Vehicle door

Abstract

A vehicle door (10) includes: an outer panel (20) having an outer side surface configured as an outer wall surface of a vehicle; and an inner panel (22) disposed on the vehicle inner side with respect to the outer panel (20) and having an inner side surface facing a cabin space of the vehicle. The inner panel (22) comprises at least a first and a second panel member (24, 25, 26). Each of the first and second panel members (24, 25, 26) includes a non-overlapping portion (30B, 30C, 34A) having an inner side surface facing the cabin space and an outer side surface directly facing the outer panel (20) without any panel between the non-overlapping portion and the outer panel (20).

Description

Technical Field

[0001] The technology described herein relates to a vehicle door. Background Art

[0002] A vehicle door is known, which includes a door panel and a resin trim. The door panel includes an inner panel and a metal outer panel configured as an outer surface of the door. The resin trim is configured as an inner surface of the door. Another configuration is also known, in which various functional components are mounted on an inner panel made of synthetic resin, and the inner panel having the various functional components is assembled to the outer panel. In this case, the number of mounting steps and the production cost can be reduced. This configuration is disclosed in Japanese Patent Application No. 2000-318532. Summary of the Invention

[0003] In the above configuration, a mounting member for mounting a metal door panel to a vehicle body member needs to have high rigidity. Therefore, the mounting member needs to have a large thickness and can be fixed to a plate surface of the metal door panel by welding. A vehicle door generally has a configuration including three plate members overlapping in the vehicle interior and exterior directions. In this case, the number of components of the vehicle door increases, and thus the production steps and the production cost also increase.

[0004] The object of the technology described herein is to provide a vehicle door with a low production cost. In addition, a vehicle door produced by a simplified production process is provided.

[0005] (1) A vehicle door according to the technology described herein includes an outer panel and an inner panel. The outer panel has an outer surface configured as an outer wall surface of the vehicle. The inner panel is arranged on the vehicle inner side with respect to the outer panel and has an inner surface facing a cabin space of the vehicle. The inner panel includes at least a first panel member and a second panel member. Each of the first panel member and the second panel member includes a non-overlapping portion having an inner surface facing the cabin space and an outer surface directly facing the outer panel without any panel therebetween in the non-overlapping portion and the outer panel.

[0006] A generally known vehicle door panel includes a door panel made of metal and a door trim made of resin. The door panel includes an outer panel and an inner panel made of metal. The resin door trim is mounted on the metal door panel on the inner side of the vehicle. That is, a generally known vehicle door has a three-plate structure in which three plate members overlap in the vehicle interior-exterior direction. The vehicle door described herein includes a plurality of parts configured as an inner design surface of the vehicle and having a double structure in which an outer panel and an inner panel overlap. Therefore, the number of parts of the vehicle door can be easily reduced. There is no plate member on the inner side of the vehicle door, and there is a large space in the vehicle door. Therefore, functional components can be installed in the space in various configurations. This simplifies the process of manufacturing the vehicle door and reduces the production cost.

[0007] In the vehicle door described herein, the outer panel can be made of metal or resin. The panel member of the inner panel may not be made of resin, but a part of the panel member may be made of metal. For example, one of the first panel member and the second panel member can be made of metal and configured as a base member, and the second panel member can be made of resin. The second panel member made of resin can be mounted on the first panel member as a base member on the inner side of the vehicle.

[0008] The vehicle door having the above configuration may include the following configuration. This technology is not limited to the following configuration and can be modified based on the skills of those skilled in the art.

[0009] (2) In the vehicle door according to (1), the first panel member includes a first panel main body portion, a first front wall portion, and a rear wall portion. The first panel main body portion includes a non-overlapping portion and a hole. The first front wall portion extends from the front edge of the first panel main body portion toward the outside of the vehicle, and the rear wall portion extends from the rear edge of the first panel main body portion toward the outside of the vehicle. The second panel member is mounted on the first panel member on the inner side of the vehicle relative to the first panel member to cover the hole of the first panel main body portion.

[0010] The first panel member can be configured as a base member of the inner panel. Many components of the vehicle door can be attached to the first panel member in addition to the outer panel. For example, the second panel member can be mounted on the first panel member on the inner side of the vehicle, and functional components can be attached to the first panel member on the inner side and the outer side of the vehicle. In the case of a vehicle door having such a configuration, the stiffness of the inner panel and the stiffness of the vehicle door can be ensured, and the installation operation can be easily performed.

[0011] (3) In the vehicle door according to (2), the second panel member covers the lower section of the first panel main body portion to have a space between the inner surface of the first panel main body portion and the second panel member, and the space is open upward.

[0012] In the case of a vehicle door having such a structure, small items can be placed in the space from the inside of the vehicle. According to such a vehicle door, the door pocket is constructed of two panel members. Therefore, no additional components are required to form the door pocket, and an increase in cost can be suppressed.

[0013] (4) The vehicle door according to (2) or (3) further includes a reinforcing member disposed on the outer side of the vehicle relative to the inner panel and extending from the front wall portion to the rear wall portion in the vehicle longitudinal direction.

[0014] The reinforcing member increases the strength of the vehicle door having such a structure. Two or more reinforcing members may be included in the vehicle door. In the case where the reinforcing member is disposed in the middle section of the inner panel in the up-down direction, the reinforcing member may be configured as a shock beam for reducing the shock of vibrations from the outside of the vehicle.

[0015] (5) In the vehicle door according to any one of (1) to (4), the first panel member is made of aluminum alloy by die casting.

[0016] Different from known vehicle doors, when producing a vehicle door having such a structure, an operation of welding a plurality of metal members is not required. This simplifies the production process of the vehicle door and suppresses an increase in production cost. Compared with a vehicle door made of resin, the vehicle door having the above structure can easily have rigidity, and a new vehicle door including interior parts made of metal is obtained.

[0017] (6) In the vehicle door according to any one of (1) to (5), the inner panel is fixed to the vehicle body via a hinge portion such that the vehicle door opens and closes as it moves around the hinge portion, and the outer panel is mounted on the inner panel in a manner detachable from the inner panel when the inner panel is fixed to the vehicle body.

[0018] In the above structure, the outer panel is mounted on the inner panel in a detachable manner as follows. After hooking the upper edge of the outer panel on the inner panel, the side and lower edges of the outer panel can be fitted to the inner panel. By sliding the outer panel laterally relative to the inner panel, the outer panel is mounted on the inner panel in a detachable manner. In the case where the vehicle door has such a structure, if there are large scratches or dents on the outer surface of the outer panel, for example, it is possible to easily detach only the outer panel from the inner panel and replace it with a new one without replacing the inner panel including most of the components of the vehicle door. Therefore, the repair operation is simplified and an increase in cost is suppressed.

[0019] (7)In the vehicle door according to (1), the first panel member includes a first panel main body portion that includes a non-overlapping portion and a hole, and the second panel member is mounted on the first panel member on the vehicle inner side with respect to the first panel member so as to cover the hole of the first panel main body portion, and an overlapping portion of the second panel member faces an outer panel through the hole of the first panel main body portion.

[0020] In such a configuration, it is possible to easily reduce the number of components of the vehicle door. There is no plate member on the inner side of the vehicle door, and there is a large space in the vehicle door. Therefore, functional components can be mounted in the space in various configurations. This simplifies the process of manufacturing the vehicle door and reduces the production cost.

[0021] (8)In the vehicle door according to (2), an upper edge portion of the first panel member above the hole is configured as an overlapping portion.

[0022] According to the present disclosure, there is provided a vehicle door having a low production cost. In addition, there is provided a vehicle door produced by a simplified production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a perspective view of a side door seen from the vehicle inner side.

[0024] Figure 2 is a cross-sectional view of the side door seen from the vehicle rear side.

[0025] Figure 3 is an exploded perspective view of the side door.

[0026] Figure 4 is a cross-sectional view of a part of the side door including a hinge mechanism.

[0027] Figure 5 is a cross-sectional view of another part of the side door including a hinge mechanism. DETAILED DESCRIPTION

[0028] will be described with reference to Figures 1 to 5 a side door 10 as an example of a vehicle door. The side door 10 of the present embodiment is a front side door of an automobile. In each drawing, arrows FR and RR respectively indicate the vehicle front side and the vehicle rear side, and arrows IN and OUT respectively indicate the vehicle inner side and the vehicle outer side.

[0029] As Figure 1As shown, on the inner surface of the vehicle, the side door 10 of the present embodiment includes a door pocket 11, an armrest 12 for a passenger to place their arm, an inner handle 13 for opening and closing the side door 10, a pull handle 14 held by a passenger to open or close the side door 10, and a switch base 15 including operation switches for opening and closing a window and locking and unlocking the side door 10. On the outer surface of the vehicle, the side door 10 includes a side view mirror 16. In addition, the side door 10 includes a window assembly 17 and a locking unit 18 for locking and unlocking the side door 10 relative to the vehicle body. As Figure 4 and Figure 5 shown, the side door 10 of the present embodiment is fixed to the front portion of the vehicle body BD via a hinge mechanism 19. Accordingly, the side door 10 moves around the hinge mechanism 19 to open and close.

[0030] As Figure 2 shown, the side door 10 includes two panels, which are an outer panel 20 and an inner panel 22. The outer panel 20 and the inner panel 22 are joined together and configured as the side door 10. The outer panel 20 is the outermost panel of the vehicle configured as the exterior trim of the vehicle. The outer panel 20 is a steel plate panel. The inner panel 22 is a panel configured as an inner member or interior (inner design surface) of the vehicle. As Figure 2 shown, no panel is arranged between the outer panel 20 and the inner panel 22. The outer panel 20 and the inner panel 22 face each other directly and are configured as the side door 10.

[0031] In the present embodiment, the outer panel 20 is made of steel; however, the outer panel 20 can be made of other metals or can be made of resin. Examples of the resin for the outer panel 20 include fiber-reinforced plastics (obtained by reinforcing thermosetting resins (such as unsaturated polyester, epoxy resin, polyamide resin, phenolic resin) with glass fiber, carbon fiber, aramid fiber, polyethylene fiber), polyacetal resin, polyamide resin, polycarbonate resin, polyimide resin, and ultra-high molecular weight polyolefin (polyethylene) resin. Most components of the side door 10 are mounted on the inner panel 22, while few components are included in the outer panel 20.

[0032] As Figure 3As shown, the inner panel 22 includes four panel members, including a first panel member 24, a second panel member 25, a third panel member 26, and a fourth panel member 27. The first panel member 24 has a frame shape including the outer peripheral portion of the inner panel 22. The first panel member 24 is configured as a base member on which the second panel member 25, the third panel member 26, the fourth panel member 27, and various functional components are mounted. In the present embodiment, the second panel member 25, the third panel member 26, and the fourth panel member 27 are made of resin, while the first panel member 24 is made of aluminum alloy and formed by die casting. The first panel member 24 may be made of resin. Examples of the resin for the inner panel 22 include one of a polypropylene resin, a polyethylene resin, a polystyrene resin, a polyester resin, and a resin including natural fibers.

[0033] As Figure 3 shown, the first panel member 24 includes a first panel main body portion 30, a first front wall portion 31, and a rear wall portion 32. The first panel main body portion 30 has plate surfaces facing the vehicle interior and the vehicle exterior, respectively. The first front wall portion 31 projects and extends outward from the front edge of the vehicle exterior surface of the first panel main body portion 30. The rear wall portion 32 projects and extends outward from the rear edge of the first panel main body portion 30. The first panel main body portion 30 has a hole 30A in the middle section and has a rectangular frame shape surrounding the hole 30A. As Figure 1 and Figure 2 shown, the first panel main body portion 30 includes a front upper portion 30B and an upper edge portion 30C facing the vehicle interior. The front upper portion 30B and the upper edge portion 30C are exposed and face the vehicle cabin space and are configured as inner design surfaces. No other panel members are arranged to overlap the front upper portion 30B and the upper edge portion 30C on the vehicle exterior. The front upper portion 30B and the upper edge portion 30C are arranged to face directly the outer panel 20 with no other panel members therebetween (see Figure 2 ). The front upper portion 30B and the upper edge portion 30C are configured as non-overlapping portions of the first panel member 24. The front upper portion 30B and the upper edge portion 30C have a vehicle interior surface facing the cabin space and a vehicle exterior surface facing directly the outer panel 20 with no other panel members therebetween.

[0034] The second panel member 25 is disposed on the inner side of the vehicle relative to the first panel member 24. The second panel member 25 covers the lower portion of the first panel member 24. More specifically, the second panel member 25 includes a second panel main body portion 34, a second front wall portion 35, and an extension portion 36. The second panel main body portion 34 has plate surfaces facing the inner side and the outer side of the vehicle, respectively. The second front wall portion 35 projects and extends outward from the front edge of the outer surface of the second panel main body portion 34 facing the outer side of the vehicle. The extension portion 36 extends outward from the lower edge and the rear edge of the second panel main body portion 34. The second panel main body portion 34 includes a rear portion 34A and a front portion 34B. The rear portion 34A covers the rear portion 30E and the lower portion 30F of the first panel main body portion 30. As Figure 2 shown, the rear portion 34A is directly opposed to the outer panel 20 with no panel member therebetween. No other panel member is arranged to overlap the rear portion 34A on the outer side of the vehicle. The rear portion 34A is configured as a non-overlapping portion of the second panel member 25. The rear portion 34A has an inner surface facing the cabin space and an outer surface directly facing the outer panel with no panel member therebetween. The rear portion 34A faces the outer panel through the hole 30A of the first panel main body portion 30.

[0035] As Figure 2 shown, when the second panel member 25 and the first panel member 24 are joined together, the front portion 34B of the second panel main body portion 34 is opposed to and spaced apart from the front lower portion 30D of the first panel main body portion 30. The front portion 34B is disposed on the inner side of the front lower portion 30D. An upwardly open door pocket 11 is defined by the front portion 34B of the second panel main body portion 34 and the front lower portion 30D of the first panel main body portion 30. The door pocket 11 has a space defined between the front portion 34B and the front lower portion 30D.

[0036] The second front wall portion 35 of the second panel member 25 extends upward from the lower edge of the second panel main body portion 34. As Figure 4 and Figure 5As shown, the second front wall portion 35 of the first panel member 24 and the first front wall portion 31 overlap in contact with each other. The first front wall portion 31 and the second front wall portion 35 are fixed to the vehicle body BD via the hinge mechanism 19. Thus, the first panel member 24 and the second panel member 25 are fixed to the vehicle body BD. Since the force is concentrated on the hinge mechanism 19 when the door is opened and closed, the hinge mechanism 19 needs to be fixed to the first panel member 24 and the second panel member 25 with high strength. In this regard, according to the present embodiment, the first front wall portion 31 of the first panel member 24 of the inner panel 22 and the second front wall portion 35 of the second panel member 25 are fixed together with high strength by the hinge mechanism 19. The hinge mechanism 19 includes a hinge plate 40, a hinge bracket 45 including a first hinge bracket portion 41 and a second hinge bracket portion 44, a screw 42, and a rotating shaft 43. The hinge bracket 45 includes a second hinge bracket portion 44 and a first hinge bracket portion 41 extending from the second hinge bracket portion 44.

[0037] Specifically, as Figure 5 shown, the first front wall portion 31 of the first panel member 24 and the second front wall portion 35 of the second panel member 25 overlap each other and are fixed together by the screw 42, wherein the hinge plate 40 supports the overlapping wall portions 31, 35 from the outside of the vehicle, and the first hinge bracket portion 41 sandwiches the overlapping wall portions 31, 35 and the screw head of the screw 42 from the inside of the vehicle. That is, as Figure 5 shown, the hinge plate 40, the first front wall portion 31, the second front wall portion 35, and the hinge bracket 45 are joined together by the screw 42. As Figure 4 shown, the rotating shaft 43 is assembled in the second hinge bracket portion 44. The second hinge bracket portion 44 of the hinge bracket 45 is fixed to the vehicle body BD, and the first hinge bracket portion 41 of the hinge bracket 45 is fixed to the first panel member 24 and the second panel member 25. Thus, the first panel member 24 and the second panel member 25 are fixed to the vehicle body BD via the hinge mechanism 19. In this configuration, the side door 10 can move around the rotating shaft 43 to open and close. Thus, only the inner panel 22 is fixed to the vehicle body BD via the hinge mechanism 19.

[0038] As described above, the first panel member 24 is formed by die casting of aluminum and is an integral part made of aluminum alloy. Thus, the first panel member 24 has higher stiffness than a panel member made of resin. In addition, by forming the first panel member 24 by die casting of aluminum, the thickness of the first panel member 24 can be easily changed in different parts, and the stiffness can be easily changed in different parts. Thus, when the first front wall portion 31 is formed to be thicker than the first panel main body portion 30, the stiffness of the first front wall portion 31 increases. For the second panel member 25 made of resin, when the second front wall portion 35 is formed to be thicker than the second panel main body portion 34, the stiffness of the second front wall portion 35 increases.

[0039] The second panel member 25 and the first panel member 24 are joined together, and the extension portion 36 of the second panel member 25 overlaps with the rear wall portion 32 of the first panel member 24 and covers the entire surface of the rear wall portion 32. When the side door 10 is opened, the extension portion 36, which is configured as the rear end portion of the side door 10, is exposed and can be seen by the passengers. Embossing is performed on the extension portion 36 that can be seen by the passengers when the door is opened, improving the design of the surface of the extension portion 36.

[0040] The locking unit 18 is disposed in front of the rear wall portion 32 of the first panel member 24 and on the outer side of the vehicle of the rear portion 30E of the first panel main body portion 30. The side door 10 is locked to the vehicle body BD by the locking unit 18 disposed near the rear wall portion 32. Therefore, the rigidity of the rear wall portion 32 of the first panel member 24 also needs to be increased. Similar to the first front wall portion 31, the rear wall portion 32 is formed to be thicker than the first panel main body portion 30, and the rigidity of the rear wall portion 32 is increased.

[0041] As Figure 2 and Figure 3 shown, the third panel member 26 has a shape protruding toward the inner side of the vehicle. In this configuration, the armrest 12 and the pull handle 14 are formed, and mounting portions for receiving the inner handle 13 and the switch base 15 are formed. Specifically, as Figure 2 shown, the third panel member 26 includes a first protrusion portion 50 and a second protrusion portion 51 protruding toward the cabin space. The first protrusion portion 50 is located above the second protrusion portion 51. The first protrusion portion 50 is the front section of the third panel member 26 in the front-rear direction. The first protrusion portion 50 has an upper surface extending horizontally, and the switch base 15 is mounted on the upper surface. The second protrusion portion 51 is located below the first protrusion portion 50. The second protrusion portion 51 is the rear section of the third panel member 26 in the front-rear direction. The second protrusion portion 51 has an upper surface configured as the armrest 12, and a recessed portion 52 is included in the upper surface in front of the armrest 12. The recessed portion 52 is configured as the pull handle 14. The portion of the third panel member 26 between the first protrusion portion 50 and the second protrusion portion 51 in the up-down direction is configured as a recessed portion 53 that is recessed toward the outer side of the vehicle because the first protrusion portion 50 and the second protrusion portion 51 protrude toward the inner side of the vehicle. The inner handle 13 is located in the recessed portion 53.

[0042] The third panel member 26 is mounted on the first panel member 24 to cover the front region of the hole 30A that is not covered by the second panel member 25. Almost the entire area of the inner surface of the vehicle side of the third panel member 26 is configured as an inner design surface of the vehicle facing the cabin space. In addition, the third panel member 26 is arranged to be directly opposite to the outer panel 20 with no other panel members therebetween. The third panel member 26 is configured as a non-overlapping portion as a whole.

[0043] The fourth panel member 27 is an elongated member extending in the front-rear direction and covers the upper edge of the first panel member 24. The first panel member 24 includes an upper protruding portion 60 that protrudes upward from its front edge portion. The upper protruding portion 60 protrudes upward compared to the fourth panel member 27. The upper protruding portion 60 is a mounting base for mounting the side mirror 16. The side mirror 16 is fixed to the upper protruding portion 60 by a fixing member so as to protrude toward the outside of the vehicle. A covering member 61 for covering the fixing member is attached to the inner surface of the vehicle side of the upper protruding portion 60. Therefore, the side mirror 16 is attached to the inner panel 22.

[0044] As Figure 2 and Figure 3 shown, the inner panel 22 includes a first reinforcing member 62, a second reinforcing member 63, and a third reinforcing member 64 on its outer side of the vehicle. The first reinforcing member 62, the second reinforcing member 63, and the third reinforcing member 64 have an elongated shape extending in the front-rear direction. More specifically, the first reinforcing member 62, the second reinforcing member 63, and the third reinforcing member 64 are arranged on the outer side of the vehicle of the first panel member 24 and extend from the first front wall portion 31 to the rear wall portion 32 of the first panel member. The front edge portions of the first reinforcing member 62, the second reinforcing member 63, and the third reinforcing member 64 are fixed to the first front wall portion 31, and the rear edge portions of the first reinforcing member 62, the second reinforcing member 63, and the third reinforcing member 64 are fixed to the rear wall portion 32. The first reinforcing member 62 extends along the upper edge of the first panel main body portion 30. The second reinforcing member 63 is arranged below the first reinforcing member 62 and extends along the middle section of the inner surface of the outer panel 20 with respect to the up-down direction. The middle section of the outer panel 20 corresponds to the outermost part of the outer panel 20. The third reinforcing member 64 is configured as a shock beam for reducing the impact from the outside of the vehicle in the case of a side collision. The third reinforcing member 64 is arranged at the hip level of the seated occupant.

[0045] The outer panel 20 is detachably mounted on the inner panel 22 and covers the inner panel 22 from the outside of the vehicle. Specifically, as Figure 2 and Figure 3As shown, the outer panel 20 includes a folding portion 20A at the upper edge and a fitting protrusion 20B at the lower edge portion on the back surface (inner surface) thereof. The folding portion 20A is folded on the back side (inside the vehicle), and the fitting protrusion 20B protrudes from the inner surface of the outer panel 20. The fitting protrusion 20B is fitted into a through hole formed in the inner panel 22. Specifically, the fitting protrusion 20B is fitted into a through hole formed in the lower edge section of the extension 36 of the second panel member 25. When the folding portion 20A is hooked on the first reinforcing member 62, the fitting protrusion 20B is fitted into the through hole of the second panel member 25, and accordingly, the outer panel 20 is attached to the inner panel 22.

[0046] The window assembly 17 is disposed on the vehicle outer side of the inner panel 22 and on the vehicle inner side of the first reinforcing member 62, the second reinforcing member 63, and the third reinforcing member 64. The window assembly 17 includes a plate-shaped window glass 70 and a regulator 71 that serves as a drive source for moving the window glass 70 up and down. As Figure 2 shown, a weatherstrip 72 is attached to the outer surface of the upper edge of the first panel member 24 to seal the gap between the window glass 70 and the first panel member 24 and to enable the window glass 70 to move up and down. A weatherstrip 73 is attached to the inner surface of the folding portion 20A of the upper edge of the outer panel 20 to seal the gap between the window glass 70 and the outer panel 20 and to enable the window glass 70 to move up and down. The window glass 70 is movably disposed between the weatherstrips 72, 73 facing each other.

[0047] A wire 74 connecting the regulator 71 and the switch base 15 and a wire 75 connecting the locking unit 18 and the inner handle 13 are supported by the inner panel 22. In this configuration, when the outer panel 20 is separated from the inner panel 22, the wires 74, 75 do not need to be detached from the inner panel 22. When the outer panel 20 is separated from the inner panel 22, only the weatherstrip 73 located on the vehicle outer side is mounted on the outer panel 20.

[0048] As described above, the side door 10 of the present embodiment includes an inner panel 22, and the inner panel 22 includes a plurality of panel members. The panel members include a first panel member 24, a second panel member 25, and a third panel member 26. Each of the first panel member 24, the second panel member 25, and the third panel member 26 includes a non-overlapping portion that is configured as a designed surface inside the vehicle and is directly opposite to the outer panel 20, and there is no any other panel member between each of the first panel 24, the second panel 25, and the third panel 26 and the outer panel 20. The non-overlapping portion has a double structure, which is composed of the outer panel 20 and the inner panel 22 that are directly opposite to each other, and there is no any panel member therebetween. The side door 10 of the present embodiment includes a plurality of portions that are configured as designed surfaces inside the vehicle and have a double structure. Therefore, the number of components of the side door 10 is relatively small.

[0049] As Figure 2 shown, the side door 10 does not include a board member between the outer panel 20 and the inner panel 22, and there is a large inner space between the outer panel 20 and the inner panel 22. Therefore, functional components can be installed in various configurations. In the case of the side door 10 of the present embodiment, the production process is simplified and made easy, and the production cost is reduced.

[0050] Generally known vehicle door panels include a door panel made of metal and a door trim made of resin. The door panel includes an outer panel and an inner panel made of metal. The resin door trim is installed on the metal door panel on the inner side of the vehicle. That is, generally known vehicle doors have a three-board structure in which three board members overlap in the vehicle interior and exterior direction. The vehicle door described herein includes a plurality of portions that are configured as designed surfaces inside the vehicle and have a double structure in which the outer panel 20 and the inner panel 22 overlap. Therefore, the number of components of the vehicle door 1 can be easily reduced. There is no board member on the inner side of the vehicle door, and there is a large space in the vehicle door. Therefore, functional components can be installed in the space in various configurations. This simplifies the process of manufacturing the vehicle door and reduces the production cost.

[0051] The outer panel 20 can be made of metal or resin. The panel members of the inner panel 22 may not be made of resin, but a part of the panel members may be made of metal. For example, one of the first panel member and the second panel member can be made of metal and configured as a base member, and the second panel member can be made of resin. The second panel member made of resin can be installed on the first panel member as the base member on the inner side of the vehicle.

[0052] The first panel member 24 includes a first panel main body portion 30, a first front wall portion 31, and a rear wall portion 32. The first panel main body portion 30 includes a non-overlapping portion and a hole 30A. The first front wall portion 31 extends from the front edge of the first panel main body portion 30 toward the outside of the vehicle. The rear wall portion 32 extends from the rear edge of the first panel main body portion 30 toward the outside of the vehicle. The second panel member 25 is mounted on the first panel member 24 on the inner side of the vehicle in such a manner as to cover the hole 30A of the first panel main body portion 30.

[0053] The first panel member 24 can be configured as a base member of the inner panel 22. In addition to the outer panel 20, many components of the vehicle door can be attached to the first panel member 24. For example, the second panel member 25 can be mounted on the first panel member 24 on the inner side of the vehicle, and functional components can be attached to the first panel member 24 on the inner side and the outer side of the vehicle. In the case of a vehicle door having such a configuration, the stiffness of the inner panel and the stiffness of the vehicle door can be ensured, and the installation operation can be easily performed.

[0054] The second panel member 25 covers the lower section of the first panel main body portion 30 so as to have a space between the inner surface of the first panel main body portion 30 and the second panel member 25, and the space is open upward.

[0055] In the case of a vehicle door having such a configuration, small items can be placed into the space from the inner side of the vehicle. According to such a vehicle door, the door pocket 11 is constructed by two panel members 24, 25. Therefore, no additional components are required to form the door pocket 11, and an increase in cost can be suppressed.

[0056] The vehicle door further includes reinforcing members 62, 63, 64 that are arranged on the outer side of the vehicle with respect to the inner panel 22 and extend from the first front wall portion 31 to the rear wall portion 32 in the longitudinal direction of the vehicle.

[0057] The reinforcing members 62, 63, 64 increase the strength of the vehicle door. In the case where the reinforcing member 64 is arranged in the middle section of the inner panel 22 with respect to the vertical direction, the reinforcing member 64 can be configured as a shock beam for reducing vibrations from the outside of the vehicle.

[0058] The first panel member 24 is made of aluminum alloy by die casting. Different from known vehicle doors, when manufacturing a vehicle door having such a configuration, an operation of welding a plurality of metal members is not required. This simplifies the manufacturing process of the vehicle door and suppresses an increase in manufacturing cost. Compared with a vehicle door made of resin, the vehicle door having the above configuration can easily have stiffness, and a new vehicle door including interior parts made of metal is obtained.

[0059] The inner panel 22 is fixed to the vehicle body BD via a hinge mechanism 19 such that the vehicle door opens and closes as it moves around the hinge mechanism 19, and the outer panel 20 is mounted on the inner panel 22 in a manner detachable from the inner panel 22 when the inner panel 22 is fixed to the vehicle body BD.

[0060] In the above structure, the outer panel 20 is detachably mounted on the inner panel 22 as described below. After hooking the upper edge of the outer panel 20 on the inner panel 22, the side and lower edges of the outer panel 20 can be fitted to the inner panel 22. Further, by laterally sliding the outer panel 20 relative to the inner panel 22, the outer panel 20 is detachably mounted on the inner panel 22. In the case where the vehicle door has such a structure, if there are large scratches or dents on the outer surface of the outer panel 20, for example, it is possible to easily detach only the outer panel 20 from the inner panel 22 and replace it with a new one without replacing the inner panel 22 which includes most of the components of the vehicle door. Thus, the repair operation is simplified and an increase in cost is suppressed.

[0061] <Other embodiments>

[0062] The technology described herein is not limited to the embodiments described above with reference to the accompanying drawings. The technology described herein can be modified within the technical scope. The following embodiments can be included within the technical scope.

[0063] The inner panel 22 may include two, four or more panel members including non-overlapping portions.

[0064] In the above embodiment, the first panel member 24 of the inner panel 22 includes a first front wall portion 31 and a rear wall portion 32 and is configured as a base member of the inner panel 22. However, the panel member including the front wall portion and the panel member including the rear wall portion may be combined and configured as a base member of the inner panel.

[0065] In the above embodiment, the outer panel 20 is detachably mounted on the inner panel 22. However, by laterally sliding the outer panel relative to the inner panel, the outer panel can be mounted on the inner panel. In the case of such a structure, when separating the outer panel from the inner panel, the outer panel is moved by sliding it in a direction away from the hinge mechanism (backward) and pulling the outer panel from the opposite side (rear side) of the hinge mechanism of the inner panel. Thus, the outer panel can be separated from the inner panel. On the other hand, the outer panel 20 and the inner panel are combined by sliding the outer panel 20 in a direction closer to the hinge mechanism (forward) from the opposite side (rear side) of the hinge mechanism and overlapping the outer panel and the inner panel.

[0066] The present technology is not necessarily applied to automobiles, but can be applied to various types of vehicles, including ground vehicles such as trains and amusement ride vehicles, aircraft such as airplanes and helicopters, watercraft such as ships, and underwater vehicles such as submarines.

Claims

1. A vehicle door, comprising: An outer panel having an outer surface configured as an outer wall surface of the vehicle; And An inner panel disposed on the inner side of the vehicle relative to the outer panel and having an inner surface facing the cabin space of the vehicle. The inner panel includes at least a first panel member and a second panel member, and Each of the first panel member and the second panel member includes a non-overlapping portion having an inner surface facing the cabin space and an outer surface directly facing the outer panel with no panel therebetween between the non-overlapping portion and the outer panel.

2. The vehicle door according to claim 1, wherein The first panel member includes: A first panel main body portion including the non-overlapping portion and a hole; A front wall portion extending outward from the front edge of the first panel main body portion toward the outside of the vehicle; And A rear wall portion extending outward from the rear edge of the first panel main body portion toward the outside of the vehicle, and The second panel member is mounted on the first panel member on the inner side of the vehicle relative to the first panel member to cover the hole of the first panel main body portion.

3. The vehicle door according to claim 2, wherein the second panel member covers a lower section of the first panel main body portion to have a space between the inner surface of the first panel main body portion and the second panel member, and the space is open upward.

4. The vehicle door according to claim 2 or 3, further comprising a reinforcing member disposed on the outer side of the vehicle relative to the inner panel and extending from the front wall portion to the rear wall portion in the longitudinal direction of the vehicle.

5. The vehicle door according to any one of claims 1 to 4, wherein the first panel member is made of aluminum alloy by die casting.

6. The vehicle door according to any one of claims 1 to 5, wherein The inner panel is fixed to the vehicle body via a hinge portion such that the vehicle door opens and closes with movement around the hinge portion, and The outer panel is mounted on the inner panel in a manner that can be detached from the inner panel when the inner panel is fixed to the vehicle body.

7. The vehicle door according to claim 1, wherein The first panel member includes a first panel main body portion including the non-overlapping portion and a hole, and The second panel member is mounted on the first panel member on the inner side of the vehicle relative to the first panel member to cover the hole of the first panel main body portion, and the overlapping portion of the second panel member faces the outer panel through the hole of the first panel main body portion.

8. The vehicle door according to claim 2, wherein an upper edge portion of the first panel member above the hole is configured as the overlapping portion.

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