VEHICLE DOOR ASSEMBLY WITH AN ORGANOBLACK DOOR MODULE SUPPORT STRETCHING A BRACE AREA

Description

[0001] The proposed solution relates in particular to a vehicle door assembly according to the preamble of claim 1.

[0002] A typical vehicle door assembly comprises a first frame component as part of a door frame structure, which includes a window frame for a window opening and two opposing side frame sections defining a frame cutout. The window opening and the frame cutout are separated by a longitudinal sill section that connects the two side frame sections of the first frame component. In the assembled state of the vehicle door assembly, a sill area of ​​the vehicle door is formed at this sill section. In practice, a second frame component is provided as a window frame reinforcement and fixed to the first frame component to strengthen the window frame, i.e., the area above the sill section, and the sill area itself. Typically, this second frame component also extends along the sill section to stiffen it.

[0003] To at least partially close the frame opening on the first frame component below the sill section, a door module carrier is mounted, formed from an organosheet. A generic vehicle door assembly with a door module carrier is known, for example, from WO 2016 / 177711 A1. Here, the door module carrier is fixed to the sill section at multiple points along a longitudinal direction via an edge section near the sill. Due to its design, the door module carrier of WO 2016 / 177711 A1 is comparatively flexible in the area of ​​the edge section by which it is fixed to the sill section of the door frame. In other words, a certain degree of flexibility is intentionally introduced via the organosheet at the edge section to facilitate the mounting of the door module carrier to the frame opening, which, when the vehicle door is mounted, provides access to a door channel between a door outer skin (e.g., the frame, frame, or door frame).The door module support is defined as the outer door panel (e.g., in the form of an outer door panel) and the inner door panel (e.g., in the form of an inner door panel). In this way, the door module support can only partially bear the loads occurring during operation of the vehicle door in the area of ​​the sill section. Therefore, a structure of at least two parts with window frame reinforcement must still be provided, particularly in the area of ​​the sill section. The door module support thus contributes only secondarily to the stiffness of the vehicle door. Accordingly, load paths for the forces occurring during operation of the vehicle door are routed around the frame opening.

[0004] Based on this, the proposed solution is based on the task of further improving a vehicle door assembly.

[0005] This problem is solved with a vehicle door assembly according to claim 1.

[0006] One proposed vehicle door assembly provides that the door module carrier formed with organosheet is designed as a load-bearing structural component and for this purpose is stiffened at its edge section by at least one stiffening structure injected onto the organosheet and reinforces the parapet section of the first frame component with its edge section in a continuous area in which no section of the second frame component is provided.

[0007] The proposed solution is based on the fundamental principle that the door module carrier, which is largely formed from organosheet, is stiffened in its edge section near the sill, where it is also attached to the first frame component, to such an extent that the door module carrier becomes a load-bearing component of the vehicle door. Through the targeted stiffening of the door module carrier, which is made of fiber-reinforced, in particular continuous fiber-reinforced plastic material, it is achieved that the door module carrier, at a comparatively low weight, exhibits such a significantly increased mechanical stiffness that additional reinforcement of the sill section by a second frame component is unnecessary. This also makes it possible to considerably enlarge the frame opening compared to previously known designs.The frame cutout for the door module carrier can therefore only be framed around its perimeter by relatively narrow sections of the door frame. The installed door module carrier then spans, for example, more than 85%, and in particular more than 90%, of the area defined by the door frame below the window opening.

[0008] The term "door module carrier made of an organosheet" refers to the fact that the door module carrier is largely formed by an organosheet. The door module carrier extends along a main plane. Functional elements, such as those of a window regulator or door lock, are attached to the door module carrier. The door module carrier can, for example, be formed from a plate-shaped semi-finished product made of an organosheet. This organosheet is, for example, a continuous fiber-reinforced thermoplastic material in which continuous fibers in the form of non-woven, woven, or knitted fabrics of glass, Kevlar, carbon, or synthetic fibers are embedded in a thermoplastic matrix. Suitable thermoplastic materials for the matrix include polyamide and polypropylene.The term "continuous fiber reinforced" means that the length of the reinforcing fibers is essentially limited by the size of the sheet-shaped organosheet. Within the organosheet, a fiber is therefore generally uninterrupted.

[0009] The fact that the door module carrier is largely formed from organosheet means that the organosheet constitutes the part of the door module carrier that experiences the majority of the forces occurring under normal operating conditions. For example, one (e.g., a continuous, guide-rail-supporting) section of the door module carrier made of organosheet, or several (e.g., guide-rail-supporting) sections of the door module carrier made of organosheet, extend over approximately 30% or more of the door module carrier's surface area.

[0010] In principle, the organosheet can therefore extend over more than 30%, in particular more than 40%, and generally at least 50% of the area of ​​the door module carrier, so that the organosheet also forms a corresponding proportion of more than 30%, in particular more than 40% or approximately 50% or more of the surface of the door module carrier in the main plane defined by it. To fully utilize the strength advantages of the organosheet, one will generally try to maximize the proportion of the organosheet to the surface of the door module carrier. A multi-part design of the organosheet on a door module carrier is not excluded in this context.

[0011] A key component of the door module carrier is, for example, a plate-shaped semi-finished product made of an organosheet. Thus, the organosheet defines a significant surface area of ​​the door module carrier, but can be supplemented by other components or materials. For instance, metallic and / or plastic elements can be incorporated into or attached to the organosheet.

[0012] In one variant of the proposed solution, the sill section of the first frame component is not reinforced by the second frame component, which defines the window frame reinforcement. The second frame component, fixed to the first, is therefore not continuous in the area of ​​the sill section and is essentially U-shaped. This results in weight and cost advantages compared to a second frame component that also extends along the sill section.

[0013] For example, the sill section of the first frame component extends between two opposing flange sections of the second frame component, which are connected to each other on the second frame component only by a window frame reinforcement of the second frame component, which reinforces the window frame. The two opposing flange sections (right and left in a side view of the vehicle door assembly) are therefore only connected to each other by the window frame reinforcement of the second frame component, which extends above the sill section, but not in the sill area of ​​the vehicle door.

[0014] In one embodiment, the flange sections of the second frame component do not extend across a transition area of ​​the first frame component where one of the two side frame sections transitions into the parapet section. The respective flange section is fixed to the first frame component via a corresponding transition area, for example, by single or multiple bolts. However, a continuous extension of the second frame component beyond the flange section along the parapet section is not provided.

[0015] The stiffening structure of the door module support is designed, for example, with a plurality of stiffening ribs. A corresponding stiffening structure, which is injection-molded onto the organosheet of the door module support, can thus have a plurality of reinforcing ribs extending in different spatial directions in order to stiffen the edge section of the door module support near the sill for load bearing and to enable the door module support to function as a load-bearing structural component. The stiffening structure, particularly in this embodiment, is provided, for example, in a narrow band near an upper edge of the door module support (relative to the intended mounting orientation). This narrow band, in which the stiffening structure is formed, runs, for example, with a width of approximately 2 to 10 cm, and in particular 5 to 10 cm, along the upper edge of the door module support.

[0016] In one embodiment, at least one edge of the door module support opposite the parapet section of the first frame component is partially or completely formed by material injection-molded onto the organosheet. For example, a continuous edge rib is formed by injection-molded material, on which a seal is provided for sealing in the area of ​​the parapet section.

[0017] The stiffening structure can also include at least one fastening point through which the edge section of the door module support is fixed to the sill section of the first frame component. The injection-molded stiffening structure thus includes, for example, at least one through-opening, such as at least one screw boss, through which the door module support is screwed to the sill section of the first frame component. One or more stiffening ribs of the stiffening structure can also be formed at such a screw boss.

[0018] With particular regard to the design of the door module carrier as a load-bearing, large-area structural component within the vehicle door, one embodiment provides a longitudinally extended guide rail for a window regulator on the door module carrier, which lies entirely within the frame cutout of the first frame component. Consequently, no projection is provided in the longitudinal direction of the guide rail that would allow it to extend beyond an edge of the door module carrier. By designing the door module carrier as a load-bearing structural component, it can be constructed with such a large surface area that a guide rail provided on it fits completely within the door module carrier without restricting the stroke of the adjustable window pane.This also facilitates the mounting of the door module carrier, which is already equipped with at least one guide rail, to the first frame component, as this is possible without any tilting of the door module carrier and the guide rail can be guided through the frame cutout perpendicular to its longitudinal extent.

[0019] For additional functional integration into the door module carrier, at least one component of a window regulator can be injection-molded onto the organosheet of the door module carrier. For example, at least one guide rail of the window regulator is injection-molded onto the organosheet. The guide rail is therefore formed from material injection-molded onto the organosheet and is thus an integral part of the door module carrier.

[0020] The stiffening structure and the at least one component of the window regulator that is injection-molded onto the organosheet can also be made of the same material.

[0021] In principle, the organosheet of the door module carrier can consist of a fiber-reinforced plastic material, in particular a glass fiber-reinforced plastic material, for example, fiber-reinforced polypropylene. Fiber fabrics or woven fibers are embedded in the plastic material. In one variant, the organosheet of the door module carrier consists of a fiber-reinforced thermoset material.

[0022] For additional stiffening of the door module carrier, one embodiment, for example, incorporates at least one strip (or "tape") of bidirectionally oriented reinforcing fibers. This additional strip with bidirectionally oriented reinforcing fibers is applied to the door module carrier, thus increasing its stiffness at least locally. By applying such a strip along the load paths where forces propagate through the door module carrier, which acts as a load-bearing structural component, during operation of the vehicle door, targeted reinforcement of the door module carrier is achieved. In particular, such strips can be incorporated into an injection-molded organosheet door module carrier, which is largely composed of long- or continuous-fiber reinforced polypropylene.

[0023] The at least one band of bidirectionally oriented reinforcing fibers can also be formed, for example, by a laminate.

[0024] Another, unclaimed aspect of the proposed solution concerns a door module carrier for a vehicle door, formed from organosheet and providing a support surface. This support surface can, for example, be used to carry functional components of the vehicle door. A longitudinally extended edge section is provided on the support surface, intended for fixing the door module carrier to a sill section of a frame component of the vehicle door that defines the lower edge of a window opening. The door module carrier thus forms a sill-adjacent edge section at its upper edge (relative to the intended installed state), via which the door module carrier is fixed to a sill section of the door frame, either simply or multiple times, for example by gluing or screwing.

[0025] The door module support formed with the organosheet is designed as a load-bearing structural component and is intended for this purpose. at its edge section it is stiffened by at least one stiffening structure injected onto the organosheet and its edge section is designed to reinforce the parapet section of the frame component and to absorb loads acting on the vehicle door during operation.

[0026] A proposed organosheet door module support, designed and intended for stiffening a sill area of ​​a vehicle door and thus forming a load-bearing structural component within the vehicle door, is particularly suitable for use in one embodiment of a proposed vehicle door assembly. Consequently, the advantages and features of exemplary embodiments of a proposed vehicle door assembly explained above and below also apply to embodiments of a proposed door module support, and vice versa.

[0027] The attached figures illustrate possible implementation variants of the proposed solution.

[0028] This shows: FIG 1Ain Exploded view of a vehicle door assembly with a large-area organosheet door module carrier according to the proposed solution; FIG 1Bin Perspective view looking at an inside of a vehicle door assembly Figure 1A formed vehicle door (without interior trim part or parts); FIG 2A a side view looking at an outside of the door frame of the vehicle door assembly defined by two frame parts Figures 1A and 1B ; FIG 2Bin with the Figure 2 Art of concurring view the door shell with attached outer door skin and additional stiffening cross braces to absorb crash-induced forces occurring at the vehicle door; FIG 3in with the Figure 2In a similar view, the vehicle door assembly with the door module carrier mounted on the door frame is shown; FIGS. 4 to 7 are enlarged scale views of sections of the vehicle door assembly corresponding to the Figure 3 ; FIGS. 8 to 11 each in enlarged scale sections of the door module support with a view of a stiffened and stiffening edge section, via which the door module support is fixed to a parapet section of the door frame.

[0029] In the Figures 1A to 11The illustrations depict a variant of a proposed vehicle door assembly in different views. The door structure consists of a first frame component 1 and a second, reinforcing frame component 2 fixed to it. The first frame component 1 defines a window frame 1A for a window opening 10 in a vehicle door T and has two opposing lateral frame sections 13A and 13B to define a frame cutout 11 below the window opening 10. To separate the window opening 10 from the frame cutout 11, a continuous sill section 12 is formed on the first frame component 1. This section connects the two lateral (right and left) frame sections 13A and 13B and defines a sill area B on the properly installed vehicle door T.

[0030] The comparatively large frame opening 10 is closed by a large-area door module support 3. This door module support 3 is formed with an organosheet, i.e., it is largely formed by an organosheet and is designed here as a load-bearing structural component. For this purpose, an edge section 302 of a support surface 30 of the door module support 3 is stiffened by at least one stiffening structure 32 with several stiffening ribs, which is injection-molded onto the organosheet. Due to the load-bearing function of the door module support 3, no additional reinforcement by the second frame component 2 is necessary at the sill section 12 of the first frame component 1. The second frame component 2 merely forms a substantially U-shaped window frame reinforcement 20 in the area of ​​a window frame 1A of the first frame component 1.The second frame component 2 is fixed via lateral flange sections 22A and 22B only in transition areas 14A and 14B of the first frame component 1, where the lateral frame sections 13A and 13B each transition into the parapet section 12.

[0031] The reinforcing structure 32 with its reinforcing ribs is not only injection-molded onto the organosheet of the door module carrier 3, but also, in particular, two guide rails 31A and 31B, which form components of a window regulator. The door module carrier 3 also carries a window regulator drive A and a control unit 4 for this window regulator.

[0032] Furthermore, a continuous edge web 30A is formed on the door module carrier 3 at least on the parapet-adjacent edge section 302 by means of injected material, on which a seal is provided for sealing in the area of ​​the parapet section 12.

[0033] The stiffening structure 32, through which the door module carrier 3 stiffens the sill section 12 in the sill area B of the vehicle door T, is formed with several screw points 32A to 32F. These screw points 32A to 32F form attachment points for the door module carrier 3, at which the door module carrier 3 is fixed to the sill section 12 of the first frame component 1. These screw points 32A to 32F are also formed by material injection-molded onto the organosheet and are shaped within the stiffening structure 32 with stiffening ribs. Reference symbol list

[0034] 11. Frame component 1A Window frame 10 Window opening 11 Frame cutout 12 Sill section 13A, 13B Side frame section 14A, 14B Transition area 22. Frame component / Frame reinforcement 20 Window frame reinforcement 22A, 22B Side flange section 3 Door module support 30 Support surface 30A Edge web for seal 302 Sill-near edge section 31A, 31B Guide rail 32 Reinforcing structure 32A - 32F Mounting point 4 Control unit 5 Door outer skin 6.1, 6.2, 6.3 Crossbar A Window regulator drive B Sill area S Window pane T Vehicle door

Claims

1. A vehicle door assembly for a vehicle door (T), having - a first frame component (1) which comprises a window frame (1A) for a window opening (10) and two mutually opposite lateral frame sections (13A, 13B) for definition of a frame cutout (11) and forms a sill section (12) which connects the two lateral frame sections (13A, 13B) to one another and separates the window opening (10) and the frame cutout (11) from one another, - a second frame component (2) for reinforcing the window frame (1A), which is fixed to the first frame component (1), and - an areal door module carrier (3) which is formed with an organosheet and at least partially closes the frame cutout (11) on the first frame component (1), wherein the door module carrier (3) forms a carrier surface (30) provided for supporting functional components (31A, 32B, 4, A) of the vehicle door (T) and comprises a longitudinally extending edge section (302) which is fixed to the sill section (12) along a longitudinal extension direction of the sill section (12), characterized in that the door module carrier (3) formed with organosheet is configured in the form of a load-bearing structural component and for this purpose - is stiffened on its edge section (302) by at least one stiffening structure (32) injection-molded onto the organosheet, and - by way of its edge section (302) reinforces the sill section (12) of the first frame component (1) in a continuous region in which no section of the second frame component (2) is provided.

2. The vehicle door assembly as claimed in claim 1, characterized in that the sill section (12) of the first frame component (1) is not reinforced by the second frame component (2).

3. The vehicle door assembly as claimed in claim 1 or 2, characterized in that the sill section (12) of the first frame component (1) extends between two mutually opposite flange sections (22A, 22B) of the second frame component (2), which are connected to one another on the second frame component (2) only by a window frame reinforcement of the second frame component (2), said window frame reinforcement reinforcing the window frame (1A).

4. The vehicle door assembly as claimed in claim 3, characterized in that the flange sections (22A, 22B) of the second frame component (2) in each case do not extend beyond a transition region (14A, 14B) of the first frame component (1), via which one of the two lateral frame sections (13A, 13B) transitions into the sill section (12).

5. The vehicle door assembly as claimed in claim 4, characterized in that a flange section (22A, 22B) is fixed in each case to the associated transition region (14A, 14B) of the first frame component (1).

6. The vehicle door assembly as claimed in one of the preceding claims, characterized in that the stiffening structure (32) is formed with a plurality of stiffening ribs.

7. The vehicle door assembly as claimed in one of the preceding claims, characterized in that at least one edge (30A) of the door module carrier (3), said edge lying opposite the sill section (12), is formed partially or completely by material injection-molded on the organosheet.

8. The vehicle door assembly as claimed in one of the preceding claims, characterized in that the stiffening structure (32) forms at least one fastening point (32A-32F) by which the edge section (302) of the door module carrier (3) is fixed to the sill section (12) of the first frame component (1).

9. The vehicle door assembly as claimed in one of the preceding claims, characterized in that a longitudinally extended guide rail (31A, 31B) of a window regulator is provided on the door module carrier (3) and said longitudinally extended guide rail (31A, 31B) lies completely within the frame cutout (11) of the first frame component (1).

10. The vehicle door assembly as claimed in one of the preceding claims, characterized in that at least one functional component (31A, 31B) of a window regulator is injection-molded on the organosheet of the door module carrier (3).

11. The vehicle door assembly as claimed in claim 10, characterized in that at least one guide rail (31A, 31B) of the window regulator is injection-molded on the organosheet of the door module carrier (3).

12. The vehicle door assembly as claimed in claim 10 or 11, characterized in that the stiffening structure (32) and the at least one functional component (31A, 31B), which is injection-molded on the organosheet, of the window regulator are composed of the same material.

13. The vehicle door assembly as claimed in one of the preceding claims, characterized in that the organosheet of the door module carrier (3) is composed of a fiber-reinforced thermoset material.

14. The vehicle door assembly as claimed in one of the preceding claims, characterized in that the door module carrier (3) has at least one tape of unidirectionally oriented reinforcing fibers for stiffening purposes, wherein the at least one tape of unidirectionally oriented reinforcing fibers may be formed by a laminate.