Method for manufacturing a vehicle door, vehicle door and motor vehicle

Abstract

A method for manufacturing a vehicle door (100) is proposed, wherein a reinforcing element (6) is arranged between one of the outer shells (3) and a door jamb (5) of the vehicle door (100), the reinforcing element (6) comprising an outer part (1) oriented towards the outer shell (3) and an inner part (2), the reinforcing element (6) being provided by connecting the outer part (1) to the inner part (2), the reinforcing element (6) being joined to the outer shell (3), and the geometry of the reinforcing element (6) being adapted as required by adjusting the orientation of the outer part (1) and the inner part (2) relative to each other. Furthermore, a vehicle door (100) and a motor vehicle (200) are proposed.

Description

[0001] The present invention relates to a vehicle door comprising an outer shell and an inner shell, as well as a door channel formed between the outer shell and the inner shell. The invention further relates to a motor vehicle and a method for manufacturing a vehicle door.

[0002] Vehicle doors are among the safety-relevant components of a modern motor vehicle. In a side impact, the doors must absorb and dissipate kinetic energy. Furthermore, they must be robust enough that any deformation does not extend into the passenger's safety or seating area behind the door. Finally, after a collision, the doors must be easy to open for egress or potential rescue operations.

[0003] To ensure all of this, vehicle doors must be extensively reinforced on the inside. For example, reinforcing elements are regularly incorporated into the vehicle door between an outer and an inner shell, located either on the inside or on the outside of the door frame.

[0004] The driver's view in the side mirror extends along the door sill to the rear. Even slight deviations from the ideal visual design are therefore clearly noticeable. Tolerances in the manufacturing of the vehicle door can be concealed at this point with a decorative strip along the door sill. This is not possible with door sills that lack such strips. It is therefore an object of the present invention to provide a vehicle door, a motor vehicle, and a method for manufacturing a vehicle door that does not exhibit the aforementioned disadvantages of the prior art, but rather offers the possibility of adapting the components of the vehicle door, in particular the reinforcement element, to the exact geometry of the outer shell of the vehicle door, for example, after changes in material supply or in the tools used for part production.

[0005] Vehicle doors are known from the publications US 12 319 130 B2, DE 100 38 200 A1, EP 2 885 143 B1, US 5 544 448 A and US 7 448 670 B2, which have a reinforcement element with an inner part and an outer part.

[0006] This problem is solved by a method for manufacturing a vehicle door according to claim 1. Furthermore, the problem is solved by a vehicle door according to claim 9 and by a motor vehicle according to claim 10.

[0007] The method according to the invention is a method for manufacturing a vehicle door, in particular a vehicle door of a passenger car. The vehicle door has an outer shell and an inner shell. A door channel is formed between the inner shell and the outer shell. This channel is specifically designed to accommodate a retractable door window. A reinforcing element is provided between the outer shell and the door channel. In the event of a side collision, the reinforcing element absorbs kinetic energy and stabilizes the vehicle door. According to the invention, the reinforcing element has an outer part. The outer part is oriented towards the outer shell, i.e., adjacent to the outer shell. Furthermore, the reinforcing element has an inner part. The inner part is arranged on the outer part of the reinforcing element.Because the reinforcement element is two-part, its geometry can be adjusted by sliding the inner part relative to the outer part, thus precisely matching the geometry of the outer shells. This compensates for tolerances in the production of the outer shell or the reinforcement element, ensuring a highly accurate alignment of the vehicle door components. Minor dimensional variations in individual parts, such as the outer shell, can sometimes occur during the manufacturing of vehicle doors. This can be caused, for example, by using a slightly different batch of raw materials. If such a variation is detected during production, the reinforcement element can be adjusted by changing the relative position of the inner part to the outer part.The modified relative positioning is then used to provide the reinforcement element until another dimensional deviation occurs. This allows for a response to changed dimensions without the need for further adjustments.

[0008] The need to adapt tools for the reinforcement element is eliminated. The reinforcement element is provided by connecting the outer part to the inner part. The reinforcement element is joined to the outer shell, preferably by folding the outer shell to the inner part. According to the invention, the geometry of the reinforcement element is adapted as required by adjusting the orientation of the outer and inner parts relative to each other, for example, after changes in the manufacturing process of the vehicle door. This advantageously makes it possible to adjust the reinforcement element, particularly along its vertical axis, so that it meets the requirements of the outer shell's geometry without, for example, having to change the tools used to manufacture the reinforcement element.

[0009] Advantageous embodiments and further developments of the invention can be found in the dependent claims and in the description with reference to the drawings.

[0010] According to a preferred embodiment of the present invention, the inner part is joined to the outer shell and connected to the outer shell. This advantageously allows the reinforcing element to be securely attached to the outer shell on one side and flexibly adjusted on the other. It is conceivable that the inner part is folded to the outer shell, preferably using a folding adhesive. It is also conceivable that the inner part is riveted and / or glued to the outer shell. Alternatively, it is conceivable that the inner part is welded to the outer shell.

[0011] In particular, the outer part is designed to be bonded to the outer shell. This bonding does not ensure the correct fit of the outer part relative to the outer shell. This is achieved by joining the inner part to the outer shell and connecting the inner part to the outer part. The bonding serves only to prevent relative movement, such as fluttering, between the reinforcing element and the outer shell. This significantly improves the vehicle's ride comfort.

[0012] According to a further preferred embodiment of the present invention, the vehicle door has a trim-free door jamb sill at the door jamb, with the inner part extending underneath the door jamb sill. This ensures that the sensitive area in the upper part of the door is reinforced and prepared for a side impact.

[0013] Preferably, the inner part supports a closing element of the door channel. The closing element is positioned between the inner part and the door channel. The closing element preferably has a sealing lip for sealing the door channel. The closing element seals the door channel at the top on the outer side. The inner part supports the closing element, particularly in the transverse and vertical directions, thereby providing significantly greater stability to the vehicle door, especially in its upper region.

[0014] According to a further preferred embodiment of the present invention, the outer part and the inner part have extended vertically extending bonding surfaces for connecting the outer part to the inner part. This advantageously makes it possible to provide a large adjustment range for the reinforcement element. The flat bonding surfaces allow for optimal connection of the outer part to the inner part in different orientations or relative positions to each other.

[0015] A particularly preferred embodiment of the present invention is one in which a space is formed between the outer and inner parts. This space is provided, in particular, between the bonding surfaces and preferably extends along the longitudinal direction. This results in a crash-optimized shape for the reinforcement element. Preferably, the inner and / or outer parts are at least partially shell-shaped for this purpose.

[0016] According to a further preferred embodiment of the present invention, the outer part and the inner part are deep-drawn. This allows for the cost-effective production of the parts of the reinforcement element.

[0017] According to a further preferred embodiment of the present invention, the vehicle door is provided with a door frame sill without decorative trim. The orientation is adjusted so that the inner part engages under the door frame sill and the inner part supports the end element.

[0018] According to a preferred embodiment, the reinforcing element is first attached to the inner shell of the vehicle door. For this purpose, the outer part of the reinforcing element is joined to the inner shell of the vehicle door, for example by riveting, bonding, and / or welding. This is preferably done at a front and / or rear end of the reinforcing element, while maintaining the door channel between the inner part of the reinforcing element and the inner shell of the vehicle door. Once the outer part of the reinforcing element is attached to the inner shell of the vehicle door, the outer shell of the vehicle door is fitted and joined to the inner part of the reinforcing element.

[0019] It is particularly preferred that an internal reinforcing element for absorbing kinetic energy in the event of an accident is arranged between the inner shell of the vehicle door and the door shaft.

[0020] Another object of the present invention for solving the problem formulated at the outset is a vehicle door which is manufactured according to the inventive method.

[0021] Another object of the present invention for solving the problem formulated at the outset is a motor vehicle comprising a vehicle door according to the invention.

[0022] All details, features and advantages previously disclosed in connection with the vehicle door according to the invention also relate to the motor vehicle according to the invention and to the method according to the invention, and vice versa.

[0023] Further details, features, and advantages of the invention will become apparent from the drawings and from the following description of preferred embodiments with reference to the drawings. The drawings merely illustrate exemplary embodiments of the invention, which do not limit the inventive concept. Fig. Figure 1 schematically illustrates a vehicle door according to an exemplary embodiment of the present invention of a motor vehicle according to an exemplary embodiment of the present invention in a sectional view with a section plane parallel to a vertical axis and a transverse axis of the motor vehicle. Fig. Figure 2 schematically illustrates a vehicle door according to an exemplary embodiment of the present invention of a motor vehicle according to an exemplary embodiment of the present invention in a sectional view with a section plane parallel to a vertical axis and a longitudinal axis of the motor vehicle. Fig. Figure 3 schematically illustrates a motor vehicle according to an exemplary embodiment of the present invention.

[0024] Fig. Figure 1 schematically illustrates a vehicle door 100 according to an exemplary embodiment of the present invention of a motor vehicle 200 (see Figure 1). Fig. 3) according to an exemplary embodiment of the present invention in a sectional view with a section plane parallel to a vertical axis Z and a transverse axis Y of the motor vehicle 200.

[0025] It is clearly visible that the vehicle door 100 has an outer shell 3 and an inner shell 4. A door channel 5 is provided between the outer shell 3 and the inner shell 4, into which a side window 11 of the motor vehicle 200 can be lowered.

[0026] In the door shaft 5, a closing element 8 is provided at its upper end, which closes off the door shaft 5 at the top and, with sealing lips 12 which lie against the side window 11, secures the door shaft 5 against penetrating water and dirt.

[0027] A reinforcing element 6 is provided between the door shaft 5 and the outer shell 3. The reinforcing element 6 increases crash safety by absorbing kinetic energy in the event of a side impact and stabilizing the vehicle door 100.

[0028] The reinforcement element 6 is designed in two parts. It has an outer part 1 and an inner part 2. A good view of the outer part 1 with the inner part 2 behind it is shown. Fig. 2.

[0029] The inner part 2 is joined to the outer shell 3 by folding. The inner part 2 is further connected to the outer part 1 at attachment surfaces 13. For this purpose, the inner part 2 and outer part 1 are glued and riveted at the attachment surfaces 13. The attachment surfaces 13 are designed to be flat and extend in the vertical direction Z, so that when arranging the inner part 2 and the outer part 1 before joining, there is freedom in positioning the outer part 1 and the inner part 2 relative to each other. This makes it possible to adapt the reinforcing element 6 to the geometry of the outer shell 3 as needed and with high precision by moving the inner part 2 and the outer part 1 relative to each other.

[0030] In the embodiment shown here, the vehicle door 100 is a vehicle door 100 with a door frame sill 7 without decorative trim. The inner part 2 of the reinforcement element 6 is arranged on the outer part 1 such that it engages under the door frame sill 7. If the geometry of the outer shell 3 changes, for example due to a change in the supply of raw materials, the two-part nature of the reinforcement element 6 makes it possible to easily adapt it to the changed geometry by simply repositioning the outer part 1 and the inner part 2 relative to each other, without having to, for example, modify the manufacturing tooling for the inner or outer part.

[0031] To improve crash safety, a sophisticated shape is provided for the reinforcement element 6. A chamber 9, formed between the outer part 1 and the inner part 2, as well as a further chamber 10, formed between the outer shell 3 and the inner part 2 and the outer part 1, give the reinforcement element 6 a high degree of rigidity. The chamber 9 also serves to provide sufficient space for adjusting the relative positioning of the outer part 1 and the inner part 2.

Claims

[1] Method for manufacturing a vehicle door (100), wherein the vehicle door (100) has an inner shell (3) and an outer shell (4), wherein a door channel (5) is formed between the inner shell (4) and the outer shell (3), wherein a reinforcing element (6) is arranged between the outer shell (3) and the door channel (5), wherein the reinforcing element (6) has an outer part (1) which is oriented towards the outer shell (3), and an inner part (2) which is arranged on the outer part (1) of the reinforcing element (6), wherein the reinforcing element (6) is provided by connecting the outer part (1) with the inner part (2), wherein the reinforcing element (6) is joined to the outer shell (3), preferably by folding the outer shell (3) with the inner part (2), wherein the geometry of the reinforcing element (6) is determined by adjusting the orientation of the outer part (1) and the inner part (2) relative to each other. is adapted to meet specific needs. [2] Method according to claim 1, characterized by , that the inner part (2) is joined to the outer shell (3), preferably folded, and that the inner part (2) is connected to the outer part (1), preferably riveted and / or glued. [3] Method according to any one of the preceding claims, characterized by , that the vehicle door (100) has a trimless door shaft sill (7) on the door shaft (5), wherein the inner part (2) engages under the door shaft sill (7) and is preferably folded with the door shaft sill (7). [4] Method according to claim 3, characterized by , that the inner part (2) supports a closing element (8) of the door shaft (5), wherein the closing element (8) is arranged between the inner part (2) and the door shaft (5), wherein the closing element (8) preferably has a sealing lip for sealing the door shaft (5). [5] Method according to any one of the preceding claims, characterized by, that the outer part (1) and the inner part (2) have extended attachment surfaces (13) in the vertical direction (Z) for connecting the outer part (1) to the inner part (2). [6] Method according to any one of the preceding claims, characterized by , that a space (9) is formed between the outer part (1) and the inner part (2). [7] Method according to any one of the preceding claims, characterized by that the outer part (1) and the inner part (2) are deep-drawn parts. [8] Method according to any one of the preceding claims, characterized by , that the vehicle door (100) is provided with a door shaft sill without decorative bars (7), the alignment being adjusted so that the inner part (2) engages under the door shaft sill (7) and the inner part (2) supports the end element (8). [9] Vehicle door (100), characterized by that the vehicle door (100) is manufactured using a method according to one of the preceding claims. [10] Motor vehicle (200) comprising a vehicle door (100) Claim 9.

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