Panel assembly for vehicle

Abstract

A panel assembly for a vehicle door includes an interior panel having an inner surface and an outer surface. The inner and outer surfaces collectively define a body and a trim element integrally formed with the body with a living hinge disposed therebetween. The panel assembly also includes an outer panel having an inner surface coupled to the body at the inner surface of the inner panel and having an opposing outer surface coupled to the trim element in the folded position of the trim element.

Description

Technical Field

[0001] The present invention generally relates to a panel assembly for a vehicle. Background Art

[0002] As a vehicle travels along a road, dust, dirt, and various debris may contact the lower area of ​​the vehicle. Repeated contact with these materials may eventually wear or affect the vehicle's paint. Conventional vehicles include a piece of plastic material along the bottom edge of the panel to cushion the contact with the material from the road. The plastic material is typically a separately formed component that is attached to the exterior panel using various clips and fasteners.

[0003] The separate manufacture and attachment of the plastic material can increase the overall production cost and manufacturing time. The exterior panels are typically formed with holes to accommodate fasteners that secure the plastic material to the exterior panels for support during use. Conventional assembly of the panels first assembles the vehicle's panels and subsequently adds the plastic material along the bottom edge of the exterior panels via upper and lower fasteners. Thus, conventional solutions using plastic materials to protect exterior panels from damage can increase the overall cost and manufacture of vehicle panels. Summary of the invention

[0004] In some configurations, a panel assembly for a vehicle includes an inner panel including an upper portion having an outer surface and an inner surface and a lower portion integrally formed with the upper portion. The lower portion has a first surface and a second surface. The inner panel also includes a living hinge defined between the upper portion and the lower portion, wherein the lower portion is operable about the living hinge between a deployed position and a folded position. The panel assembly also includes an outer panel coupled to the inner panel to define a cavity and including a first end and an opposing second end, the second end coupled to the lower portion of the inner panel in the folded position, wherein the lower portion is at least partially disposed on the second end of the outer panel.

[0005] In some aspects, the living hinge can be integrally formed with the upper portion and the lower portion. The lower portion can be coupled to the outer panel via an attachment flange disposed between the outer panel and the inner panel. The outer panel can include a flange that is coupled to the attachment flange of the lower portion in a folded position of the lower portion. In some examples, the center frame can be disposed within a cavity defined between the inner panel and the outer panel. Optionally, the lower portion can be coupled to an inner surface of the outer panel. A vehicle door can include a panel assembly.

[0006] In another configuration, a vehicle panel assembly may include a first panel having an outer surface and an inner surface. The first panel includes an upper portion and a lower portion coupled to the upper portion by a living hinge. The lower portion is operable about the living hinge between a first position and a second position. The vehicle panel assembly also includes a second panel having an outer surface and an opposing inner surface coupled to the inner surface of the first panel and defining a cavity with the first panel. The lower portion of the first panel is coupled to the outer surface of the second panel at a second position of the lower portion.

[0007] In some examples, when the lower portion is in the second position, the living hinge can define at least a portion of a bottom edge of the vehicle panel assembly. Optionally, the thickness of the living hinge can be less than the thickness of at least one of the upper portion and the lower portion. When the lower portion is in the second position, the inner surface defined along the lower portion can be radially opposite to the inner surface defined along the upper portion. In some aspects, the length of the first panel can be greater than the length of the second panel. In other examples, the second panel can define a plurality of holes along a flange of the second panel. The lower portion may include an attachment flange, which may include a plurality of fasteners, and the fasteners may be selectively disposed in the plurality of holes defined along the flange when the lower portion is in the second position.

[0008] In yet another configuration, a panel assembly for a vehicle door includes an inner panel having an inner surface and an outer surface. The inner surface and the outer surface together define a body and a decorative element, the decorative element being integrally formed with the body with a living hinge disposed therebetween. The panel assembly also includes an outer panel having an inner surface coupled to the body at an inner surface of the inner panel and having an opposite outer surface coupled to the decorative element in a folded position of the decorative element.

[0009] In some aspects, the decorative element can be operated between an extended position and a folded position about a living hinge. The living hinge and the decorative element can define an extension of the inner panel and can define a bottom edge of the panel assembly in the folded position of the decorative element. The decorative element can have a stepped configuration including a protrusion defining a lip. In some examples, the body can define a recessed portion, and the decorative element can be aligned relative to the recessed portion in the folded position. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0011] Figure 1 is a top perspective view of a vehicle having a panel assembly according to the present invention;

[0012] Figure 2 is a perspective view of a panel assembly according to the present disclosure;

[0013] Figure 3 yes Figure 2An exploded perspective view of a panel assembly;

[0014] Figure 4 is a perspective view of an interior panel of a panel assembly according to the present disclosure;

[0015] Figure 4A It was captured in area 4A Figure 4 an enlarged partial perspective view of a decorative element of an interior panel;

[0016] Figure 5 is a cross-section of a panel assembly according to the present disclosure with an outer panel removed from an inner panel and a center frame;

[0017] Figure 6 yes Figure 5 Another cross-sectional view of the panel assembly of FIG. 1 , wherein the outer panel is assembled with the inner panel and the trim element in the extended position; and

[0018] Figure 7 yes Figure 6 Another cross-sectional view of the panel assembly of FIG. 1 , wherein the decorative element is in a folded position.

[0019] Corresponding reference characters indicate corresponding parts throughout the several views. DETAILED DESCRIPTION

[0020] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that the present disclosure will be thorough and will fully convey the scope of the present disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that the example configurations may be implemented in many different forms, and that the specific details and example configurations should not be construed as limiting the scope of the present disclosure.

[0021] The terms used herein are only for describing specific exemplary configurations, not for limiting. As used herein, the singular articles "a", "an" and "the" may also be intended to include plural forms, unless the context clearly indicates otherwise. The terms "comprise", "include", "contain" and "have" are inclusive, thus specifying the presence of features, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts and / or combinations thereof. The method steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or shown, unless specifically identified as an execution order. Additional or alternative steps may be adopted.

[0022] When an element or layer is referred to as being "on another element or layer," "engaged to," "connected to," "attached to," or "coupled to" another element or layer, it may be directly on, engaged, connected, attached to, or coupled to another element or layer, or there may be intermediate elements or layers. Conversely, when an element is referred to as being "directly on another element or layer," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0023] The terms first, second, third, etc. can be used here to describe various elements, components, regions, layers and / or parts. These elements, components, regions, layers and / or parts should not be limited by these terms. These terms are only used to distinguish an element, component, region, layer or part from another region, layer or part. Terms such as "first", "second" and other numerical terms do not imply order or sequence unless the context clearly indicates. Therefore, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or part, without departing from the teaching of the example configuration.

[0024] In this application, including the definitions below, the term module may be replaced by the term circuit. The term "module" may refer to an application specific integrated circuit (ASIC) or a portion thereof, or include an application specific integrated circuit (ASIC); a digital, analog or mixed analog / digital discrete circuit; a digital, analog or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated or group) that executes code; a memory (shared, dedicated or group) that stores code executed by the processor; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system on a chip.

[0025] The term code used above may include software, firmware and / or microcode, and may refer to a program, routine, function, class and / or object. The term shared processor includes a single processor that executes some or all of the code from multiple modules. The term group processor includes a processor combined with additional processors that executes some or all of the code from one or more modules. The term shared memory includes a single memory that stores some or all of the code from multiple modules. The term group memory includes a memory combined with additional memory that stores some or all of the code from one or more modules. The term memory may be a subset of the term computer-readable medium. The term computer-readable medium does not include transient electrical signals and electromagnetic signals that propagate through the medium and can therefore be considered to be tangible and non-transient memory. Non-limiting examples of non-temporary memory include tangible computer-readable media, including non-volatile memory, magnetic storage, and optical storage.

[0026] The apparatus and methods described in this application may be implemented in part or in whole by one or more computer programs executed by one or more processors. The computer program includes processor executable instructions stored on at least one non-transitory tangible computer readable medium. The computer program may also include and / or rely on stored data.

[0027] Software applications (i.e., software resources) may refer to computer software that enables a computing device to perform tasks. In some examples, software applications may be referred to as "applications," "apps," or "programs." Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0028] Non-transitory memory can be a physical device used to temporarily or permanently store programs (e.g., instruction sequences) or data (e.g., program state information) for use by a computing device. Non-transitory memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used for firmware, such as bootloaders). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM), and disk or tape.

[0029] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and may be implemented in high-level procedural and / or object-oriented programming languages ​​and / or assembly / machine languages. As used herein, the terms "machine-readable medium" and "computer-readable medium" refer to any computer program product, non-transitory computer-readable medium, apparatus, and / or device (e.g., disk, optical disk, memory, programmable logic device (PLD)) for providing machine instructions and / or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal for providing machine instructions and / or data to a programmable processor.

[0030] Various implementations of the systems and techniques described herein can be realized in digital electronic and / or optical circuits, integrated circuits, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations may include implementations in one or more computer programs executable and / or interpretable on a programmable system comprising at least one programmable processor, at least one input device, and at least one output device, the programmable processor being either special purpose or general purpose, coupled to receive data and instructions from a storage system, and to send data and instructions to the storage system.

[0031] The processes and logic flows described in this specification can be performed by one or more programmable processors, also known as data processing hardware, executing one or more computer programs to perform functions by operating on input data and generating outputs. These processes and logic flows can also be performed by dedicated logic circuits, such as FPGAs (field programmable gate arrays) or ASICs (application-specific integrated circuits). For example, processors suitable for executing computer programs include general-purpose and special-purpose microprocessors, and any one or more processors of any kind of digital computer. Typically, the processor will receive instructions and data from a read-only memory or a random access memory or both. The basic elements of a computer are a processor for executing instructions and one or more storage devices for storing instructions and data. Typically, a computer will also include or be operably coupled to one or more mass storage devices for storing data, such as a magnetic disk, a magneto-optical disk, or an optical disk, to receive data from the mass storage device or to transmit data to it, or both. However, a computer does not need to have such a device. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and storage devices, including, for example, semiconductor memory devices, such as EPROM, EEPROM and flash memory devices; magnetic disks, such as internal hard disks or removable disks; magneto-optical disks; and CD ROM and DVD-ROM disks. The processor and memory may be supplemented by or incorporated in special purpose logic circuitry.

[0032] To provide interaction with a user, one or more aspects of the present disclosure may be implemented on a computer having a display device for displaying information to the user, such as a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touch screen, and an optional keyboard and pointing device, such as a mouse or trackball, through which the user can provide input to the computer. Other types of devices may also be used to provide interaction with the user; for example, the feedback provided to the user may be any form of sensory feedback, such as visual feedback, auditory feedback, or tactile feedback; and input from the user may be received in any form, including sound, voice, or tactile input. In addition, the computer may interact with the user by sending documents to and receiving documents from a device used by the user; for example, by sending a web page to a web browser on a user's client device in response to a request received from the web browser.

[0033] Many embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of the present disclosure. Therefore, other embodiments are also within the scope of the following claims.

[0034] refer to Figure 1-3 , the vehicle 10 includes a body 12 that defines an interior 14 of the vehicle 10, including a passenger compartment 16. A plurality of doors 18 are coupled to the body 12 to provide selective access to the passenger compartment 16. For example, the plurality of doors 18 may include a driver's side door 18a, a passenger side door 18b, and a rear passenger door 18c. The vehicle 10 may be driver-based, semi-automatic, or fully automatic, and may include a variety of vehicle types, including but not limited to sedans, sport utility vehicles, trucks, vans, crossovers, utility vehicles, service vehicles, and / or any other vehicle configuration. In some configurations, the plurality of doors 18 may include a rear door to provide access to the interior 14. In other aspects, the plurality of doors 18 may slide along the body 12 such that the plurality of doors 18 may be coupled to the body 12 via a track element.

[0035] The plurality of doors 18 may be operable along a horizontal plane such that the plurality of doors 18 may provide access to the passenger compartment 16 by a passenger hingedly hinged the respective door 18 toward the vehicle front 20 or the vehicle rear 22. Additionally or alternatively, one or more of the doors 18 may be operable along a vertical plane such that the respective door 18 may be hinged toward and away from a roof 24 of the vehicle body 12. Each door 18 of the plurality of doors 18 comprises a panel assembly 100 of the vehicle 10. The panel assembly 100 is described herein with respect to a single door 18 of the vehicle 10. However, it is contemplated that the panel assembly 100 may be used with any of the plurality of doors 18 described above.

[0036] refer to Figure 1-4A, the door 18 is formed by a panel assembly 100 and may include a window panel 30 coupled to the panel assembly 100 and selectively received within the panel assembly 100. The panel assembly 100 includes a first panel 102 and a second panel 104 defining a cavity 106, and a center frame 108 may be disposed in the cavity 106. The center frame 108 is positioned against the first panel 102 to define contact between the first panel 102 and the center frame 108. Therefore, when the door 18 is closed relative to the vehicle body 12, the center frame 108 and the first panel 102 may engage the vehicle body 12. For purposes of illustration, the depicted cross-section may illustrate that the center frame 108 is at least partially spaced apart from the first panel 102. However, the space defined between the center frame 108 and the first panel 102 is for purposes of illustration, and the center frame 108 is assumed to be in direct contact with the first panel 102.

[0037] In addition, the center frame 108 can extend from the front and rear edges of each of the first panel 102 and the second panel 104. For example, the center frame 108 can be at least partially exposed along the sides of the first panel 102 and the second panel 104 to help attach the panel assembly 100 and the door 18 to the vehicle body 12. The window panel 30 can be received within the cavity 106 and disposed within a recess 110 defined by the center frame 108. Although the panel assembly 100 is described herein with respect to the door 18, it is contemplated that the panel assembly 100 can be used in different locations of the vehicle 10, including but not limited to along the side panels of the vehicle body 12.

[0038] The first panel 102 can be configured as the inner panel 102 of the panel assembly 100. The inner panel 102 includes an upper portion 120 and a lower portion 122, which are integrally formed with each other and separated by a living hinge 124 defined therebetween. For example, the living hinge 124 and the lower portion 122 can define an extension of the inner panel 102. The living hinge 124 is integrally formed with each of the upper portion 120 and the lower portion 122 and is configured to translate the lower portion 122 between a first position 126 and a second position 128, which will be described in more detail below. The upper portion 120 of the inner panel 102 can be referred to as the body 120 of the inner panel 102, such that the body 120 defines a majority of the inner panel 102. The body 120 has a first outer surface 130 and an opposite second inner surface 132 defined relative to the second panel 104, and a cavity 106 defined therebetween.

[0039] For example, in the assembled configuration of the panel assembly 100, the inner surface 132 of the body 120 is proximate to the center frame 108, and the outer surface 130 is opposite to the inner surface 132. In some aspects, the outer surface 130 is located within the interior 14 of the vehicle 10, so that the outer surface 130 of the body 120 can be exposed within the passenger compartment 16. For example, the outer surface 130 is defined as being opposite to the cavity 106 defined between the first panel 102 and the second panel 104. The outer surface 130 of the body 120 may include a support 134 extending from the outer surface 130 near the first end 136 of the body 120. The support 134 can be positioned near the window panel 30 and can provide support for the passenger. In some aspects, the support 134 can accommodate a controller for the window panel 30 and / or can include a component for fixing the door 18 in a locked position relative to the vehicle body 12.

[0040] The second end 138 of the body 120 can be angled toward the interior 14 of the vehicle 10. For example, the second end 138 can include an angled portion 140. The angled portion 140 can help maximize space within the passenger compartment 16 near the footwell of the vehicle 10. While the angled portion 140 is generally defined along the exterior surface 130, the angled portion 140 can also define a recessed portion 142 along the interior surface 132 of the body 120. As described below, the recessed portion 142 is generally configured to accommodate the lower portion 122 of the interior panel 102 in the second position 128 of the lower portion 122.

[0041] Further references Figure 1-4A , the lower portion 122 of the interior panel 102 may be referred to throughout as a trim element 122. For example, the lower portion 122 of the first panel 102 is selectively disposed on the second panel 104, as described in more detail below, to define a trim element 122 of the vehicle 10. The lower portion 122 is operable between a first position 126 and a second position 128 to define the lower portion 122 as a trim element 122 along the second panel 104. As described herein, the terms lower portion 122 and trim element 122 may be used interchangeably.

[0042] The upper portion 120, the lower portion 122, and the living hinge 124 are all integrally formed of a single polymeric material to define the first panel 102. For example, the first panel 102 can be formed by injection molding. It is also contemplated that in some aspects, the upper portion 120 can be formed of a stamped metal material. The thickness of the living hinge 124 is less than the thickness of the upper portion 120 and the lower portion 122, which advantageously facilitates the flexibility and integral articulation of the living hinge 124 relative to each of the upper portion 120 and the lower portion 122. The living hinge 124 can be defined as a piano hinge between the upper portion 120 and the lower portion 122 because the living hinge 124 extends along the length of each of the upper portion 120 and the lower portion 122.

[0043] Still refer to Figure 1-4A , the first position 126 of the decorative element 122 is defined as the extended position 126, such as Figure 4 1 and 12. As shown, the decorative element 122 is disposed between the main body 120 and the decorative element 122 and interconnects them. As described above, each of the decorative element 122, the living hinge 124, and the main body 120 are integrally formed, and the living hinge 124 is operable to hinge the decorative element 122 relative to the main body 120. The decorative element 122 translates between an extended position 126 and a second or folded position 128. In the assembled configuration of the panel assembly 100, it is contemplated that the decorative element 122 is fixed in the folded position 128 relative to the second panel 104, as described in more detail below. In the unassembled configuration of the panel assembly 100, the decorative element 122 is in the extended position 126. The assembly of the panel assembly 100 is described below with reference to FIG. Figure 5-7 Describe in more detail.

[0044] The trim element 122 includes a first surface 152 and a second surface 154. In the extended position 126, the first surface 152 generally corresponds to the first outer surface 130 of the body 120, and the second surface 154 generally corresponds to the second inner surface 132 of the body 120. The first surface 152 of the trim element 122 may also be referred to as the inner surface 152 when the first surface 152 is directed toward the cavity 106 in both the first position 126 and the second position 128. For example, when the trim element 122 is in the second position 128, the inner surface 152 defined along the trim element 122 is diametrically opposed to the inner surface 132 defined along the body 120. In some aspects, the first surface 152 has a stepped configuration, wherein the first surface 152 extends at an angle from a first end 156 of the trim element 122 to a second end 158 of the trim element 122. It is generally contemplated that the angled first surface 152 is configured to provide a structure that is consistent with the wheel well 32 of the vehicle body 12, as described below with respect to the second panel 104.

[0045] like Figure 4A As shown, the trim element 122 can taper from the second end 158 toward the first end 156 to generally define a low profile trim element 122 in the assembled configuration of the panel assembly 100. The low profile trim element 122 can advantageously save production and manufacturing costs while also providing a smooth configuration of the panel assembly 100. The trim element 122 can include a protrusion 160 defined by the first surface 152, with a lip 162 adjacent the protrusion 160. The protrusion 160 and the lip 162 can define a stepped configuration of the trim element 122 along the first surface 152. As described above, in the assembled configuration of the panel assembly 100, the protrusion 160 can cooperate with the vehicle body 12 to at least partially define the wheel well 32.

[0046] like Figure 4As shown, the second surface 154 of the decorative element 122 can be angled away from the first end 156 of the decorative element 122 and can match the contour of the inner surface 132 of the body 120. For example, as described below, in the second position 128 of the decorative element 122, the decorative element 122 can be received within the recess 142 of the body 120. The second surface 154 of the decorative element 122 is generally planar and defines an attachment surface 164 at the second end 158 of the decorative element 122 between the first surface 152 and the second surface 154 of the decorative element 122. An attachment flange 166 can extend from the attachment surface 164 and can engage the second panel 104 in the assembled configuration of the panel assembly 100. In some examples, the attachment flange 166 can be positioned between the first panel 102 and the second panel 104 to define an attachment point 168 between the first panel 102 and the second panel 104. In other configurations, the attachment point 168 may be defined by an attachment flange 166 located along an exterior surface 180 of the second panel 104 .

[0047] Further references Figure 1-4A , as the decorative element 122 articulates about the living hinge 124, the second surface 154 of the decorative element 122 gradually approaches the inner surface 132 of the inner panel. In the assembled configuration of the panel assembly 100, the second surface 154 of the decorative element 122 can be substantially parallel to the inner surface 132 of the body 120. In some aspects, when the decorative element 122 is in the second position 128, the second surface 154 can contact or otherwise be adjacent to the center frame 108. For example, the center frame 108 can abut the inner surface 132 of the body 120 on one side and the second surface 154 of the decorative element 122 on an opposite side.

[0048] In the extended position 126 of the trim element 122, a gap 170 can be defined between the trim element 122 and the second end 138 of the body 120. The gap 170 can correspond to the thickness of the living hinge 124. In some aspects, the gap 170 can provide space for the trim element 122 to have a slight bend toward the second end 138 of the body 120 while remaining out of contact with the body 120 in the extended position 126. When the trim element 122 is in the folded position 128, the living hinge 124 can cooperate with the second end 138 of the body 120 and the first end 156 of the trim element 122 to define the bottom edge 112 of the panel assembly 100.

[0049] Reference Figure 4-7, the second or outer panel 104 is coupled to the inner panel 102, with the intermediate frame 108 defined therebetween. The center frame 108 can be a steel body that provides structural support for the door 18 in the assembled configuration of the panel assembly 100. The center frame 108 can be formed of stamped steel and can define a recess 110 configured to selectively receive the window panel 30. The center frame 108 can also partially define the support member 134. Additionally or alternatively, the center frame 108 can define other protrusions, recesses, or details defined along the door 18, which can be subsequently incorporated as part of one or both of the inner panel 102 and the outer panel 104. As described above, the inner panel 102 and the outer panel 104 are positioned against the center frame 108 to generally define a slight degree of engagement between the first surface 130 of the first panel 102 and the center frame 108 in the closed position of the door 18. For example, the center frame 108 may be pressed against the trim element 122, and due to the direct contact between the center frame 108 and the inner panel 102, the center frame 108 may be securely supported to define a seal between the door 18 and the vehicle body 12 ( Figure 1 ).

[0050] In the assembled configuration of the panel assembly 100, the outer panel 104 is coupled to the inner panel 102 and, like the inner panel 102, has an outer surface 180 and an inner surface 182. As shown, the inner surface 182 of the outer panel 104 and the inner surface 132 of the inner panel 102 define the cavity 106, and the outer surface 180 of the outer panel 104 is outside the vehicle 10. In contrast, as described above, the outer surface 130 of the inner panel 102 faces the interior 14 of the vehicle 10. In some examples, the length L of the outer panel 104 104 Less than the length L of the inner panel 102 102 For example, a first end 184 of the outer panel 104 is coupled to or proximate to a first end 136 of the inner panel 102, while a second end 186 of the outer panel 104 is offset relative to a second end 138 of the upper portion 120 of the inner panel 102. The offset configuration of the outer panel 104 accommodates the decorative element 122. In the folded position 128, when the panel assembly 100 is assembled, the window panel 30 is disposed at the first ends 136, 184 of the inner panel 102 and the outer panel 104. The first ends 136, 184 can be spaced apart to define a space for disposing the window panel 30.

[0051] The outer panel 104 is coupled to the inner panel 102 at least along the respective second ends 136, 186. In some examples, as described above, the center frame 108 can be exposed at the rear and front ends of the inner and outer panels 102, 104 to couple the door 18 and the panel assembly 100 to the vehicle body 12 ( Figure 1). The outer panel 104 includes a flange 188 coupled to the inner panel 102 proximate the second end 138 of the inner panel 102. As described below, in some aspects, the flange 188 of the outer panel 104 is directly coupled to the center frame 108. In other aspects, as described below, the flange 188 does not contact the center frame 108 and is coupled to the inner panel 102 through the trim element 122.

[0052] Further references Figure 5-7 , the outer panel 104 is depicted as having two inclined portions 190a, 190b, each of which diverges from a center portion 192. It is generally believed that the center portion 192 can be generally linear compared to the inclined portions 190a, 190b. In some aspects, the center portion 192 can be curved or curvilinear to define the shape or design of the vehicle body 12. The inclined portions 190a, 190b can include an upper inclined portion 190a and a lower inclined portion 190b.

[0053] The upper sloped portion 190a is defined at the first end 184 of the outer panel 104 and at least partially defines the window opening 34 of the vehicle body 12. In some examples, the upper sloped portion 190a slopes away from the window panel 30 toward the center portion 192. The angle of the upper sloped portion 190a can facilitate fluid flow from various areas of the vehicle body 12 along the outer panel 104, including but not limited to the window panel 30. The upper sloped portion 190a can be configured to facilitate retention of the window panel 30 with the panel assembly 100.

[0054] The lower inclined portion 190b is depicted as a mirror image of the upper inclined portion 190a. For example, the lower inclined portion 190b can extend from the center portion 192 toward the second end 186 and the inner panel 102. As shown, due to the configuration of the upper inclined portion 190a and the lower inclined portion 190b, the center portion 192 is bent outward from the center frame 108. The angle at which each inclined portion 190a, 190b is formed can vary depending on the design of the vehicle body 12, such that the angle can be greater or less than the corresponding angle shown for the inclined portions 190a, 190b.

[0055] Further references Figure 5-7 , the panel assembly 100 is configured to form at least a portion of the door 18, wherein the first panel 102 is coupled to the second panel 104 around the center frame 108. During assembly, the first panel 102 is positioned on the side of the center frame 108 opposite the second panel 104, and the decorative element 122 extends from the living hinge 124. Once the first panel 102 and the second panel 104 are positioned, the decorative element 122 can be adjusted by the living hinge 124. Finally, the decorative element 122 is coupled to the second panel 104 to define the panel assembly 100 in an assembled configuration.

[0056] As described above, before the panel assembly 100 is assembled, the decorative element 122 extends from the body 120 of the first panel 102 in the extended position 126. In some examples, the decorative element 122 is rotated about the living hinge 124 and positioned between the center frame 108 and the second panel 104. For example, the first panel 102 can be positioned near the center frame 108, and the decorative element 122 can be rotated about the living hinge 124 to wrap around the bottom 114 of the center frame 108. In this example, the second panel 104 can then be positioned near the center frame 108, wherein the attachment flange 166 of the decorative element 122 is positioned between the inner surface 182 of the second panel 104 and the center frame 108. The flange 188 defines a plurality of holes 188a, which are configured to receive fasteners 166a of the attachment flange 166. For example, when the decorative element 122 is in the second position 128, the plurality of fasteners 166a can be selectively disposed in the plurality of holes 188a defined along the flange 188. While the fasteners 166 a may couple the trim element 122 to the flange 188 , the flange 188 of the second panel 104 may be coupled to the attachment flange 166 of the trim element 122 by any feasible fastening method to secure the second panel 104 with the first panel 102 and define the panel assembly 100 .

[0057] In other aspects, such as Figure 5-7 As shown, the decorative element 122 can be coupled to the outer surface 180 of the second panel 104. For example, the second panel 104 can be positioned proximate to the center frame 108, and the decorative element 122 can be coupled to the outer surface 180 of the second panel 104. The flange 188 of the second panel 104 is proximate to the center frame 108, and the attachment flange 166 of the decorative element 122 is coupled to the outer surface 180 of the second panel 104. The decorative element 122 is attached to the second panel 104 along the attachment surface 164 to at least partially secure the first panel 102 to the second panel 104. It is generally contemplated that in any configuration, the decorative element 122 can be coupled to the second panel 104 using any feasible attachment method, including but not limited to spot welding and / or fasteners, such as clips.

[0058] As described above, the decorative element 122 may be in the extended position 126 ( Figure 6 ) and fold position 128 ( Figure 7 ). The decorative element 122 is rotated from the extended position 126 to the folded position 128 by articulation at the living hinge 124. The decorative element 122, which is integrally formed with the body 120 and the living hinge 124, forms an extension of the first panel 102 to advantageously define the bottom edge 112 of the panel assembly 100. For example, the decorative element 122 defines the bottom area 196 of the second panel 104, which provides a consistent length of the panel assembly 100 in the assembled configuration compared to the pre-assembled configuration. Figure 5In the pre-assembled configuration shown, the first panel 102 extends a greater length than the second panel 104. For example, the length of the body 120 of the first panel 102 is greater than the length of the second panel 104. The trim element 122 defines a difference in length between the body 120 and the outer panel 104 to define a uniform length of the panel assembly 100 in the assembled configuration.

[0059] In some examples, a channel 198 can be defined between the trim element 122 and the second end 186 of the second panel 104. The channel 198 can facilitate movement of fluid along the vehicle body 12 and is defined between the second end 186 of the second panel 104 and the first end 156 of the trim element 122. In other examples, the second panel 104 can be flush with the trim element 122 to define a fluid seal along the vehicle body 12. In either example, the attachment flange 166 of the second panel 104 and the flange 188 define a seal that is configured to prevent fluid from penetrating the cavity 106.

[0060] Reference again Figure 1-7 , the panel assembly 100 advantageously minimizes production and manufacturing costs while providing improved utility of the interior panel 102 through the living hinge 124 and the decorative element 122. By wrapping the decorative element 122 around the bottom 114 of the center frame 108, the decorative element 122 minimizes the number of fasteners 166a used to secure the decorative element 122 to the exterior panel 104. In addition, the decorative element 122 provides additional protection to the center frame 108 by wrapping around the bottom 114 of the center frame 108. The bottom 114 of the center frame 108 is covered by the living hinge 124 and the decorative element 122. The living hinge 124 facilitates movement of the decorative element 122 between the extended position 126 and the folded position 128, which advantageously facilitates assembly of the panel assembly 100.

[0061] The foregoing description has been provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but where applicable, they are interchangeable and can be used in a selected configuration even if not specifically shown or described. This can also be varied in a variety of ways. Such variations should not be considered a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A panel assembly for a vehicle, the panel assembly comprising: an interior panel including an upper portion having an outer surface and an inner surface, a lower portion integrally formed with the upper portion and having a first surface and a second surface, and a living hinge defined between the upper portion and the lower portion, the lower portion being operable about the living hinge between an extended position and a folded position; and An outer panel is coupled to the inner panel to define a cavity and includes a first end and an opposing second end coupled to a lower portion of the inner panel in a folded position, wherein the lower portion is at least partially disposed on the second end of the outer panel.

2. The panel assembly according to claim 1, wherein: The living hinge is integrally formed with the upper and lower portions.

3. The panel assembly according to claim 1, wherein: The lower portion is coupled to the outer panel via an attachment flange disposed between the outer panel and the inner panel.

4. The panel assembly according to claim 3, wherein: The outer panel includes a flange coupled to an attachment flange of a lower portion in a folded position of the lower portion.

5. The panel assembly of claim 1, further comprising a center frame disposed within a cavity defined between the inner panel and the outer panel.

6. The panel assembly according to claim 1, wherein: The lower portion is coupled to an inner surface of the outer panel.

7. The panel assembly according to claim 1, wherein: The living hinge defines at least a portion of a bottom edge of the panel assembly when the lower portion is in the folded position.

8. The panel assembly according to claim 1, wherein: When the lower portion is in the folded position, a second surface defined along the lower portion is diametrically opposed to an inner surface defined along the upper portion.

9. The panel assembly according to claim 1, wherein: The length of the inner panel is greater than the length of the outer panel.

10. The panel assembly according to claim 1, wherein: The upper portion defines a recess, and the lower portion is aligned relative to the recess in the folded position.

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