Door, vehicle and method for assembling door panels for vehicles

Abstract

Door (100), comprising: a first door interior structure (150) having an angled wedge bearing surface (155) and configured to receive a first releasable fastening mechanism (157); a second door interior structure (160) configured to receive a second releasable fastening mechanism (165); a door outer structure (170) having a door outer panel coupled to a mounting structure (175), the mounting structure (175) having an angled wedge bearing surface (176) and having a bearing surface (178), the bearing surface (178) configured to receive the second releasable fastening mechanism (165), the bearing surface (178) configured to abut an inner surface of the second door inner structure (160); and an adjustment wedge (180) having a receiving opening configured to receive the first releasable fastening mechanism (157) and having a first bearing surface (184) configured to engage the angled wedge bearing surface (155) of the first door inner structure (150) and a second bearing surface (186) configured to engage the angled wedge bearing surface (176) of the door outer structure (170).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the removal and installation of door panels for vehicles. STATE OF THE ART

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Conventional exterior door panels, regardless of architecture, are generally permanently attached to the interior panel. Attachment methods vary from gluing and rebating for stamped metal doors to adhesive-only for composite doors. These panel attachment methods involve assembly in a body shop before painting the assembly and then installing the trim pieces.

[0004] These assembly sequences require the door hardware (such as window regulators, door locks, and other components) to be brought into the interior of the door through an opening in the interior door panel. This opening is then covered with a thin, waterproof layer to seal the door, or with a complete door module that carries these components as a subassembly.

[0005] DE 197 11 598 A1 relates to a motor vehicle door of frame construction with a frame running around the edge and an inner and outer panel attached to the frame. To ensure that the motor vehicle door can be easily and cost-effectively installed even with the door frame already attached to the body of the vehicle, the invention proposes that the frame be designed such that the inner panel can be inserted from the outside of the door into the opening formed by the frame and can be attached to the frame from the outside of the door.

[0006] DE 103 34 143 A1 relates to a motor vehicle door with an outer assembly which has an outer door skin and forms an outer design surface of the motor vehicle door, and with an assembly carrier which is arranged on the side of the outer assembly facing a vehicle interior and is connected to the outer assembly to form an interface, characterized in that a seal runs along the interface between the assembly carrier and the outer assembly and at least partially covers the interface and that fastening means for connecting the assembly carrier and the outer door assembly are provided in the region of the interface and that at least part of the fastening means is covered by the seal. SUMMARY

[0007] Based on the state of the art, the object of the invention is to provide vehicle doors that are easier to install.

[0008] This object is achieved according to the invention by the door according to the main claim, the vehicle according to independent claim 10 and the method according to independent claim 20.

[0009] Advantageous embodiments are the subject of the subclaims.

[0010] Disclosed embodiments include structures and methods for improving the assembly of vehicle doors.

[0011] An exemplary embodiment includes a door. The door includes a first door interior structure having an angled wedge bearing surface and configured to receive a first releasable fastening mechanism, and a second door interior structure configured to receive a second releasable fastening mechanism. The door also includes a door exterior structure having an outer door panel coupled to a fastening structure, the fastening structure having an angled wedge bearing surface and having a bearing surface configured to receive the second releasable fastening mechanism, the second bearing surface configured to abut an interior surface of the second door interior structure.The door further includes an adjustment wedge having a receiving opening configured to receive the first releasable fastening mechanism and having a first bearing surface configured to engage the angled wedge bearing surface of the first door interior structure and a second bearing surface configured to engage the angled wedge bearing surface of the door exterior structure.

[0012] Another illustrative embodiment includes a vehicle. The vehicle includes a body structure forming a cab. The vehicle has a drive system and at least one wheel coupled to and driven by the drive system and further coupled to the body structure, and at least one door for opening and closing the cab. The at least one door includes a first door interior structure having an angled wedge bearing surface and configured to receive a first releasable attachment mechanism, and a second door interior structure configured to receive a second releasable attachment mechanism.The door further includes an exterior door structure having an exterior door panel coupled to a mounting structure, the mounting structure having an angled wedge bearing surface and a bearing surface configured to receive the second releasable fastening mechanism, the second bearing surface configured to abut an interior surface of the second interior door structure. The door further includes an adjustment wedge having a receiving opening configured to receive the first releasable fastening mechanism and having a first bearing surface configured to abut the angled wedge bearing surface of the first interior door structure and a second bearing surface configured to abut the angled wedge bearing surface of the exterior door structure.

[0013] Yet another illustrative embodiment includes a method of assembling a vehicle door. The method includes providing a first interior door structure having an angled wedge bearing surface and configured to receive a first releasable fastening mechanism. The method also includes providing a second interior door structure configured to receive a second releasable fastening mechanism. The method further includes coupling to the first interior door structure an adjustment wedge having a receiving opening configured to receive the first releasable fastening mechanism and having a first bearing surface configured to abut the angled wedge bearing surface of the first interior door structure and a second bearing surface configured to abut the angled wedge bearing surface of the exterior door structure.An outer door structure is positioned relative to the second inner door structure, the outer door structure including an outer door panel coupled to a mounting structure, the mounting structure including an angled wedge bearing surface and a bearing surface, the bearing surface configured to receive the second releasable mounting mechanism, the second bearing surface configured to abut an inner surface of the second inner door structure. The adjustment wedge is adjusted relative to the first inner door structure based on the position of the outer door structure and the mounting of the outer door structure to the second inner door structure using the second releasable mounting mechanism.

[0014] The foregoing summary is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, other aspects, embodiments, and features will become apparent upon reference to the drawings and the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Illustrative embodiments are illustrated in the referenced figures of the drawings. The embodiments and figures illustrated herein are not to be understood as limiting, but rather as illustrative. Fig. Figure 1 is a cross-sectional view of two illustrative doors utilizing an adjustable fastening mechanism. Fig. Figure 2 is a cross-sectional view of details of one of the fastening mechanisms of one of the doors of Fig. 1. Fig. 3 is a perspective view of an illustrative vehicle with doors incorporating various illustrative embodiments. Fig. 4 is a flowchart of an illustrative method for assembling an illustrative door assembly.

[0016] The same reference symbols in the different drawings generally indicate the same elements. DETAILED DESCRIPTION

[0017] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, like symbols generally refer to similar components unless the context indicates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized and other changes may be made without departing from the spirit or scope of the subject matter presented herein.

[0018] It will be appreciated that in various embodiments, the structure and methods disclosed herein may help eliminate a need for a pass-through for mounting equipment within a vehicle door by providing access to the door cavity from the outside with the outer door panel removed.

[0019] Referring to Fig. 1 shows cross-sectional views of doors 100 and 105 of a vehicle, where "F" and the arrow represent the front of the vehicle. The doors 100 and 105 have the same structure, but are located on opposite sides of the vehicle. A first attachment structure 110 and a second attachment structure 115 couple the door outer structure or the door panel 120 to the door inner structure 130. The first and second attachment structures illustrate the same type of attachment structure at different points on the door, which in Fig. 2 is provided in more detail. There may be more than one of these attachment structures to couple the door panel 120 to the door interior structure 130.

[0020] With reference to the Fig. 1 and Fig. 2, a door 100 according to an illustrative embodiment, which may be any of a variety of vehicle or other doors that provide internal structure and an aesthetic exterior door panel, includes a first door interior structure 150 having an angled wedge bearing surface 155 and configured to receive a first releasable fastening mechanism or adjustment screw 157 at an opening 158. A second door interior structure 160 is configured to receive a second releasable fastening mechanism or screw 165 through an opening 168. A door exterior structure includes a door exterior structure or door panel 170 coupled to a fastening structure 175.The mounting structure 175 includes an angled first wedge bearing surface 176 and a second bearing surface 178, with the second bearing surface 178 configured to receive the second releasable fastening mechanism or screw 165 through an opening 179. The second bearing surface 178 is configured to abut an interior surface of the second door interior structure 160. An adjustment wedge 180 includes a receiving opening 182 configured to receive the first releasable fastening mechanism or screw 157. The adjustment wedge 180 includes a first bearing surface 184 configured to abut the angled wedge bearing surface 155 of the first door interior structure 150 and a second bearing surface 186 configured to abut the angled first wedge bearing surface 176 of the mounting structure 175.

[0021] According to an illustrative embodiment, the second door interior structure 160 receives the second releasable fastening mechanism or screw 165 through the second door interior structure opening 168, and the second door interior structure opening 168 is accessible on a side opposite the door exterior structure or door panel 170. This allows an installer to easily access the screw 165 from the inside of the vehicle. In various embodiments, the fastening structure 175 includes a post, as shown in Fig. 2 as the mounting structure 175. In various embodiments, the post may be a hollow post. However, in some other embodiments, a solid post may be used.

[0022] In various embodiments, the adjustment wedge 180 enables the first releasable fastening mechanism or screw 157 to provide relative adjustment of the door panel 120 with respect to both the first door interior structure 150 and the second door interior structure 160.

[0023] Now referring to Fig. 3, a vehicle 300 may be any of a variety of vehicles, including, but not limited to, trucks, cars, trains, buses, SUVs, etc., all of which include a body structure 310 forming a cabin, a propulsion system, such as, but not limited to, electric motors 320 and 325 that drive front wheels 330 and rear wheels 335, respectively. The propulsion system may be of any type, including, but not limited to, electric motors, diesel engines, gasoline engines, hybrid engines, and the like.

[0024] In various embodiments, the vehicle 300 also includes at least one door 340 for opening and closing the cabin. Returning to Fig. 1 and Fig. 2, the at least one door 340 includes a first door interior structure 150. The at least one door 340 also includes an angled wedge bearing surface 176 and is configured to receive a first releasable fastening mechanism or screw 157. The second door interior structure 160 is configured to receive a second releasable fastening mechanism or screw 165.

[0025] In various embodiments, the door exterior structure includes the door outer panel 170 coupled to the attachment structure 175. The attachment structure 175 has an angled first wedge bearing surface 176 and has the second bearing surface 178. The second bearing surface 178 is configured to receive the second releasable fastening mechanism or screw 165. The second bearing surface 178 is configured to abut an interior surface of the second door interior structure 160. The adjustment wedge 180 has the receiving opening 182 configured to receive the first releasable fastening mechanism or screw 158.The adjustment wedge 180 also includes the first bearing surface 184 configured to engage the angled wedge bearing surface of the first door inner structure 150 and the second bearing surface 186 configured to engage the angled wedge bearing surface or the first bearing surface of the door outer structure 170.

[0026] An illustrative embodiment includes a method 400 for assembling a door structure beginning at a starting block 405. The method 400 includes, at a block 410, providing a first door interior structure having an angled wedge bearing surface and configured to receive a first releasable fastening mechanism, and at a block 420, providing a second door interior structure configured to receive a second releasable fastening mechanism.At a block 430, the method 400 includes coupling an adjustment wedge having a receiving opening configured to receive the first releasable fastening mechanism and having a first bearing surface configured to abut the angled wedge bearing surface of the first door interior structure and a second bearing surface configured to abut the angled wedge bearing surface of the door exterior structure to the first door interior structure. The method 400 further includes, at a block 440, positioning an outer door structure with respect to the second door interior structure. The outer door structure includes an outer door panel coupled to a fastening structure, the fastening structure having an angled wedge bearing surface and a bearing surface, the bearing surface configured to receive the second releasable fastening mechanism.The second bearing surface is configured to abut an inner surface of the second door inner structure. The method 400 further includes, at a block 450, adjusting the adjustment wedge relative to the first door inner structure based on the position of the door outer structure. Still further, at a block 460, the method 400 includes attaching the door outer structure to the second door inner structure using the second releasable attachment mechanism. The method 400 terminates at a stop block 465.

[0027] In illustrative embodiments, the outer door panel may be secured in such a way that it can be easily removed if necessary. The attachment points may be located directly on the inside of the primary door seal, and the outer door panel is secured to the inner door structure using screws, bolts, or other similar fastening mechanisms. To ensure a precise fit, adjustable wedges or blocks are located at the front and rear of the inner panel to help align the outer door panel and allow some adjustability in its position relative to the inner door structure. Illustrative adjustment blocks are shaped like a wedge and slide toward and away from the interior of the vehicle. If the panel is too far forward or rearward, the blocks can be adjusted accordingly until the fit is aligned.This alignment helps maintain door clearance and flushness without having to adjust the door hinges.

[0028] By arranging the outer door panel on the inner door structure in this way, the door panel appears like a bolted-on panel component. If the panel is damaged, it can be easily removed and replaced without additional bodywork or painting.

[0029] From a manufacturing perspective, the outer door panel can be added late in the vehicle's assembly process. This means the interior components can be installed without the panel getting in the way. This allows for greater assembly freedom than in conventional vehicles. In a conventional assembly, the outer door panel is a structural component, typically seamed and welded to the interior panel. Thus, it is in place before any interior components can be added. In this setup, the components are added before the outer door panel is finally coupled to the interior door structure.

[0030] The illustrative embodiments of structures and methods provide assembly and maintenance advantages, offering the ability to replace a door panel as a bolt-on panel component without requiring body work or painting. The illustrative embodiments of structures and methods enable faster maintenance times and reduced maintenance complexity. A damaged exterior door panel typically requires body and paint work to repair. The ability to remove and replace the panel reduces overall maintenance requirements. In addition, the ease of maintenance of door hardware and other components further reduces overall maintenance costs.

[0031] In some cases, one or more components may be referred to herein as "configured to," "configured by," "configurable to," "operable / capable of," "adapted / adaptable," "capable of," "adaptable / compliant to," etc. Those skilled in the art will recognize that such terms (e.g., "configured to") generally include components in the active state and / or components in the inactive state and / or components in the standby state, unless the context dictates otherwise.

[0032] Although certain aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made based on the teachings herein without departing from the subject matter described herein and its broader aspects, and therefore, the appended claims are intended to include within their scope all such changes and modifications that are within the true spirit and scope of the subject matter described herein. It will be understood by those skilled in the art that terms used herein, and particularly in the appended claims (e.g., the body of the appended claims), are generally intended to be "open" terms (e.g.,the term "including" should be interpreted as "including, but not limited to," the term "comprising" should be interpreted as "at least comprising," the term "includes" should be interpreted as "includes, but not limited to," etc.). It will further be understood by those skilled in the art that when a particular number of an introduced claim citation is intended, such intent will be explicitly stated in the claim, and in the absence of such citation, no such intent exists. For example, as an aid to understanding, the following appended claims may include the use of the introductory phrases "at least one" and "one or more" to introduce claim citations.However, the use of such expressions should not be interpreted to imply that the introduction of a claim citation by the indefinite articles "a / an" restricts a particular claim containing such an introduced claim citation to claims containing only such a citation, even if the same claim includes the introductory expressions "one or more" or "at least one" and indefinite articles such as "a" (e.g., the expression "a / an" should normally be interpreted to mean "at least one" or "one or more"). The same applies to the use of definite articles used to introduce claim citations. Even if a specific number of an introduced claim citation is explicitly stated, the skilled person will recognize that such a citation should normally be interpreted to mean at least the stated number (e.g.,(The mere citation of "two citations" without other modifiers usually means at least two citations or two or more citations.) Furthermore, where a convention is used analogously to "at least one of A, B, and C, etc.", such construction is generally intended in the sense in which a person skilled in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include, but is not limited to, systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.).It will further be understood by those skilled in the art that, as a general rule, a disjoint word and / or phrase representing two or more alternative terms, whether in the description, claims, or drawings, should be understood to include the possibilities of either of the terms, either of the terms, or both of the terms, unless the context dictates otherwise. For example, the phrase "A or B" is generally understood to include the possibilities of "A" or "B" or "A and B."

[0033] With reference to the appended claims, one skilled in the art will recognize that acts recited herein may generally be performed in any order. Although various operations are illustrated in one or more sequences, the various acts may be performed in a different order than that illustrated, or concurrently. Examples of such alternative orderings may include overlapping, nested, interrupted, rearranged, incremental, preparatory, supplemental, concurrent, reverse, or other variant orderings, unless the context dictates otherwise. Furthermore, terms such as "in response to," "with respect to," or other past-tense adjectives generally do not serve to preclude such variants unless the context dictates otherwise.

[0034] Although the disclosed subject matter has been described with respect to illustrative embodiments, it will be understood by those skilled in the art that various modifications may be made thereto without departing from the scope of the claimed subject matter as set forth in the claims.

Claims

[1] Door (100), comprising: a first door interior structure (150) having an angled wedge bearing surface (155) and configured to receive a first releasable fastening mechanism (157); a second door interior structure (160) configured to receive a second releasable fastening mechanism (165); a door outer structure (170) having a door outer panel coupled to a mounting structure (175), the mounting structure (175) having an angled wedge bearing surface (176) and having a bearing surface (178), the bearing surface (178) configured to receive the second releasable fastening mechanism (165), the bearing surface (178) configured to abut an inner surface of the second door inner structure (160); and an adjustment wedge (180) having a receiving opening configured to receive the first releasable fastening mechanism (157) and having a first bearing surface (184) configured to engage the angled wedge bearing surface (155) of the first door inner structure (150) and a second bearing surface (186) configured to engage the angled wedge bearing surface (176) of the door outer structure (170). [2] The door (100) of claim 1, wherein the first door interior structure (150) is configured to receive the first releasable fastening mechanism (157) through a first door interior structure opening. [3] The door (100) of claim 1, wherein the second door interior structure (160) is configured to receive the second releasable fastening mechanism (165) through a second door interior structure opening. [4] The door (100) of claim 1, wherein the second door interior structure (160) is configured to receive the second releasable fastening mechanism (165) through a second door interior structure opening, and the second door interior structure opening is configured to be accessible on a side opposite the door exterior structure (170). [5] The door (100) of claim 1, wherein the mounting structure (175) includes a post. [6] The door (100) of claim 1, wherein the mounting structure (175) includes a post and the bearing surface is a portion of the post that receives the second releasable fastening mechanism through an opening in the post. [7] The door (100) of claim 1, wherein the adjustment wedge (180) and the first releasable fastening mechanism (157) are configured to provide relative adjustment of the door outer structure (170) with respect to both the first and second door inner structures (150, 170). [8] The door (100) of claim 1, wherein the first releasable fastening mechanism (157) includes a screw. [9] The door (100) of claim 1, wherein the second releasable fastening mechanism (165) includes a screw. [10] Vehicle (300), comprising: a body structure (310) forming a cabin; a drive system (320, 325); at least one wheel (330, 335) coupled to the drive system (320, 325) and is driven thereby, wherein the at least one wheel (330, 335) is coupled to the body structure (310); and at least one door (340) for opening and closing the cabin, wherein the at least one door (340) includes: a first door interior structure (150) having an angled wedge bearing surface (155) and configured to receive a first releasable fastening mechanism (157); a second door interior structure (160) configured to receive a second releasable fastening mechanism (165); a door outer structure (170) having a door outer panel coupled to a mounting structure (175), the mounting structure (175) having an angled wedge bearing surface (176) and having a bearing surface (178), the bearing surface (178) configured to receive the second releasable fastening mechanism (165), the bearing surface (178) configured to abut an inner surface of the second door inner structure (160); and an adjustment wedge (180) having a receiving opening configured to receive the first releasable fastening mechanism (157) and having a first bearing surface (184) configured to engage the angled wedge bearing surface (155) of the first door inner structure (150) and a second bearing surface (186) configured to engage the angled wedge bearing surface (176) of the door outer structure (170). [11] The vehicle (300) of claim 10, wherein the first door interior structure (150) is configured to receive the first releasable attachment mechanism (157) through a first door interior structure opening. [12] The vehicle (300) of claim 10, wherein the second door interior structure (160) is configured to receive the second releasable attachment mechanism (165) through a second door interior structure opening. [13] The vehicle (300) of claim 10, wherein the second door interior structure (160) is further configured to receive the second releasable fastening mechanism (165) through a second door interior structure opening, and the second door interior structure opening is accessible on a side opposite the door exterior structure (170). [14] The vehicle (300) of claim 10, wherein the mounting structure (175) includes a post. [15] The vehicle (300) of claim 10, wherein the mounting structure (175) includes a post and the bearing surface (178) is a portion of the post that receives the second releasable attachment mechanism (165) through an opening in the post. [16] The vehicle (300) of claim 10, wherein the adjustment wedge (180) and the first releasable attachment mechanism (157) are configured to provide relative adjustment of the door outer structure (170) with respect to both the first and second door inner structures (150, 160). [17] The vehicle (300) of claim 10, wherein the first releasable fastening mechanism (157) includes a screw. [18] The vehicle (300) of claim 10, wherein the second releasable fastening mechanism (165) includes a screw. [19] The vehicle (300) of claim 10, wherein the drive system (320, 325) includes an electric motor. [20] Method (400) comprising: Providing (410) a first door interior structure having an angled wedge bearing surface and configured to receive a first releasable fastening mechanism; Providing (420) a second door interior structure configured to receive a second releasable fastening mechanism; coupling (430) an adjustment wedge having a receiving opening configured to receive the first releasable fastening mechanism and having a first bearing surface configured to engage the angled wedge bearing surface of the first door interior structure and a second bearing surface configured to engage the angled wedge bearing surface of the door exterior structure to the first door interior structure; Positioning (440) a door outer structure with respect to the second door inner structure, the door outer structure comprising an outer door panel coupled to a mounting structure, the mounting structure comprising an angled wedge bearing surface and comprising a bearing surface, the bearing surface configured to receive the second releasable fastening mechanism, the second bearing surface configured to abut an inner surface of the second door inner structure; Adjusting (450) the adjustment wedge with respect to the first door inner structure based on the position of the door outer structure; and Attaching (460) the outer door structure to the second inner door structure using the second releasable attachment mechanism.

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