modules 814a and 814b are attached to door modules 812a and 812b at multiple attachment points. Door modules 812a and 812b can be actuated by corresponding actuators such as linear actuators, spindles, or the like. Door modules 812a and 812b may be pre-assembled with window adjusters, glass, channels, etc., in a pre-painted state for attachment to hinge modules 814a and 814b in the manner previously described herein.

[0134] System 800 may also include a magnetic door limiting mechanism 817 installed on one or both of door modules 812a and 812b. For example... Figure 11 As shown, the magnetic door limiting mechanism 817 is mounted on the door module 812a. The magnetic door limiting mechanism 817 will be described in further detail below.

[0135] Now refer to Figure 12 The system 800 may also include a door opener mechanism 819 disposed at the bottom edge of the door module 812a. Figure 12 The diagram also illustrates that the auxiliary latching mechanisms 815a and 815c (B-pillar position and a-pillar position) can have a common design. This common design provides convenience for installation and operation, which will be described in further detail below.

[0136] Figure 13Additional details are illustrated with respect to the secondary latch mechanisms. For purposes of discussion, secondary latch mechanism 815a will be described, with the details applicable to each secondary latch mechanism. Secondary latch mechanism 815a has a compact packaging arrangement that enables installation at the top of the b-pillar. Secondary latch mechanism 815a is actuatable primarily via an electric power mechanism, and secondary latch mechanism 815a also includes a mechanical release mechanism as a back-up.

[0137] Secondary latch mechanism 815a can be operable without the use of a cinching mechanism in accordance with an aspect of the present disclosure. The cinching mechanism can be eliminated due to improved alignment of the door with the vehicle body.

[0138] As previously described in the present disclosure, door modules 812a, 812b are independently operable. Thus, secondary latch mechanisms 815a, 815b are independently operable. Actuation of one door module to release the corresponding door module can be performed without actuation or opening of the other door module.

[0139] As previously described in the present disclosure, door modules 812a, 812b are independently operable. Thus, secondary latch mechanisms 815a, 815b are independently operable. Actuation of one door module to release the corresponding door module can be performed without actuation or opening of the other door module. Figures 13 to 14 As shown in FIG. 17, secondary latch mechanism 815a includes a protective cover 815d within which the components of the latch mechanism are stored. Protective cover 815d generally defines the packaging size of latch mechanism 815a, and can be attached to a mounting plate 815e of latch mechanism 815a. Mounting plate 815e is attachable to the b-pillar, as described in further detail below.

[0140] Latch mechanism 815a also includes an electric power release cable 821 that provides electric power to an electric power release actuator 823, such as a motor. Actuator 823 is operable to cause rotational motion of a shaft that rotates a gear 829, such as a worm gear, attached to the shaft. Worm gear 829 is meshingly engaged with a cam mechanism 829 that operates on a self-centering pawl 831 described in further detail below. A compression spring 833 acts on self-centering pawl 831 to bias pawl 831 to a closed position in engagement with a vehicle body mounted striker 835. Vehicle body mounted striker 835 includes a tapered head portion operable to force pawl 831 open in the closing direction, but prevents the tapered head portion from retracting in the door opening direction if pawl 831 is not actuated to the open position.

[0141] Latch mechanism 813 also includes a mechanical back-up release cable 837 that mechanically pulls cam mechanism 829 via a rod 837a to open pawl 831 and release striker 835.

[0142] Mounting plate 815e is adjustable with respect to the vehicle body and vehicle body mounted striker 835. As shown in FIG. 17, mounting plate 815e includes a threaded hole 815f that is threadably engaged with a threaded rod 815g that is attached to the vehicle body. Threaded rod 815g is operable to adjust the position of mounting plate 815e, and thus latch mechanism 815a, with respect to the vehicle body. Figure 15As shown, mounting plate 815e includes oversized mounting holes 815f, thereby allowing adjustment along the X and Z axes. Additionally, the stop pin 835 is adjustable along the Y direction, as... Figure 16 As shown in the diagram. Therefore, the structural variations of the body and door modules 812a and 812b can be adapted through normal operation.

[0143] like Figure 17 and Figure 18 As shown, the self-centering pawl 831 accommodates misalignment between the latching mechanism 815a and the striking pin 835. The pawl 831 is mounted to the mounting plate 815e via a pivot axis 831a, allowing the pawl 831 to pivot relative to the mounting plate 815e. A compression spring 833 biases the pawl 831 toward the pin 835, holding the pawl engaged with the pin 835 even as the pawl 831 pivots relative to the pivot axis 831a. Therefore, the striking pin 835 may be misaligned if it is not yet engaged with the pawl 831. During door closing operation, when in contact with the pawl 831, the pin 835 may engage the pawl 831 in an offset position, such as... Figure 17 As shown in the diagram. When this is done, the pawl 831 will pivot about axis 831a, and the compression spring 833 on one side will be compressed, while the compression spring 833 on the other side applies pressure to the pawl 831 so that the pawl 831 engages with the pin 835.

[0144] After latching is complete, the compression spring 833 will balance, causing the mounting plate 815e to shift so that the pawl 831 is centered on the pin 835 and the compression spring 833 is in approximately the same position. Therefore, the pivoting of the pawl 831 occurs during the door closing operation, but once the door is closed, the pawl 831 returns to the intermediate position. The pawl 831 can be released upon actuation by an electric actuator or a mechanical backup mechanism 837.

[0145] As shown in the attached diagram, the above process can be used at different locations on the vehicle body relative to the door module, where the operation is the same, thereby improving installation efficiency. When located on each B-pillar, door modules 812a and 812b can be opened independently, wherein each door module retains a latch and is secured to the vehicle body even when the other door module is opened.

[0146] Reference Figure 19 and Figure 20 The door limit mechanism 817 is shown in more detail. Figure 11 The diagram also shows a door limiting mechanism mounted relative to door module 812a. Door limiting mechanism 817 includes a claw-like clutch-like mechanism to hold door module 812a in various positions within its travel range. It will be understood that door limiting mechanism 817 may be additionally or alternatively mounted on door module 812b.

[0147] A door stop mechanism 817 is mounted on the hinge module 814a. The hinge module 814a includes a lower hinge bar 837 and an upper hinge bar 839, each of which is part of an upper portion of the hinge module 814a, the lower hinge bar 837 and the upper hinge bar 839 pivot or rotate relative to each other when the door module 812a is moved to an open position. The relative movement of the upper hinge bar 837 and the lower hinge bar 839 can be controlled or held in place by the door stop mechanism 817, thereby controlling and holding in place the door module 812a (attached to the upper hinge bar 839).

[0148] The hinge pin 841 extends generally vertically and between the lower hinge bar 837 and the upper hinge bar 839. In one aspect, the hinge pin 841 is fixed to the upper hinge bar 839. The hinge pin 841 can include an annular flange 841a that is disposed axially between the upper hinge bar 837 and the lower hinge bar 839, which can serve as a bearing surface or the like.

[0149] A permanent magnet 843 is fixed to a bottom surface or a bottom flange of the lower hinge bar 837. The permanent magnet 843 can have an annular shape and encircle the hinge pin 841, which extends axially through the permanent magnet 843. An annular bracket 845 is fixed to the bottom of the magnet 843 and includes a plurality of downwardly extending teeth at an outer periphery of the annular bracket 845.

[0150] A steel plate 847 is slidably mounted on a bottom of the hinge pin 841 and is actuatable between a closed position and an open position. The steel plate 847 includes a plurality of notches sized and arranged to receive the teeth of the annular bracket 845. A stop 849 is fixed to the bottom of the hinge pin 841 to retain the steel plate 847 and terminate the sliding travel of the steel plate 847. A disc spring 851 is disposed radially within the magnet 843 and biases against the steel plate 847 to bias the steel plate 847 away from the annular bracket 845. The steel plate 847 is rotationally fixed relative to the hinge pin 841.

[0151] In the closed position, the steel plate 847 is engaged with the teeth of the annular bracket 845 such that the upper hinge bar 839 cannot pivot relative to the lower hinge bar 837 because the steel plate 847 is engaged with the annular plate 845 that is fixed to the magnet 843, which is fixed to the lower hinge bar 837. The magnetic force of the magnet 843 pulls the steel plate 847 upward and into engagement with the annular bracket 845.

[0152] In the open position, the steel plate 847 is displaced downward and away from the magnet 843 and the annular bracket 845, thereby allowing the lower hinge bar 837 to move relative to the hinge pin 841 and the steel plate 847, and thus relative to the upper hinge bar 839.

[0153] To move the steel plate 847 to the open position, the magnetic flux of the permanent magnet 843 is reversed by supplying power to the magnet 843, which causes the steel plate 847 to be repelled away from the magnet 843. Without the application of power, the steel plate 847 will be pulled back against the magnet 843 and pulled back to the closed position to lock the hinge rods 837 and 839 relative to each other.

[0154] Thus, when power is applied, the door module 812a can open a distance until power is no longer applied, at which point the steel plate 847 will shift and cause the clutch mechanism to close and lock the door module 812a and hinge module 814a in place.

[0155] Figure 20 The open position of the steel plate 847 is illustrated in solid lines. The closed position of the steel plate 847 is illustrated in dashed lines.

[0156] Referring to Figure 21 and Figure 22 the door opener mechanism 819 is shown in more detail, including a closed position and an open position. The door opener mechanism 819 is used to push the door module 812a (and / or the door module 812b) open a predetermined distance to assist the door module 812a in opening and to avoid interfering with surrounding components.

[0157] In one aspect, the pawl 857 is pivotally mounted to a bracket 859. The bracket can be mounted to a side beam 861 of the vehicle body. The door opener mechanism 819 can also include a power actuator 863 and a link 865. The link 865 extends from the actuator 863 to the pawl 857. Upon actuation, the actuator 863 can pull the link 865, which pulls the pawl 857, causing the pawl 857 to pivot relative to the bracket 859 and apply an outward force to the door module 812a to push the door open a predetermined distance.

[0158] Referring now to Figures 23 to 26 another aspect of the sealing arrangement between the door modules 812a, 812b. The sealing arrangement described with reference to the door modules 812a, 812b can also be applied to other door modules described herein. Similarly, aspects of the previously described sealing arrangements can be applied to the door modules 812a, 812b, unless there is a conflict.

[0159] In one aspect, the spacing between adjacent door modules 812a, 812b varies according to the vertical position along the interface between the door modules 812a, 812b. For example, at an outer portion of the interface, along the B-pillar and in the area of the door's existence window (when the window is in the closed position), the spacing of the interface between the door modules 812a, 812b can be smaller than the spacing at a lower portion of the interface. At an inner portion of the interface, the spacing can be substantially the same.

[0160] In one aspect, the primary seal 867 extends vertically along the interface between the modules 812a, 812b on the inner portion of the interface, since the spacing between the modules is substantially the same. The primary seal 867 can extend substantially along the entire length of the modules 812a, 812b. In other words, the same seal 867 is present in both the upper and lower portions of the interface.

[0161] In one aspect, the secondary seal 869 also extends vertically along the interface between the modules on the outer portion of the interface. However, at the outer portion, since the spacing between the modules is greater on the lower portion of the interface relative to the upper portion, the sealing arrangement can also include a filler 871 applied to the door modules 812a, 812b, such that the spacing between the modules is substantially the same at both the upper and lower portions, and the secondary seal 869 can extend along both the upper and lower portions of the interface. This provides an alternative to using a larger sealing member at the lower portion of the interface and a smaller seal at the upper portion of the interface.

[0162] In one aspect, the primary seal 867 and the secondary seal 869 are applied to the same door module (812a or 812b). It can be desirable to apply the seals to the same door module, such that either door module can be opened independently, without one sealing member interfering with the other during opening and closing.

[0163] In one aspect, multiple primary and secondary sealing members 867, 869 can be used, which have substantially the same cross-sectional size and shape, and can be combined to substantially define a continuous seal along the combined length of the sealing members.

[0164] Thus, the use of the filler 871 also provides for the use of a constant cross-sectional sealing member, even in the case of different structures at different vertical locations along the interface.

[0165] It is clear that many modifications and changes to the present application can be made in light of the above teachings, and therefore, the present application is not to be limited to the specific embodiments described, but can be practiced with variations that are within the scope of the appended claims. These previous recitations should be interpreted to cover any combination of the inventive features that accomplish the same results.

Claims

1. A system for opening and closing a door relative to a vehicle body, the system comprising: a first door and a second door, each of the first and second doors comprising: a hinge module configured to be mounted to a vehicle body; a door module configured to be mounted to the hinge module and further configured to close a door opening defined by the vehicle body, wherein the door module comprises an embedded pillar structure disposed at a front or rear edge of the door module; a latch mechanism disposed on the door module and configured to engage a striker protruding from the vehicle body, the latch mechanism comprising: a mounting plate configured to be attached to the pillar structure; a pawl pivotally attached to the mounting plate and pivotable about a pivot axis; a compression spring attached to opposite sides of the pawl, the compression spring biasing the pawl to a nominal closed position; wherein misalignment of the striker into causes the pawl to pivot about the pivot axis from a nominal position to a displaced position, and upon insertion of the striker, the pawl returns to the nominal position and the mounting plate is displaced relative to the pillar structure.

2. The system of claim 1, wherein, the pawl comprises a first portion and a second portion, the first and second portions being pivotable outward about the pivot axis in response to insertion of the striker.

3. The system of claim 2, wherein, the compression spring is attached to each of the first and second portions of the pawl and biases the first and second portions into a closed position.

4. The system of claim 1, wherein, the latch mechanism can be released by an electric actuator and a cam that opens the pawl.

5. The system of claim 4, wherein, the latch mechanism can be released via a mechanical back-up lever that moves the cam that opens the pawl.

6. The system of claim 1, wherein, the mounting plate or the pillar structure comprises an oversized mounting hole that allows the mounting plate to be displaced relative to the pillar structure.

7. The system of claim 1, further comprising a door opener mechanism disposed between the vehicle body and the doors.

8. A system for opening and closing a door relative to a vehicle body, the system comprising: a first door and a second door, each of the first and second doors comprising: a hinge module configured to be mounted to a vehicle body; a door module configured to be mounted to the hinge module and further configured to close a door opening defined by the vehicle body, wherein the door module comprises an embedded pillar structure disposed at a front or rear edge of the door module; wherein the door module comprises a latch mechanism configured to latch with the vehicle body; wherein the first and second doors cooperate and define an interface therebetween, wherein the embedded pillars of the first and second doors are disposed adjacent to each other at the interface. wherein the embedded column structure defines a closed loop adjacent to the interface, wherein the closed loop is provided at both a lower portion and an upper portion of the door module, wherein the upper portion extends to an uppermost edge of the door module and the lower portion extends to a lowermost edge of the door module; wherein the interface comprises a gap defined between the front edge and the rear edge, and a sealing arrangement comprising a primary seal provided at an inner side of the interface and a secondary seal provided at an outer side of the interface, wherein the primary seal and the secondary seal have a constant cross section extending substantially entirely along the interface.

9. The system of claim 8, wherein, At a location of the secondary seal, the gap at a lower portion of the interface is wider than the gap at an upper portion, and wherein in the lower portion a filler is provided in the gap between the secondary seal and the front edge or the rear edge of the door module, such that the secondary seal and the filler in combination fill the gap in the lower portion.

10. The system of claim 8, wherein, The primary seal and the secondary seal are attached to a single door.

11. A system for opening and closing a door relative to a vehicle body, the system comprising: a first door and a second door, each of the first and second doors comprising: a hinge module configured to be mounted to a vehicle body; a door module configured to be mounted to the hinge module and further configured to close a door opening defined by the vehicle body, wherein the door module comprises an embedded column structure provided at a front edge or a rear edge of the door module; wherein the door module comprises a latching mechanism configured to latch with the vehicle body; wherein the hinge module comprises a first hinge lever and a second hinge lever, the first and second hinge levers being pivotable relative to each other during a door opening operation; a hinge pin extending between the first and second hinge levers, the hinge pin being fixed to the first hinge lever; a permanent magnet fixed to a lower hinge lever; a ring-shaped bracket fixed to the permanent magnet; a steel plate biased towards the permanent magnet, wherein in a closed position, the steel plate is locked with the ring-shaped bracket adjacent to the permanent magnet, and wherein in an open position, the steel plate is rotatable relative to the ring-shaped bracket, with the steel plate being distanced from the permanent magnet; wherein exciting the permanent magnet displaces the steel plate from the closed position to the open position, thereby allowing relative movement between the first and second hinge levers.

12. The system of claim 11, wherein, The steel plate is mounted to the hinge pin and slidably attached to the hinge pin.

13. The system of claim 12, wherein, The steel plate is rotationally fixed to the hinge pin.

14. The system of claim 11, wherein, The first hinge lever is an upper hinge lever attached to the door module, and the second hinge lever is a lower hinge lever pivotably attached to the vehicle body.

15. The system of claim 11, wherein, The annular stent comprises axially protruding teeth and the steel plate comprises corresponding notches for receiving the teeth in the closed position.

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