VEHICLE DOOR ASSEMBLY WITH A STORAGE CONTAINER THAT IS LONGITUDINALLY SLIDING

Abstract

Vehicle door assembly comprising: an inner door structure (12) having an outer side panel (18) and an armrest (22), the armrest (22) projecting laterally inwardly from the outer side panel (18); and a storage container (16) disposed below the armrest (22), secured to the inner door structure (12), and movable between a rearward and a forward position relative to the inner door structure (12); characterized in that the inner door structure (12) further includes a support shelf (24) projecting laterally inwardly from the outer side panel (18); the armrest (22) is arranged above the support tray (24), wherein the support tray (24) supports the storage container (16) in both the rear position and the front position; the vehicle door assembly further comprises at least one rail (13) secured to at least one of the support tray (24), the outer side panel (18), and the armrest (22); and the storage container (16) is attached to the at least one rail (13).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a vehicle door assembly according to the preamble of claim 1 or claim 8, respectively, with a storage container that is displaceable in the longitudinal direction. Such a vehicle door assembly is essentially known from DE 100 33 375 C1. Regarding the further prior art, reference is made to US 2007 / 0 194 582 A1. BACKGROUND

[0002] A vehicle door assembly typically includes an outer door structure located on the outside of the vehicle and an inner door structure located inside the vehicle. The outer door structure is typically made of sheet metal, while the inner door structure is typically made of plastic. Various components are often mounted to the inner door structure. Examples of these components include a handle, a control panel for window switches and / or lock switches, a window opening and closing mechanism, and / or speakers.

[0003] The interior door structure typically includes an armrest, storage compartments for items such as an umbrella, and cup holders. The storage compartments and cup holders are often integrally formed with the rest of the interior door structure, for example, through injection molding. Thus, the storage compartments and cup holders are typically attached to the rest of the interior door structure. Furthermore, the items stored in the storage compartments or cup holders are clearly visible to anyone near the vehicle. Therefore, the storage compartments and cup holders are not ideal for storing valuable or fragile items. Although some storage compartments are equipped with covers or lids, access to the interior of these storage compartments is not easy because the lids must be opened.In addition, the interior spaces and access openings of these storage compartments are relatively small and may be located in regions that are not easily accessible ergonomically. SUMMARY

[0004] According to the invention, a vehicle door arrangement is presented which is characterized by the features of claim 1 or claim 8.

[0005] Further applicability of the present disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are provided for purposes of illustration only. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present disclosure will become more fully understood with reference to the detailed description and the accompanying drawings, in which: Fig. 1 is a perspective view of a door assembly according to the principles of the present disclosure, showing the door assembly including a storage container in a rearward position; Fig. 2 is a perspective view of the door assembly of Fig. 1 with the storage container in the front position; Fig. 3. is an exploded perspective view of the door assembly of Fig. 1; Fig. 4 is a sectional view of a portion of the door assembly of Fig. 1 with the storage container in the rear position; Fig. 5 is a sectional view of a portion of the door assembly of Fig. 1 with the storage container in the front position; Fig. 6 is a side view of another door assembly according to the principles of the present disclosure, showing the door assembly including a handle, a latch, a track, and a storage container in a rearward position; Fig. 7 is a side view of the door assembly of Fig. 6 with the storage container in a forward position; Fig. Figure 8 is a perspective view of a portion of the door assembly of Fig. 6 with the handle and the lock; Fig. 9 is a split plan view of the portion of the door assembly of Fig. 6, shown in Fig. 8; Fig. 10 is a perspective view of a third door assembly according to the principles of the present disclosure, the fourth door assembly having a plurality of tracks, a rearwardly shown storage bin, and a discontinuous support shelf; Fig. 11 is a sectional view of the rail of the third door assembly; Fig. 12 is a perspective view of another door assembly according to the principles of the present disclosure, the door assembly including a storage container and a fastener extending through a slot in the storage container and into an interior door structure; Fig. 13 is a perspective view of another door assembly according to the principles of the present disclosure, the door assembly including a storage bin, a storage compartment disposed beneath the storage bin, and a cup holder that is removable or collapsible to provide access to the storage compartment; Fig. 14 is a perspective view of another door assembly according to the principles of the present disclosure, the door assembly including a storage container and a partition disposed within an interior compartment of the storage container; Fig. 15 and Fig. 16 are perspective views of interior door structures including stiffeners according to the principles of the present disclosure; Fig. 17 and Fig. 18 are perspective views of storage containers including energy absorbing features according to the principles of the present disclosure; Fig. 19 to 23 are sectional views of a storage container and an inertia member for preventing the storage container from shifting during high vehicle deceleration in accordance with the principles of the present disclosure; Fig. 24 is a perspective view of another storage container according to the principles of the present disclosure, showing the storage container including a hinged door in a closed position; Fig. 25 is a perspective view of the storage container of Fig. 23 with the flap door open; Fig. 26 is a perspective view of a selector lock for locking a storage container according to the principles of the present disclosure; Fig. 27 is a perspective view of a storage container including a mesh opening according to the principles of the present disclosure; and Fig. 28 is a perspective view of a storage container including lighting according to the principles of the present disclosure.

[0007] In the drawings, the same reference numerals are used for similar and / or identical elements. DETAILED DESCRIPTION

[0008] A vehicle door assembly according to the present disclosure includes an inner door structure and a storage bin slidable relative to the inner door structure between a rearward position and a forward position. When the storage bin is in the rearward position, an interior compartment of the storage bin is concealed by an inner side panel of the inner door structure. When the storage bin is in the rearward position, an interior compartment of the storage bin becomes accessible. Thus, a vehicle occupant can store valuable items in the storage bin.

[0009] In one example, the storage bin is mounted on a rail attached to the interior door structure, and a motor is operable to move the storage bin between the rearward and forward positions. The motor is operable only when a vehicle ignition switch is in the ON position. Thus, the items stored in the storage bin are securely enclosed within the storage bin and rendered invisible when the storage bin is in the rearward position and the ignition switch is in the OFF position.

[0010] In another example, the storage bin is manually moved along the rail between the rear position and the front position using a handle on the storage bin. The storage bin can be locked in the rear position with an automatic or manual lock. This way, the items stored in the storage bin are securely enclosed and concealed within the storage bin when the storage bin is in the rear position and the automatic or manual lock is activated.

[0011] In another example, the interior of the storage container is accessible not only from the top of the storage container, but also from an interior side of the storage container (i.e., the side of the storage container opposite the vehicle occupant sitting next to the storage container). This makes the access opening of the storage container relatively large compared to the access opening of most non-movable storage containers, making the interior compartment of the storage container easier to access compared to non-movable storage containers. Furthermore, the interior of the storage container may be covered by a door that opens due to gravity when the storage container is moved to the forward position. This allows the interior compartment of the storage container to be larger than the interior compartments of most non-movable storage containers while maintaining a large access opening in a position that allows easy access.

[0012] With reference to the Fig. 1 to 3, a door assembly 10 is configured for installation in a vehicle (not shown). The door assembly 10 includes an inner door structure 12, a rail 13, a motor 14, a bin switch 15, and a storage bin 16 movable relative to the inner door structure 12 between a rearward position ( Fig. 1) and a front position ( Fig. 2) is movable. The inner door structure 12 may be made of plastic. The inner door structure 12 includes an outer side panel 18, an inner side panel 20, a boundary panel 21, an armrest 22, a support shelf 24, and one or more cup holders 26. In the illustrated example, the inner door structure 12 includes two of the cup holders 26.

[0013] The inner side panel 20 is disposed laterally within the outer side panel 18 and includes a first portion 28 and a second portion 30. The first portion 28 of the inner side panel 20 has a rectangular shape and conceals the entire storage container 16, including an interior compartment 34, when the storage container 16 is in the rearward position. Thus, the interior compartment 34 can be used to store valuables, such as a tablet. The second portion 30 of the inner side panel 20 cooperates with the first portion 28 and the armrest 22 to define an access opening 32 that allows access to the interior compartment 34 of the storage container 16 when the storage container 16 is in the forward position. The first and second portions 28 and 30 of the inner side panel 20 can be integrally molded as a single panel or molded separately and joined together.

[0014] The limiting plate 21 and the armrest 22 protrude laterally inwardly from the outer side panel 18. The limiting plate 21 extends around the perimeter of the inner side panel 20. The armrest 22 is located above the storage bin 16. In various implementations, the armrest 22 may include a power source (not shown), such as an electrical outlet, disposed on a bottom surface 78 of the armrest 22. The power source may be accessible when the storage bin 16 is in the rearward position, the forward position, or any position therebetween. When the storage bin 16 is in the forward position, a gap may be formed between the front end 46 of the storage bin 16 and the front end or edge of the access opening 32, as shown in Fig. 2, so that the outer side panel 18 is visible. Alternatively, when the storage container 16 is in the forward position, the front end 46 of the storage container 16 may be flush with or forward of the front edge of the access opening 32 so that the outer side panel 18 is not visible.

[0015] The support tray 24 is configured to support the storage container 16 when the storage container 16 is in the rear position and the storage container 16 is in the front position. As shown in Fig. 3, the support tray 24 has a rear surface 36 and a front surface 38. The rear surface 36 of the support tray 24 is located below the storage container 16 when the storage container 16 is in the rearward position. The front surface 38 of the support tray 24 is interrupted by the rear surface 36 and is located below the storage container 16 when the storage container 16 is in the forward position. The cup holders 26 form the front surface 38 of the support tray 24.

[0016] Further with reference to Fig. 3, the support tray 24 defines a groove or channel 40 that projects into the rear surface 36 of the support tray 24. The rail 13 and the motor 14 are arranged in the channel 40. The rail 13 and the motor 14 can be attached to the underside 42 ( Fig. 4 and Fig. 5) of the channel 40 with fasteners and / or adhesive.

[0017] With continued reference to Fig. 3, the storage container 16 includes a main body 44 having a front end 46 and a rear end 48 defining the interior compartment 34. The main body 44 of the storage container 16 includes an outer side panel 50, an inner side panel 52, a front panel 54, a rear side panel 56, and a bottom panel 58. The outer, inner, front, and rear side panels 50, 52, 54, and 56 cooperate to define an access opening 60 that provides access to the interior compartment 34 of the storage container 16. In the illustrated example, a height 62 of the inner side panel 52 is less than a height 64 of the outer side panel 50 to increase the size of the access opening 60.The storage container 16 may also include a cover plate (not shown) that cooperates with the outer, inner, front and rear side panels 50, 52, 54 and 56 to define the access opening 60 (and define the perimeter of the storage container 16).

[0018] With additional reference to the Fig. 4 and Fig. 5, the rail 13 includes a mechanical actuation system including a threaded rod 66, a container nut 68, and an end support 70. The storage container 16 is attached to the container nut 68 using, for example, a fastener, a snap-in feature, a receiving feature, and / or adhesive. The motor 14 supports a first end 72 of the threaded rod 66, and the end support 70 supports a second end 74 of the threaded rod 66 opposite the first end 72, while the threaded rod 66 can rotate. The motor 14 is operable to translate the container nut 68 in the longitudinal direction 76 by rotating the threaded rod 66. Since the storage container 16 is attached to the container nut 68, the storage container 16 translates between the rear position ( Fig. 1 and Fig. 4) and the front position ( Fig. 2 and Fig. 5), while the motor 14 moves the container nut 68 in the longitudinal direction 76.

[0019] The threaded rod 66, the container nut 68, and / or the end support 70 may be made of metal and / or plastic. In one example, the container nut 68 and the storage container 16 are integrally formed (e.g., cast) from plastic. Additionally or alternatively, the container nut 68 may not completely enclose the threaded area (i.e., the internal threads of the container nut 68 may not extend completely around the circumference of the threaded rod 66). Instead, the container nut 68 may define a threaded bearing surface that extends only around the top of the threaded rod 66, and a mechanism (e.g., a compression spring) may maintain contact between the bearing surface and the threaded rod 66.

[0020] The bin switch 15 is located in the armrest 22 and can be actuated to activate the motor 14 to move the storage bin 16 between the rearward and forward positions. For example, a vehicle occupant can push the switch 15 down to move the storage bin 16 to the forward position, and the vehicle occupant can pull the switch 15 up to move the storage bin 16 to the rearward position. The bin switch 15 can be electrically connected to the motor 14 via a wired or wireless connection. The bin switch 15 can only be actuated to activate the motor 14 when a vehicle ignition key or switch (not shown) is in the ON position.When the ignition key or switch is in the OFF position, the motor 14 may act as a lock preventing the storage bin 16 from moving to the forward position and thus preventing access to the interior 34 of the storage bin 16.

[0021] In the illustrated example, the door assembly 10 includes only the rail 13 and the motor 14, and the rail 13 is mounted on the support tray 24. However, in various embodiments, the door assembly 10 may include more than one rail and more than one motor, and the rails may be mounted to other components in addition to or instead of the support tray 24. The rails may, for example, be mounted to the outer side panel 18 and / or to a bottom surface 78 ( Fig. 1-3) of the armrest 22.

[0022] The storage bin 16 of the door assembly 10 can be referred to as an automatic storage bin because a vehicle occupant can move the storage bin 16 between the rear and front positions using the bin switch 15 without touching the storage bin 16. In contrast, the Fig. 6 and Fig. 7 shows a door assembly 100 with a storage container 102 which can be moved with respect to the inner door structure 12 between a rearward position ( Fig. 6) and a front position ( Fig. 7) is manually movable. The door assembly 100 does not include a motor for moving the storage container 102. Thus, the storage container 102 of the door assembly 100 can be referred to as a manual storage container.

[0023] The storage container 102 includes a main body 108 having a front end 110 and a rear end 112, and the storage container 102 includes a handle 114 attached to the front end 110 of the main body 108. The main body 108 of the storage container 102 defines an interior compartment 116 configured for storing items, such as a tablet. The main body 108 of the storage container 102 includes an outer side panel 118 ( Fig. 7), an inner side panel 120 disposed laterally inside the outer side panel 118, a front panel 122, a rear panel 124, and a bottom panel 126. A vehicle occupant can exert a force on the handle 114 to move the storage container 102 between the rear and forward positions. When the storage container 102 is in the forward position, a gap may be formed between the front end 110 of the storage container 102 and the front end or edge of the access opening 32, as shown in Fig. 6, so that the outer side panel 18 is visible. Alternatively, when the storage container 16 is in the forward position, the front end 110 of the storage container 102 may be flush with or forward of the front edge of the access opening 32 so that the outer side panel 18 is not visible.

[0024] The door assembly 100 further includes an inner door structure 128, a track 130, a latch 132, an optional biasing member 134, an electric lock 136, and a latch switch 138. The inner door structure 128 is similar to the inner door structure 12 in that the inner door structure 128 includes the outer side panel 18, an inner side panel 140, the limiter plate 21, and the armrest 22. In addition, although not shown, the inner door structure 128 may also include the support tray 24 and the cup holders 26.

[0025] The inner side panel 140 of the inner door structure 128 is similar to the inner side panel 20 of the inner door structure 12 in that the inner side panel 140 includes a first portion 142 and the second portion 30. However, the first portion 142 of the inner side panel 140 differs slightly from the first portion 28 of the inner side panel 20. To this end, the first portion 142 of the inner side panel 140 defines a notch 144 that allows access to the handle 114 when the storage container 102 is in the rearward position. Thus, when the storage container 102 is in the rearward position, the first portion 142 of the inner side panel 140 conceals the interior compartment 116 of the storage container 102 while maintaining access to the handle 114.

[0026] The rail 130 may be a sliding rail, such as that described below with reference to Fig. 10 and Fig. 11. Thus, the storage container 102 is attached to the inner door structure 128 via the rail 130 and is movable on the rail 130 between the rear and front positions.

[0027] The latch 132 holds the storage bin 102 in the rearward position without applying an external force to the storage bin 102 sufficient to overcome a holding force of the latch 132. The optional biasing member 134 biases the storage bin 102 toward the forward position to assist a vehicle occupant in overcoming the holding force of the latch 132 when moving the storage bin 102 from the rearward position to the forward position. The biasing member 134 is disposed between the inner door structure 12 and the rear end 112 of the storage bin 102 and exerts a biasing force on the rear end 112. The biasing member 134 may be a compression spring.

[0028] The electric lock 136 is operable to lock the storage container 102 in the rearward position. For example, the electric lock 136 can engage the outer side panel 118 of the storage container 102 to lock the storage container 102 in the rearward position. The lock switch 138 is operable to turn the electric lock 136 on or off, thereby locking or unlocking the storage container 102. For example, a vehicle occupant can press a front end 146 of the lock switch 138 to activate the electric lock 136, and the vehicle occupant can press a rear end 148 of the lock switch 138 to deactivate the electric lock 136.The lock switch 138 may generate a lock command signal when the front end 146 of the lock switch 138 is pressed, and the lock switch 138 may generate an unlock command signal when the rear end 148 of the lock switch 138 is pressed. The electric lock 136 may lock the storage container 102 in response to the lock command signal and unlock the storage container 102 in response to the unlock command signal. The lock switch 138 may communicate with the electric lock 136 via a wired or wireless connection. In various implementations, a mechanical lock may be used in addition to or instead of the electric lock 136, and a combination or key may be used to activate or deactivate the mechanical lock.

[0029] With reference to the Fig. 8 and Fig. 9, the handle 114, the latch 132 and portions of the inner side panel 120 of the storage container 102, the front panel 122 of the storage container 102, and the inner side panel 140 of the inner door structure 128 are shown in more detail. One or more (e.g., all) of the Fig. 8 and Fig. 9 can cooperate to form the lock 132. When the lock 132 is activated, as shown in the Fig. 8 and Fig. 9, the latch 132 holds the storage container 102 in the rearward position without applying an external force to the storage container 102 sufficient to overcome the holding force of the latch 132. When the latch 132 is released, the latch 132 does not prevent the storage container 102 from moving from the rearward to the forward position.

[0030] The handle 114 includes a graspable body 150, a spring retainer 152 extending laterally outward from the graspable body 150, a pivot arm 154 extending rearward from the graspable body 150, and a locking arm 156 extending laterally inward from the graspable body 150. The inner side panel 120 of the storage container 102 includes a hinge projection 158 and a stroke stop 160. The first portion 142 of the inner side panel 140 of the inner door structure 128 defines a detent 162. When the latch 132 is engaged, the locking arm 156 of the handle 114 engages the detent 162 in the inner side panel 140.

[0031] A pivot pin 164 extends vertically through the hinge projection 158 on the inner side panel 120 of the storage container 102 and through the pivot arm 154 on the handle 114 to pivotally connect the handle 114 to the inner side panel 120. The handle 114 is pivotable about the pivot pin 164 to engage or release the latch 132. When the latch 132 is engaged, the handle 114 can be rotated in a first direction 166 about the pivot pin 164 to disengage the latch arm 156 of the handle 114 from the detent 162 in the inner side panel 140, thereby releasing the latch 132. When the lock 132 is released, a spring 168 exerts a biasing force on the handle 114, urging the handle 114 to rotate in a second direction 170 opposite to the first direction 166.When the handle 114 rotates in the second direction 170 and the storage container 102 is in the rearward position, the locking arm 156 of the handle 114 engages the detent 162 in the inner side panel 140 and thereby engages the lock 132.

[0032] The front panel 122 of the storage container 102 defines a rectangular notch 172 and includes a spring retainer 174 extending laterally inwardly from the notch 172. The spring retainer 174 on the front panel 122 of the storage container 102 cooperates with the spring retainer 152 on the handle 114 and retains the spring 168 therebetween. Additionally, the spring retainer 174 on the front panel 122 of the storage container 102 and / or an inner edge 175 of the front panel 122 acts as an end stop, limiting the travel of the handle 114 as the handle 114 rotates in the first direction 166. Likewise, the travel stop 160 on the inner side panel 120 limits the travel of the handle 114 as the handle 114 rotates in the second direction 170.

[0033] To move the storage bin 102 from the rearward to the forward position, a vehicle occupant exerts a force on the handle 114 in the forward direction 176. In turn, the handle 114 rotates in the first direction 166 until the spring retainer 152 on the handle 114 contacts the spring retainer 174 on the storage bin 102 and / or until the handle 114 contacts the inner edge 175 of the front panel 122. When the pusher 114 rotates in the first direction, the locking arm 156 of the handle 114 disengages from the detent 162 in the inner side panel 140, which releases the latch 132. After the lock 132 is released, the storage container 102 moves on the rail 130 to the forward position by the force exerted on the handle 114 in the forward direction 176.When the vehicle occupant releases the handle 114 while the storage container 102 is in the forward position, the handle 114 rotates in the second direction 170 due to the biasing force of the spring 169. However, the locking arm 156 of the handle 114 does not engage the detent 162 in the inner side panel 140 because the storage container 102 is not in the rearward position.

[0034] To move the storage bin 102 from the forward to the rearward position, a vehicle occupant applies force to the handle 114 in the rearward direction 178. As the storage bin 102 moves in the rearward direction 178 due to the force exerted by the vehicle occupant, a ramped surface 180 on the locking arm 156 of the handle 114 engages a ramped surface 182 on the first portion 142 of the inner side panel 140. This engagement causes the handle 114 to rotate in the first direction 166, causing the locking arm 156 of the handle 114 to move past the ramped surface 182 of the inner side panel 140, ultimately allowing the storage bin 102 to be moved to the rearward position.On the other hand, if the handle 114 is pulled rearward with high force, the engagement may cause the first portion 142 of the inner side panel 140 to push inward (elastically deform), causing the locking arm 156 of the handle 114 to move past the ramped surface 182 of the inner side panel 140 and ultimately allowing the storage bin 102 to slide into the rearward position. When the storage bin 102 reaches the rearward position, the handle 114 rotates in the second direction 170 due to the biasing force of the spring 168. The handle 114 rotates in the second direction 170 until the handle 114 contacts the stroke stop 160 on the inner side panel 120 of the storage bin 102. At this point, the locking arm 156 of the handle 114 is engaged with the catch 162 in the inner side panel 140, thus engaging the lock 132.

[0035] With reference to Fig. 10 is a door assembly 200 similar to door assembly 10 in that door assembly 10 includes outer side panel 18, an armrest 202, support tray 24, cup holders 26, and a longitudinally slidable storage bin 204. Although not shown, door assembly 200 may also include inner side panel 20 and limiter plate 21. However, unlike door assembly 10, door assembly 200 does not include a motor that translates storage bin 204. Therefore, storage bin 204 may also be referred to as a manual storage bin. Unlike door assembly 10 and door assembly 200, door assembly 200 includes a first rail 208, a second rail 210, and a third rail 212 instead of a single rail. Additionally, armrest 202 of door assembly 200 includes a lower portion 214 that forms part of third rail 212.In addition, the storage container 204 includes a cover plate 216 in addition to the outer, inner, front, rear and lower side panels 50, 52, 54, 56 and 58.

[0036] The first rail 208 is mounted to the outer side panel 18 and includes a guide rail 218 and a carriage 220 that is slidable within the guide rail 218 in the longitudinal direction 206. The carriage 220 includes a mounting plate 222 and a sliding projection 224 that protrudes laterally from the mounting plate 222. The guide rail 218 defines a guide channel 226, and the sliding projection 224 is received and slides within the guide channel 226. The storage container 204 is attached to the mounting plate 222 of the carriage 220, for example, with fasteners, snap-in features, receiving features, and / or adhesive.The first rail 208 may also include ball bearings disposed between the sliding projection 224 and the guide channel 226 and / or a Teflon® or other low-friction coating disposed on the sliding projection 224 and / or the guide channel 226 to reduce the friction of the sliding projection 224 within the guide channel 226.

[0037] The second rail 210 is mounted to the outer side panel 18 and includes a guide rail 228 and a carriage 230 that is slidable within the guide rail 228 in the longitudinal direction 206. The carriage 230 includes a mounting plate 232 and a sliding projection 234 that projects downwardly from the mounting plate 232. The guide rail 228 defines a guide channel 236, and the sliding projection 234 is received and slides within the guide channel 236. The storage container 204 is attached to the mounting plate 232 of the carriage 230, for example, with fasteners and / or adhesive. The second rail 210 may also include ball bearings disposed between the sliding projection 234 and the guide channel 236 and / or a Teflon® coating disposed on the sliding projection 234 and / or the guide channel 236 to reduce friction of the sliding projection 234 within the guide channel 236.

[0038] With reference to Fig. 11, the third rail 212 includes a guide rail 237 and a carriage 238, which is displaceable in the guide rail 237 in the longitudinal direction 206. The guide rail 237 is formed by the lower portion 214 of the armrest 202, and the carriage 238 is attached to the cover plate 216 of the storage container 204. In the Fig. 11, the carriage 238 is formed integrally with the cover plate 216 of the storage container 204. The carriage 238 includes a vertical plate 239 and a horizontal plate 240 that projects laterally outward and inward from the mounting plate 232. The guide rail 237 defines a guide channel 242, and the horizontal plate 240 is received and slides within the guide channel 242. The third rail 212 also includes ball bearings 244 disposed between the sliding projection 234 and the guide channel 242 to reduce the friction of the sliding projection 240 within the guide channel 242. Additionally or alternatively, the third rail 212 may include a Teflon® or other low-friction coating disposed on the sliding projection 234 and / or the guide channel 242.

[0039] With reference to Fig. 12, a door assembly 250 is similar to the door assembly 10 in that the door assembly 250 includes the outer side panel 18, the support tray 24, the cup holders 26, and a storage bin 252 that is longitudinally translatable 254 between a rearward position and a forward position. The storage bin 252 in the rearward position is shown in solid lines, and the storage bin 252 in the forward position is shown in phantom lines. Although not shown, the door assembly 250 may also include the inner side panel 20, the containment panel 21, and the armrest 22. Additionally, like the storage bin 16 of the door assembly 10, the storage bin 252 includes an outer side panel 256, the inner side panel 52, the forward side panel 54, the rear side panel 56, and the floor panel 58, and the storage bin 16 has the interior compartment 34.

[0040] However, unlike the outer side panel 50 of the storage bin 16, the outer side panel 256 of the storage bin 252 defines an opening or slot 258. Furthermore, unlike the door assembly 10, the door assembly 250 additionally includes a fastener 260, such as an eyebolt, that extends through the slot 258 in the outer side panel 256 and is secured to the outer side panel 18 or other permanently mounted door structure. The slot 258 in the storage bin 252 allows the storage bin 252 to move between the rearward and forward positions without interfering with the fastener 260. The fastener 260 can be attached to the items stored in the storage bin 252 when the storage bin 252 is in the rearward position, the forward position, and any position in between.Thus, the fastener 260 can be used to secure items to the outer side panel 18 or other permanently mounted door structure. For example, a locker, laptop, or tablet located within the storage container 252 can be tethered to the fastener 260. Furthermore, it is also possible to position the fastener 260 so that it passes through the open top of the storage container 252. In this way, the fastener 260 can be attached to the items stored within the storage container 252 when the storage container 252 is in the rear position, the front position, and any position in between, without the need for the slot 258.

[0041] With reference to Fig. 13 is a door assembly 300 similar or identical to the door assembly 10 of Fig. 1-5, except that the door assembly 300 includes a storage compartment 302 disposed beneath the rear surface 36 ( Fig. 3) the support tray 24. Additionally, the door assembly 300 includes a removable cup holder 304 in place of the cup holders 26 included in the door assembly 10. The cup holder 304 conceals the storage compartment 302 when the cup holder 304 is installed in the interior door structure 12. In addition, the cup holder 304 prevents access to items stored in the storage compartment 302, such as an umbrella 306, when the cup holder 304 is installed in the interior door structure 12. The cup holder 304 is shown in solid lines when the cup holder 304 is installed in the interior door structure 12. The storage compartment 302 and the cup holder 304 provide additional concealed storage space in addition to the concealed storage space of the storage container 16.

[0042] The cup holder 304 can be manually removed from the interior door structure 12 (e.g., removing the cup holder 304 does not require any tools, such as removing fasteners). When the cup holder 304 is removed from the interior door structure 12, items stored in the storage compartment 302 can be accessed via an access opening 308. The cup holder 304 is shown in phantom lines when the cup holder 304 is removed from the interior door structure 12. The access opening 308 is completely covered by the cup holder 304 when the cup holder 304 is installed in the interior door structure 12. In various implementations, in addition to or instead of being removable, the cup holder 304 may be collapsible and / or foldable in a downward direction 310.For example, the cup holder 304 may be formed from a series of panels and hinges that allow the panels to fold into each other so that they can be folded together to allow access through the access opening 308 without removing the cup holder 304 from the interior door structure 12.

[0043] With reference to Fig. 14 is a door assembly 320 similar or identical to the door assembly 10 of Fig. 1-5, except that the door assembly 320 includes a partition 322 disposed within the interior compartment 34 of the storage container 16. The partition 322 divides the interior compartment 34 of the storage container 16 into a front portion 324 and a rear portion 326 to allow for better organization of the items. When the storage container 16 is in the forward position, as shown in Fig. 14, the items stored in both the front and rear sections 324 and 326 of the storage container 16 are accessible. However, when the storage container 16 is in different positions between the rear position and the front position, the partition 322 conceals the rear section 326 of the storage container 16 while allowing the items stored in the front section 324 of the storage container 16 to be accessible. Thus, the partition 322 provides an additional layer of security for items stored in the rear section 326 of the storage container 16. In various implementations, the partition 322 may be manually removable from the interior door structure 12 and / or foldable or collapsible to allow access to the rear section 326 of the storage container 16. Additionally, the partition 322 may be oriented horizontally instead of vertically, as shown in Fig. 14, or the partition 322 may be oriented at an angle to the horizontal and vertical planes.

[0044] With reference to the Fig. 15 and Fig. 16, the inner door structure 12 may have various energy-absorbing properties that absorb energy when the first portion 28 of the inner side panel 20 (i.e., the portion of the inner side panel 20 that conceals the storage container 16) is impacted by an object. The energy-absorbing properties may also distribute the load of the object to the inner door structure 12. In Fig. 15, the inner door structure 12 includes an energy-absorbing feature in the form of a stiffener 330 attached to the boundary plate 21 of the inner door structure 12 and disposed rearward of the storage container 16. Additionally or alternatively, the inner door structure 12 may include a stiffener similar to the stiffener 330 attached to the boundary plate 21 and disposed forward of the storage container 16.

[0045] In Fig. 16, the inner door structure 12 includes an energy-absorbing feature in the form of a stiffener 332 connected or integrally formed with the first portion 28 of the inner side panel 20. A majority of the inner door structure 12 may be made of a first material (e.g., plastic), and the stiffeners 330, 332 may be made of a second material (e.g., metal) that is stiffer than the first material and / or has higher strength than the first material (i.e., can absorb more energy without breaking or cracking compared to the first material). In one example, the stiffeners 330, 332 are metal plates, in which case, in addition to absorbing energy, the stiffeners 330, 332 may prevent thieves from breaking into the storage container 16. In another example, the stiffener 332 includes a plurality of ribs 334.The ribs 334 may be formed integrally with the first portion 28 of the inner side panel 20. In another example, one or both of the stiffeners 330, 332 may include mitigation holes or features to introduce controlled deformation in areas where deformation is desired during impact.

[0046] With reference to the Fig. 17 and Fig. 18, the storage container 16 may also have various energy-absorbing properties that absorb energy when the first portion 28 of the inner side panel 20 is impacted by an object. The energy-absorbing properties may also distribute the load of the object to the inner door structure 12. In Fig. 17, the storage container 16 includes an energy absorbing feature in the form of a plate 340 attached to the outer side panel 50 and the rear side panel 56 of the storage container 16 adjacent the rear end 48 of the storage container 16. Additionally or alternatively, the storage container 16 may include a plate (not shown) similar to plate 340 attached to the outer side panel 50 and the front side panel 54 of the storage container 16 adjacent the front end 46 of the storage container 16. Additionally or alternatively, the plate 340 and / or the plate attached to the front side panel 54 may be attached to the inner side panel 52 of the storage container 16 in addition to or in place of the outer side panel 50 of the storage container 16.The outer, inner, front, rear, and / or lower side panels 50, 52, 54, 56, and / or 58 of the storage container 16 may be constructed from a first material (e.g., plastic), and the plate 340 may be constructed from a second material (e.g., metal) that is stiffer than the first material and / or has a higher strength than the first material. Furthermore, the plate 340 may include mitigation holes 341 or features to introduce controlled deformation in areas where deformation is desired during impact.

[0047] In Fig. 18, the storage container 16 includes an energy absorbing feature in the form of a pair of protrusions 342 attached to the outer side panel 18 of the inner door structure 12 and disposed within a channel 344 that translates with the storage container 16. The protrusions 342 extend laterally from the outer side panel 18 of the inner door structure 12 into the channel 344. The channel 344 may be defined by the outer side panel 50 of the storage container 16 or separated from and attached to the outer side panel 50. In various implementations, the protrusions 342 may be attached to the outer side panel 50 of the storage container 16 and extend laterally inward. Each of the protrusions 342 may have a frustoconical shape, as shown.

[0048] In various implementations, a door assembly according to the present disclosure may include a block of material sized to fill the interior compartment of a storage container when the storage container is not in use for storing items. The material from which the block is constructed may be configured to absorb sound and absorb energy if a sidewall of the storage container is compromised. The block may be manually removed from the interior compartment of the storage container.

[0049] With reference to the Fig. 19-21, a door assembly according to the present disclosure may include a plurality of teeth 350 secured to the bottom plate 58 of the storage bin 16 and an inertia member subassembly 352 configured to selectively engage the teeth 350. The inertia member subassembly 352 may engage the teeth 350 to prevent the storage bin 16 from shifting forward from the rearward position during heavy braking or a crash. The teeth 350 project downward from the bottom plate 58 of the storage bin 16 and extend in a forward direction 353 toward the front of the vehicle.

[0050] The inertia element subassembly 352 includes a lever 354, a cup or bowl 356, and a ball 358. The lever 354 has a front end 360, a rear end 362, and a pivot point 363 disposed adjacent the front end 360. The pivot point 363 of the lever 354 can be pivotally mounted on the inner door structure 12 ( Fig. 1-3) or to another component of the inertia element subassembly 352, such as an extension of the tray 356. The point 363 of the lever 354 can be pivotally attached to the inner door structure 12 at a location from which the lever 354 can pivot to engage the teeth 350 when the storage container 16 is in the rearward position. For example, the front end 360 of the lever 354 can be pivotally attached to the rear of the cup holder 26 or to the Fig. 1-3. The support tray 24 and the cup holders 26 can be designed so that the teeth 350 do not come into contact with the support tray 24 or the cup holders 26 during longitudinal displacement of the storage container 16.

[0051] The ball 358 can roll freely within the shell 356. When the vehicle is stationary or is accelerating or decelerating at low speed, the ball 358 remains in or near a center 364 of the shell 356, as shown in the Fig. 19 and Fig. 20. However, in the event of heavy braking or an accident, the ball 358 rolls in the shell 356 in the forward direction 353 ( Fig. 19) and engages the underside 365 of the lever 354 adjacent the front end 360, as shown in Fig. 21. In turn, the rear end 362 of the lever 354 pivots upward and engages the teeth 350, preventing the storage bin 16 from translating forward away from the rearward position. In one example, the ball 358 is configured to move the lever 354 to engage the teeth 350 to prevent the storage bin 16 from translating relative to the interior door structure 12 when vehicle deceleration is greater than a threshold (e.g., a predetermined value). This can be accomplished by adjusting the mass and / or geometry of the lever 354, the cup 356, and / or the ball 358. In this way, impacts from any direction can cause the ball 358 to roll up the cup 356 and engage the lever 354.

[0052] Fig. 22 and Fig. 23 illustrate an inertial element subassembly 370 including a disk or plate 372 and a pendulum 374 in place of the cup 356 and ball 358. The pendulum 374 includes a main body 376, a neck 378, and a head 380. The main body 376 is disposed below the plate 372, the head 380 is disposed above the plate 372, and the neck 378 extends through an opening 382 in the plate 372.

[0053] When the vehicle is stationary or accelerating or decelerating at low speed, the main body 376 of the pendulum 374 is centered around a vertical axis 383 extending through the center of the opening 382. However, during heavy braking or in the event of an accident, the main body 376 of the pendulum 374 swings in the forward direction 353 ( Fig. 19), as in Fig. 23, whereby the head 380 of the pendulum 374 engages the bottom surface 365 of the lever 354 adjacent its forward end 360. In turn, the rear end 362 of the lever 354 pivots upward and engages the teeth 350, preventing the storage bin 16 from translating forward away from the rearward position. In one example, the pendulum 374 is configured to move the lever 354 to engage the teeth 350 to prevent the storage bin 16 from translating relative to the inner door structure 12 when a vehicle deceleration is greater than a threshold (e.g., a predetermined value). This may be accomplished by adjusting the mass and / or geometry of the lever 354, the plate 372, and / or the pendulum 374. In this way, shocks from any direction can cause the pendulum 374 to pivot and engage the lever 354.

[0054] With reference to the Fig. 24 and Fig. 25, a storage container 400 is similar to the storage container 16 in that the storage container 400 includes the main body 44 with the outer, inner, front, rear, and lower side panels 50, 52, 54, 56, and 58. However, unlike the storage container 16, the storage container 400 also includes an inner side panel 402 and a hinged door 404. The inner side panel 402 can be considered part of the main body 44 and can be integrally formed with the rest of the main body, e.g., by injection molding. The hinged door 404 has a lower end 406 and an upper end 408. The lower end 406 of the hinged door 404 is pivotally connected to a pivot pin 410 ( Fig. 25) is attached to the main body 44, which extends through the lower end 406 of the flap door 404 and into the front and inner side panels 54 and 402. This allows the flap door 404 to pivot about the pivot pin 410. The pivot pin 410 can be integrated into the flap door 404 or into the inner side panel 52 of the storage container 400.

[0055] The flap door 404 is movable relative to the main body 44 from a closed position ( Fig. 24) into an open position ( Fig. 25) pivots to expand the size of an access opening 411 that provides access to an interior compartment 412 of the storage container 400. When the storage container 400 is in the rearward position, the first portion 28 of the inner side panel 20 maintains the hinged door 404 in the closed position. However, when the storage container 400 moves to the forward position, the hinged door 404 pivots from the closed position to the open position due to gravity and / or spring assistance. When the storage container 400 returns to the rearward position, the hinged door 404 pivots from the open position to the closed position by engaging the inner side panel 20 of the inner door structure 12. More specifically, a rounded ramp surface 414 on the lower rear portion of the flap door 404 engages the first portion 28 of the inner side panel 20, causing the flap door 404 to close.

[0056] The storage container 400 may further include one or more stop features that maintain the hinged door 404 at a desired angle to the inner side panel 402 when the hinged door 404 is in an open position. The stop features may include a cord 416 attached to the hinged door 404 and secured to the front panel 54 by an adjustable retaining device 418 (e.g., a clamp or pin). Additionally or alternatively, the stop features may include a front wall 420 attached to the hinged door 404 and defining a slot 422, and a pin 424 extending through the slot 422 and secured to the front panel 54. Other mechanical stop features include a spring and a molded retention recess.

[0057] With reference to Fig. 26, a switch 430 is disposed in the armrest 22 and can be actuated to translate a storage bin longitudinally, lock the storage bin in the rearward position, and / or unlock the storage bin. The switch 430 includes a button 432 and a plurality of rotary knobs 434. In one example, the button 432 can be pressed to translate the storage bin longitudinally therebetween. In another example, the rotary knobs 434 can be rotated to lock and / or unlock the storage bin. In this context, the switch 430 may also be referred to as a selector lock. In various implementations, the switch 430 may be disposed in a dashboard or center console of a vehicle.Additionally or alternatively, the switch 430 may include a plurality of buttons instead of the rotary knobs 434, and the buttons may be pressed in a specific sequence to unlock, lock, and / or slide the storage container.

[0058] With reference to Fig. 27 is a door assembly 440 similar or identical to the door assembly 10 of the Fig. 1-5, except that the door assembly 440 includes a mesh or netting 442 partially covering the access opening 32. The netting 442 increases the storage capacity of the storage container 16. The netting 442 may be attached to the storage container 16, for example, using a button and loop, so that the netting 442 may be manually detached from the storage container 16.

[0059] With reference to Fig. 28 is a door assembly 450 similar or identical to the door assembly 10 of the Fig.1-5, except that the door assembly 450 includes a light 452 that automatically illuminates the storage bin 16 when the storage bin 16 is in the forward position. In one example, the door assembly 450 includes a position sensor (not shown) that detects the position of the storage bin 16 and a control module (not shown) that activates the light 452 when the position sensor indicates that the storage bin 16 is in the forward position. The position sensor may be included in the motor 14. Alternatively, the position sensor may be employed as a standalone device when the light 452 is used in conjunction with a manual storage bin.

[0060] The door assembly 450 may also include a light 453 that does not move with the storage bin 16 and that illuminates the storage bin 16 when the storage bin 16 is in the forward position. The control module may activate the light 453 when the storage bin 16 is in the forward position. When the storage bin 16 is in the rearward position, the control module may deactivate the light 453, or the control module may continue to activate the light 453 to illuminate the space in front of the storage bin 16. In this latter example, a vehicle's ambient light controller may be used to control the lighting and lighting color.

Claims

[1] Vehicle door assembly comprising: an inner door structure (12) having an outer side panel (18) and an armrest (22), the armrest (22) projecting laterally inwardly from the outer side panel (18); and a storage container (16) disposed below the armrest (22), secured to the inner door structure (12), and movable between a rearward and a forward position relative to the inner door structure (12); characterized by , that the inner door structure (12) further includes a support shelf (24) projecting laterally inwardly from the outer side panel (18); the armrest (22) is arranged above the support tray (24), wherein the support tray (24) supports the storage container (16) in both the rear position and the front position; the vehicle door assembly further comprises at least one rail (13) secured to at least one of the support tray (24), the outer side panel (18), and the armrest (22); and the storage container (16) is attached to the at least one rail (13). [2] Vehicle door assembly according to claim 1, wherein: the inner door structure (12) further includes an inner side panel (20) disposed laterally within the outer side panel (18); the storage container (16) includes a main body (44) with an interior compartment (34) configured to store items; the inner compartment (34) of the storage container (16) is covered by the inner side panel (20) when the storage container (16) is in the rear position; and the inner compartment (34) of the storage container (16) is accessible when the storage container (16) is in the front position. [3] The vehicle door assembly of claim 2, wherein the inner side panel (20) conceals the entire storage container (16) when the storage container (16) is in the rearward position. [4] Vehicle door assembly according to claim 2, wherein: the storage container (16) further includes a handle (114) attached to a front end of the main body (44); and the inner side panel (20) covers the inner compartment (34) of the storage container (16) while maintaining access to the handle (114) when the storage container (16) is in the rear position. [5] Vehicle door assembly according to claim 1, wherein: the at least one rail (13) includes a guide rail (237) and a carriage (238) which are displaceable in the guide rail (237); and the storage container (16) is attached to the carriage (238). [6] Vehicle door assembly according to claim 1, wherein: the at least one rail (13) includes a threaded rod (66) and a nut (68); the storage container (16) is attached to the nut (68); and the vehicle door assembly further includes a motor (14) operable to translate the nut (68) relative to the threaded rod (66) by rotating the threaded rod (66). [7] The vehicle door assembly of claim 6, further comprising a switch (15) operable to activate the motor (14) to translate the storage bin (16) between the rearward position and the forward position. [8] Vehicle door assembly comprising: an inner door structure (12) having an outer side panel (18) and an armrest (22), the armrest (22) projecting laterally inwardly from the outer side panel (18); and a storage container (252) disposed below the armrest (22), secured to the inner door structure (12), and movable between a rearward and a forward position relative to the inner door structure (12); where: the inner door structure (12) further includes an inner side panel (20) disposed laterally within the outer side panel (18); the storage container (16) includes a main body (44) with an interior compartment (34) configured to store items; the inner compartment (34) of the storage container (16) is covered by the inner side panel (20) when the storage container (16) is in the rear position; and the inner compartment (34) of the storage container (16) is accessible when the storage container (16) is in the front position; characterized by , that the vehicle door assembly further comprises a fastening element (260) extending into the interior compartment (34) of the storage container (252) and secured to the interior door structure (12), the fastening element (260) being capable of being secured to items stored in the storage container (252) when the storage container (252) is in the rearward position and when the storage container (252) is in the forward position. [9] The vehicle door assembly of claim 8, wherein the storage container (252) defines a slot (258) through which the fastener (260) extends, the slot (258) allowing the storage container (252) to slide between the rearward position and the forward position without interfering with the fastener (260).

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