Door structure of vehicle and method for manufacturing the same

Abstract

To achieve both securing of joint strength in collision and permission of thermal deformation of both members in a usual time, wile joining a door inner panel and a reinforcement member which are composed of different materials with a minimum amount of adhesive coating.SOLUTION: A door structure of a vehicle includes a door outer panel 4, a resin door inner panel 10, a reinforcement member 30 formed of a material different from that of the door inner panel 10, and an adhesive 80 for joining both of the members 10, 30. The door inner panel 10 includes an inner face part 11 arranged so as to be separated inside in a width direction from the door outer panel 4, and a wall part 16 extending in a vehicle width direction through a ride line part 15 from the end of the inner face part 11. The reinforcement member 30 faces the wall part 161 and the ridge line part 15 in the door inner panel 10, in the vehicle width direction. The adhesive 80 is provided on the ridge line part 15 and its peripheral region 65 and is provided so that a thickness ta in the ridge line part 15 is smaller than a thickness tb in the peripheral region 65 of the ridge line part 15.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a vehicle door structure including a door outer panel and a resin door inner panel disposed widthwise inward from the door outer panel, and a method for manufacturing the same. [Background technology]

[0002] The door structure of Patent Document 1 is said to be able to take advantage of the lightweight advantage of the resin door inner panel while also increasing its strength by reinforcing a portion of the resin door inner panel with a reinforcing member made of a material with a higher tensile strength than resin.

[0003] However, when assembling a resin door inner panel and a reinforcing member made of a different material (hereinafter also referred to as "different material") using an adhesive, it is necessary to use a special adhesive that can bond different materials together, which is costly and is a barrier to adoption. For this reason, there is a need to use a minimum amount of adhesive when joining the door inner panel and the reinforcing member.

[0004] On the other hand, if the thickness of the adhesive provided between the opposing door inner panel and reinforcing member is reduced in order to reduce the amount of adhesive used, there is a risk that the adhesive will not be able to tolerate the difference in thermal deformation under normal conditions between the two components, which have different thermal expansion coefficients due to the dissimilar materials. Therefore, in order to ensure the bonding strength of the two components in the event of a collision while using the minimum amount of adhesive, it is important to provide the adhesive in an area where the bonding strength can be effectively increased.

[0005] In response to this problem, Patent Document 1 mentions bonding a resin door inner panel and a reinforcing member with an adhesive, but does not mention at all which area of ​​the door inner panel that faces the reinforcing member should have the adhesive applied to and in what manner. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2023-55050 Summary of the Invention [Problem to be solved by the invention]

[0007] The present invention has been made in consideration of these problems, and aims to provide a vehicle door structure and a manufacturing method thereof that can join a door inner panel and a reinforcing member, which are made of different materials, using a minimum amount of adhesive, while ensuring the bonding strength of both members in the event of a collision and allowing for thermal deformation under normal conditions of both members, which have different thermal expansion coefficients. [Means for solving the problem]

[0008] The vehicle door structure of the present invention comprises a door outer panel, a resin door inner panel having an inner surface portion extending in the up-down and front-to-rear directions spaced widthwise inward from the door outer panel, and a wall portion extending in the vehicle width direction from the end of the inner surface portion via a ridge portion, a reinforcing member formed of a material different from the door inner panel and facing at least the wall portion and the ridge portion of the door inner panel in the vehicle width direction, and an adhesive that joins the door inner panel and the reinforcing member, wherein the adhesive is provided on the ridge portion and in areas other than the ridge portion, and is arranged so that the thickness at the ridge portion is thinner than the thickness at the areas other than the ridge portion.

[0009] The reinforcing member may be provided so as to face at least one of the inside and outside sides of the door inner panel in the vehicle width direction. The other area refers to a part of the door inner panel, not all of the area other than the ridge line portion, and refers to the area other than the ridge line portion in the opposing area of ​​the inner surface portion, the ridge line portion and the wall portion of the door inner panel that faces the reinforcing member in the vehicle width direction.

[0010] The material different from that of the door inner panel is preferably a material other than the resin that is the material of the door inner panel, such as metal, and is preferably a material having higher rigidity than resin. For example, if the door inner panel is made of resin that does not contain carbon fiber, the reinforcing member may be made of resin that does contain carbon fiber.

[0011] In other words, even in such a combination of materials, the reinforcing member is formed of a material different from that of the door inner panel. In this way, the material different from that of the door inner panel includes a case where the base material (main component) of the reinforcing member and the door inner panel is the same material but the materials of the secondary components are different from each other.

[0012] According to this invention, the thickness of the adhesive at the ridge line portion is thinner than the thickness of the adhesive at the other regions, so that the adhesive strength at the ridge line portion is higher than that at the other regions, and in the event of a collision, the reinforcing member bonded to the door inner panel at the ridge line portion does not peel off and break, thereby suppressing deformation of the ridge line portion.

[0013] Furthermore, the thin adhesive provided on the ridge line portion can increase the bonding strength even when bonding the door inner panel to the reinforcing member made of a different material, thereby reducing the amount of adhesive used.

[0014] Furthermore, in the other areas other than the ridge line portion, the adhesive is provided to be thicker than the adhesive provided in the ridge line portion, allowing for thermal deformation under normal conditions between the door inner panel and the reinforcing member, which have different thermal expansion coefficients.

[0015] Therefore, while reducing the amount of adhesive used to join the door inner panel and the reinforcing member, which are made of different materials, it is possible to ensure the bonding strength of the two members in the event of a collision and to tolerate thermal deformation under normal conditions of the two members, which have different thermal expansion coefficients.

[0016] In one aspect of the present invention, the ridge portion may be an inner panel ridge portion, and a reinforcing member ridge portion may be provided at a portion of the reinforcing member that faces the inner panel ridge portion on the inside or outside in the vehicle width direction, the reinforcing member ridge portion protruding in the same direction as the inner panel ridge portion protruding inward or outward in the vehicle width direction.

[0017] The present invention is preferable when the peaks (ridges) of the inner panel ridge portion and the reinforcing member ridge portion are completely aligned in the vertical and longitudinal directions, because this maximizes the reinforcing effect of the reinforcing member ridge portion on the inner panel ridge portion.

[0018] However, the present invention is not limited to this, and includes cases where the inner panel ridge portion coincides with at least a portion of the reinforcing member ridge portion in the vertical or front-to-back direction, as long as the thickness of the adhesive can be made thinner at the inner panel ridge portion than in the other areas.

[0019] According to this invention, by reinforcing the door inner panel with the reinforcing member ridge portion, which has the highest strength among the reinforcing members, the reinforcing effect of the reinforcing member on the inner panel ridge portion can be enhanced, and the contact state with the vehicle body, i.e., the vehicle body frame member, can be more effectively maintained even in the event of a collision.

[0020] In another aspect of the present invention, at least one of the inner panel ridge portion and the reinforcing member ridge portion may have a protrusion portion that protrudes toward the other ridge portion, and the tip of the protrusion portion in the protruding direction may protrude with a gap between it and the other ridge portion.

[0021] The protrusions may be solid and filled with a forming material, or may be hollow, for example, having an internal space that opens on the opposite side to the protruding direction. For example, when a hollow protrusion is provided on the ridge line of the reinforcing member, the formation location of the protrusion may be plastically deformed to form a desired bead shape when the reinforcing member is manufactured by press molding or the like.

[0022] Furthermore, the protrusion may be, for example, a protrusion member made of a separate member that is later attached to at least one of the ridge lines. Furthermore, one or more protrusions may be provided on at least one of the ridge lines, and when more than one protrusion is provided, the plurality of protrusions may be arranged along at least one of the ridge lines.

[0023] According to this invention, by providing the protrusion on at least one of the ridge lines, it becomes easier to provide the adhesive on the ridge line of the inner panel so that the adhesive is thinner than in the other region.

[0024] For example, when the protrusion is provided on the inner panel ridge, the gap between the inner panel ridge and the reinforcing member ridge corresponds to the gap between the protrusion and the reinforcing member ridge facing the protrusion, and therefore the thickness of the adhesive provided in the gap can be easily set to be thinner than the other areas depending on the amount of protrusion of the protrusion.

[0025] As another aspect of the present invention, the protrusion may be provided on a ridge line portion of the inner panel. According to this invention, the protrusion can be easily provided on the ridge line portion of the inner panel when the resin door inner panel is molded. In addition, the protrusions ensure the thickness of the ridge line portion of the inner panel, thereby increasing the strength of the ridge line portion of the inner panel, where loads tend to be concentrated during a collision.

[0026] In another aspect of the present invention, the protrusion may be a ridge that continues along at least one of the ridge lines. According to this invention, the protrusion portion of the convex rib is continuous along at least one of the ridge portions, so when the adhesive is provided continuously along at least one of the ridge portions, the thickness of the adhesive can be set to be continuously thin along at least one of the ridge portions. Therefore, in the event of a collision, the adhesive strength between the inner panel ridgeline portion and the reinforcing member via the adhesive can be increased along the protruding portion of the ridge.

[0027] The protrusion portion is not particularly limited in its protruding shape, and may be columnar or cylindrical in shape, with a cross section perpendicular to at least one of the ridge portions having a substantially constant thickness throughout the protruding direction. However, in one aspect of the present invention, the protrusion portion is preferably formed in a tapered shape (chamfered shape) in which the cross section along the protruding direction of at least one of the ridge portions is thinner at the tip end than at the base end in the protruding direction.

[0028] The protrusions may have either a stepped or tapered shape, in which the side surface in the protruding direction tapers in stages along the protruding direction. Furthermore, if the side surface in the protruding direction is tapered, it may be either linear or curved. Furthermore, the tip (top) of the protrusion in the protruding direction may be either a cone shape or a flat frustum shape.

[0029] This invention makes it possible to easily and reliably provide a thick portion of the adhesive corresponding to the base end side of the protrusion and a thin portion corresponding to the tip end side of the protrusion at the ridge line portion where the protrusion is provided, thereby ensuring the bonding strength between the door inner panel and the reinforcing member in the event of a collision while also allowing for thermal deformation under normal conditions of both members which have different thermal expansion coefficients.

[0030] In another aspect of the present invention, in a cross section along the protruding direction of the protrusion, a protrusion top surface that faces the reinforcing member is provided at the tip side of the protrusion in the protruding direction, and the protrusion top surface may be formed along the shape of the surface of the reinforcing member that faces the protrusion top surface.

[0031] According to this invention, it is possible to reliably provide the adhesive between the protrusion and the ridge line portion opposite the protrusion with a thickness thinner than that of the other region.

[0032] In another aspect of the present invention, the other region may be a peripheral region of the ridge portion, and the adhesive may be provided only on the ridge portion and its peripheral region among the inner surface portion, the ridge portion, and the wall portion.

[0033] The present invention is not limited to providing the adhesive on the ridge line portion and its surrounding area, but may also provide the adhesive on the ridge line portion, its surrounding area, and other areas, and does not exclude providing the adhesive on the ridge line portion and other areas different from the surrounding area.

[0034] This invention makes it possible to join the door inner panel and the reinforcing member, which are made of different materials, using a minimum amount of adhesive, while ensuring the bonding strength of both members in the event of a collision and allowing for thermal deformation under normal conditions of both members, which have different thermal expansion coefficients.

[0035] In detail, according to the above configuration, when the door structure displaces into the passenger compartment during a collision and comes into contact with the surrounding vehicle body frame members, the adhesive that bonds to the reinforcing member can be provided only on the ridge line portion and its surrounding area, which are areas of the door inner panel where the load received from the vehicle body frame members is likely to be concentrated.

[0036] Furthermore, as described above, by making the thickness of the adhesive thinner at the ridge line portion than in the surrounding area of ​​the ridge line portion, the door inner panel and the reinforcing member, which are made of different materials, can be joined using a minimum amount of adhesive, while effectively increasing the joining strength of the two members in the event of a collision.

[0037] In addition, as described above, by making the thickness of the adhesive thicker in the area surrounding the ridge line than in the ridge line, it is possible to tolerate thermal deformation under normal conditions of both components which have different thermal expansion coefficients.

[0038] In another aspect of the present invention, a plurality of the ridge portions may be arranged from the center of the door inner panel in a front view of the door toward an outward direction from the surface thereof, and the adhesive may be provided on each of the plurality of ridge portions.

[0039] According to this invention, the door inner panel is bonded to the reinforcing member via the adhesive provided on each of the ridge portions arranged from the center of the door inner panel in the out-of-plane direction, thereby further enhancing the above-mentioned effect of the thinner adhesive at the ridge portions, i.e., the effect of increasing the adhesive strength between the two members in the event of a collision.

[0040] Therefore, when an object strikes the door outer panel, the door structure displaces into the passenger compartment, and when it comes into contact with the body frame member arranged on the outer periphery of the door structure, it comes into contact with the body frame member in an interlocking manner, thereby increasing the efficiency of transmission of the collision load to the body frame member.

[0041] In another aspect of the present invention, a layer in which no adhesive exists may be provided between the plurality of ridge lines between the door inner panel and the reinforcing member. Here, the layer in which no adhesive is present may be a layer having a hollow space such as a closed cross-sectional space between the door inner panel and the reinforcing member, or a layer in which the two members are joined to each other so that no hollow space exists.

[0042] This invention allows for a significant reduction in the amount of adhesive used, leading to cost savings. As a result, it is possible to provide a door structure that realizes the exoskeleton concept of transmitting the collision load input into the door structure during a collision to the surrounding vehicle body frame members, even though it has a structure in which a reinforcing member made of a different material is joined to a resin door inner panel.

[0043] The present invention also provides a method for manufacturing a vehicle door structure including a door outer panel, a resin door inner panel having an inner surface extending in the up-down and front-rear directions spaced widthwise inward from the door outer panel, and a wall extending in the vehicle width direction from an end of the inner surface via a ridge portion, and a reinforcing member formed of a material different from that of the door inner panel, the method comprising the steps of: applying adhesive to the door inner panel; and assembling the reinforcing member to the door inner panel so as to face each other in the vehicle width direction by adhering the reinforcing member to the door inner panel via the adhesive, the adhesive being applied only to the ridge portion in the portion where the door inner panel and the reinforcing member face each other in the vehicle width direction in the adhesive application step; and assembling the reinforcing member against the adhesive, thereby deforming the adhesive so that it spreads from the ridge portion to a peripheral region of the ridge portion, so that the thickness of the ridge portion is thinner than the thickness of the peripheral region.

[0044] This invention makes it possible to manufacture a vehicle door structure that can bond a door inner panel and a reinforcing member, which are made of different materials, with a minimum amount of adhesive applied, while ensuring the bonding strength of both members in the event of a collision and allowing for thermal deformation under normal conditions of both members, which have different thermal expansion coefficients.

[0045] In one aspect of the present invention, the ridge line portion is provided with a protrusion that protrudes toward the reinforcing member and whose tip in the protruding direction protrudes with a gap between it and the reinforcing member, and the thickness at the ridge line portion may be the thickness at the protrusion, and the thickness at the peripheral region of the ridge line portion may be the thickness at the peripheral region of the protrusion.

[0046] By providing the protrusion on the ridge line in this way, the adhesive can be applied in the assembling step so that the thickness of the adhesive at the protrusion is thinner than the thickness of the adhesive in the surrounding area of ​​the protrusion, and therefore the adhesive can be easily applied so that the thickness of the adhesive at the ridge line is thinner than the thickness of the adhesive in areas other than the ridge line. [Effects of the Invention]

[0047] According to this invention, it is possible to provide a vehicle door structure and a manufacturing method thereof that can join a door inner panel and a reinforcing member, which are made of different materials, with a minimum amount of adhesive applied, while ensuring the joining strength of both members in the event of a collision and allowing for thermal deformation under normal conditions of both members, which have different thermal expansion coefficients. [Brief explanation of the drawings]

[0048] [Figure 1] FIG. 1 is a side view showing a front side door as viewed from the outside in the vehicle width direction, with the door outer panel shown in imaginary lines. [Figure 2] A side view of Figure 1 with various reinforcements removed. [Figure 3] FIG. 1 is a side view showing the main part of a front side door as viewed from the inside in the vehicle width direction, with the door outer panel shown in phantom lines. [Figure 4] FIG. 1 is a perspective view showing a main part of a front side door as viewed from the front of the vehicle and from the inside in the vehicle width direction. [Figure 5] Side view of the resin door inner panel seen from the inside in the vehicle width direction [Figure 6] An enlarged cross-sectional view taken along line AA in Figure 3, showing the surrounding body frame members. [Figure 7] FIG. 7 is an enlarged cross-sectional view showing the main part of FIG. [Figure 8] An enlarged cross-sectional view taken along line BB in Figure 3, showing the surrounding body frame members. [Figure 9] FIG. 9 is an enlarged cross-sectional view showing the main part of FIG. 8. [Figure 10]An enlarged cross-sectional view taken along line CC in Figure 3, showing the surrounding body frame members. [Figure 11] 11 is an enlarged cross-sectional view showing the main part of FIG. [Figure 12] (a) An explanatory diagram of a front side door with an exoskeleton door structure, showing a schematic diagram of a collision with a collision object, and (b) is a cross-sectional view taken along line DD in Figure 12(a). [Figure 13] Cross-sectional views corresponding to Figure 6 showing the behavior of the lower part of the side door at the initial stage of the collision (a), the middle stage of the collision (b), and the final stage of the collision (c) DETAILED DESCRIPTION OF THE INVENTION

[0049] An embodiment of the present invention will be described below with reference to the drawings. In this embodiment, the vehicle body of the automobile has a substantially symmetrical shape, and therefore the description will be based on the door structure on the right side of the vehicle. In the drawings, arrow F indicates the front of the vehicle, arrow U indicates the upper side of the vehicle, arrow R indicates the right side of the vehicle, arrow L indicates the left side of the vehicle, arrow OUT indicates the outer side in the vehicle width direction (outside the passenger compartment), and arrow IN indicates the inner side in the vehicle width direction (inside the passenger compartment).

[0050] The door structure of the present invention is applied to a front side door 1 that opens and closes a front opening for passengers to get in and out of a vehicle side. As shown in Fig. 1, the front side door 1 of this embodiment is composed of a door main body 2 and a door sash 3 provided above the door main body 2. Although not shown, the front side door 1 is provided with weather strips, for example, on the outer periphery of the door body 2 and the door sash 3 as appropriate.

[0051] As shown in FIG. 1, the door sash 3 has a generally arch-like shape in a side view that protrudes above the belt line BL when the front side door 1 is viewed from the front (i.e., when viewed from the outside in the vehicle width direction) (hereinafter abbreviated as "door front view") and connects the front and rear of the door body 2 of the integrated door inner panel 5 through a position above the belt line BL.

[0052] The door sash 3 has a door sash front edge portion 3f that extends at an angle from the front portion of the integrated door inner panel 5 so that the upper portion is positioned more rearward, and a door sash rear edge portion 3r that extends upward from the rear portion of the integrated door inner panel 5 to the rear edge (upper edge) of the door sash front edge portion 3f.

[0053] A door sash front-edge reinforcement 98 is joined to the door sash front edge portion 3f, and a door sash rear-edge reinforcement 99 is joined to the door sash rear edge portion 3r, each joined to the resin door inner panel 10 from the outer side in the vehicle width direction. The door sash rear-edge reinforcement 99 has a downward extending portion 99a whose lower edge extends downward beyond the door sash 3 to reach the upper part of the rear portion of the door main body 2. A window opening 6A is formed in the door sash 3, and the window opening 6A is opened and closed by a window glass (not shown) that is raised and lowered by a lifting device (not shown) provided inside the door main body 2.

[0054] The front side door 1 is configured by combining a door outer panel 4 (shown by imaginary lines in Figs. 1 to 3) located on the outer side in the vehicle width direction and an integrated door inner panel 5 (see Figs. 1 to 4) located on the inner side in the vehicle width direction. As shown in Figs. 6, 8, and 10, the door main body 2 is configured so that the cross-sectional shape along the vehicle width direction is a closed cross-section due to the door outer panel 4 and the integrated door inner panel 5.

[0055] The door outer panel 4 is an exterior panel that forms the exterior design surface of the vehicle, and is formed by press-forming a steel plate or an aluminum plate so that the entire panel, including the door sash 3 portion when viewed from the front of the door, has a thickness in the vehicle width direction (in other words, extends in the vertical and longitudinal directions). The outer edge of the door outer panel 4, excluding the upper edge of the door main body 2, is joined to the outer edge of the one-piece door inner panel 5, excluding the upper edge of the door main body 2, by hemming, which will be described later.

[0056] 3 and 4, the one-piece door inner panel 5 includes a resin door inner panel 10, an aluminum reinforcing member 30 that has a higher tensile strength (excellent ductility against tension) than the resin door inner panel 10 and reinforces the resin door inner panel 10, and an adhesive 80 (see, for example, FIGS. 1, 7, 9, and 11) that joins the resin door inner panel 10 and the reinforcing member 30. In other words, the one-piece door inner panel 5 is a door inner panel in which the resin door inner panel 10 and the reinforcing member 30, which are made of different materials, are integrally or integrally assembled via the adhesive 80. For clarity of the drawings, the reinforcing members 30 are indicated by dots in FIGS.

[0057] The resin door inner panel 10 is formed entirely by molding from thermoplastic resin so that the cross-sectional shape in a horizontal cross section along the vehicle width direction is approximately hat-shaped and protrudes inward in the vehicle width direction, and cooperates with the door outer panel 4 to form a door internal space 7 with a closed cross-section inside (see Figures 6 to 11).

[0058] Specifically, as shown in particular in Figure 5, the resin door inner panel 10 has a main inner surface portion 11s that forms the main surface in the approximately inner region (central region) of the door body 2 when viewed from the front, a lower edge portion 12 that forms the lower edge of the integrated door inner panel 5, a front edge portion 13 that also forms the front edge, and a rear edge portion 14 that forms the rear edge.

[0059] The front side door 1 is supported on the vehicle body so as to be freely opened and closed via two door hinges 80U, 80D (see Figure 1) fastened to upper and lower door hinge base portions 18 (see Figure 2) at the front edge portion 13 of the resin door inner panel 10.

[0060] As shown in FIG. 1, at the front edge 13 of the resin door inner panel 10, an upper door hinge reinforcement 95U (abbreviated as "upper door hinge reinforcement 95U") is joined to the resin door inner panel 10 from the outside in the vehicle width direction (strictly speaking, from the rear of the vehicle) at the portion corresponding to the upper door hinge 80U of the pair of upper and lower door hinges 80U, 80D.

[0061] As shown in FIG. 1, at the front edge 13 of the resin door inner panel 10, of the pair of upper and lower door hinges 80U, 80D, a lower door hinge reinforcement 95D (abbreviated as "lower door hinge reinforcement 95D") is joined to the resin door inner panel 10 from the outside in the vehicle width direction (strictly speaking, from the rear of the vehicle) at the portion corresponding to the lower door hinge 80D.

[0062] The upper and lower door hinge reinforcements 95 (upper door hinge reinforcement 95U and lower door hinge reinforcement 95D) are both made of iron or aluminum, which has higher tensile strength and compressive strength than the resin door inner panel 10.

[0063] Furthermore, as shown in Figure 1, a belt line reinforcement 91 that connects the upper part of the front edge portion 13 and the upper part of the rear edge portion 14 in the fore-and-aft direction of the vehicle along the belt line BL is joined to the resin door inner panel 10 from the outside in the vehicle width direction.

[0064] Furthermore, two door impact bars 92, 93 (an upper door impact bar 92 and a lower door impact bar 93) are arranged at a distance in the vertical direction on the resin door inner panel 10, connecting the front edge portion 13 and the rear edge portion 14 in the vehicle longitudinal direction. These two door impact bars 92, 93 cooperate with the belt line reinforcement 91 to withstand a collision load input to the front side door 1 from the outside in the vehicle width direction.

[0065] The upper door impact bar 92 extends in the front-to-rear direction along the lower edge of the beltline reinforcement 91 directly below the beltline reinforcement 91, and its front edge is joined to the resin door inner panel 10 via an upper door hinge reinforcement 95U. In addition, the rear edge of the upper door impact bar 92 is joined to the resin door inner panel 10 via a downward extending portion 99a of a door sash rear edge reinforcement 99 provided on the door sash rear edge portion 3r.

[0066] The lower door impact bar 93 extends at an angle below the upper door impact bar 92 so that it is positioned lower toward the rear, and its front edge is joined to the resin door inner panel 10 via an upper door hinge reinforcement 95U. In addition, the lower door impact bar 93 has its rear edge joined to the resin door inner panel 10 via a reinforcement 94.

[0067] 1 denotes a latch reinforcement that is provided on the resin door inner panel 10 from the vehicle width direction outer side at a vertically intermediate position of the rear edge portion 14 of the resin door inner panel 10. Also, reference numeral 8 in FIG. 1 denotes a pair of front and rear guide rails that are attached to the main inner surface portion 11s as part of a lifting device that raises and lowers a window glass (not shown). The pair of front and rear guide rails 8 each extend in the vehicle vertical direction from the one-piece door inner panel 5 to the door sash 3, and are disposed at a predetermined distance from each other in the longitudinal direction.

[0068] Next, the resin door inner panel 10 will be described in detail with reference to Figures 2 to 11. In the figures other than Figure 1, the door hinges 80U and 80D, the reinforcements 91, 92, 93, 94, 95U, 95D, 97, 98, and 99, and the guide rails 8 are not shown.

[0069] As shown in Figures 5 to 7, particularly Figure 7, the main inner surface portion 11s of the resin door inner panel 10 is positioned at a distance inward in the vehicle width direction relative to the door outer panel 4, and is formed in a generally flat plate shape having a plate thickness in the vehicle width direction.

[0070] As shown in Figures 5 to 7 and 9, the lower edge portion 12 has a first lower wall portion 161d that extends mainly outward in the vehicle width direction from the lower edge portion 11dd of the main inner surface portion 11s via the lower first ridge portion 151d, so as to define the lower surface of the door internal space 7, and a first lower inner surface portion 111d that extends downward from the outer end of the first lower wall portion 161d in the vehicle width direction via the lower second ridge portion 152d.

[0071] Furthermore, the lower edge portion 12 has a second lower wall portion 162d that extends mainly outward in the vehicle width direction from the lower end of the first lower inner surface portion 111d via the lower third ridge portion 153d, and a second lower inner surface portion 112d that extends downward from the vehicle width outer end of the second lower wall portion 162d via the lower fourth ridge portion 154d.

[0072] Furthermore, the lower edge portion 12 has a stepped vertical cross-sectional shape as shown in Figure 7, which is formed by a third lower wall portion 163d that extends mainly outward in the vehicle width direction from the lower end of the second lower inner surface portion 112d via the lower fifth ridge portion 155d, and a lower outer surface portion 17d that extends downward from the outer end of the third lower wall portion 163d in the vehicle width direction via the lower sixth ridge portion 156d.

[0073] The first lower ridge line portion 151d, the second lower ridge line portion 152d, the third lower ridge line portion 153d, the fourth lower ridge line portion 154d, the fifth lower ridge line portion 155d, and the sixth lower ridge line portion 156d each form the lower ridge line portion 15d of the resin door inner panel 10. The first lower inner surface portion 111d and the second lower inner surface portion 112d each form the lower inner surface portion 11d of the resin door inner panel 10. The first lower wall portion 161d, the second lower wall portion 162d, and the third lower wall portion 163d each form the lower wall portion 16d of the resin door inner panel 10.

[0074] As shown in FIG. 6, when the door is closed, a side sill 100 serving as a vehicle body frame member is provided inwardly and below the lower part of the front side door 1 in the vehicle width direction so as to overlap the lower part of the front side door 1 in the vertical direction.

[0075] The side sill 100 comprises a side sill inner reinforcement 100a having a hat-shaped cross section that opens outward in the vehicle width direction, a side sill outer reinforcement 100b having a hat-shaped cross section that opens inward in the vehicle width direction, and a side sill outer panel 100c also having a hat-shaped cross section that opens inward in the vehicle width direction, and a closed cross-sectional portion 100s extending in the fore-and-aft direction of the vehicle is formed between the side sill inner reinforcement 100a and the side sill outer reinforcement 100b.

[0076] As shown in Figures 5, 8, and 9, particularly Figure 9, the front edge portion 13 is formed by a front wall portion 16f that extends mainly outward in the vehicle width direction from the front edge portion 11ff of the main inner surface portion 11s via a front first ridge portion 151f so as to define the front surface of the door internal space 7, and a front outer surface portion 17f that protrudes from the vehicle width direction outer edge of the front wall portion 16f via a front second ridge portion 152f towards the front of the vehicle (outward when viewed from the front of the door).

[0077] The front first ridge line portion 151f and the front second ridge line portion 152f form the front ridge line portion 15f of the resin door inner panel 10, respectively. As shown in FIG. 5, flat door hinge bases 18, to which door hinges 80U and 80D can be attached, are formed at positions on the front wall 16f of the front edge 13 at predetermined intervals in the vertical direction of the vehicle.

[0078] As shown in FIG. 8, when the door is closed, a hinge pillar 101 serving as a vehicle body frame member is provided inward in the vehicle width direction and near the front side of the front portion of the integrated door inner panel 5 so as to overlap with the front portion of the integrated door inner panel 5 in the fore-and-aft direction of the vehicle.

[0079] The hinge pillar 101 comprises a hinge pillar inner reinforcement 101a having a hat-shaped cross section that opens outward in the vehicle width direction, a hinge pillar outer reinforcement 101b having a hat-shaped cross section that opens inward in the vehicle width direction, and a hinge pillar outer panel 101c also having a hat-shaped cross section that opens inward in the vehicle width direction, and a closed cross-sectional portion 101s extending in the vertical direction of the vehicle is formed between the hinge pillar inner reinforcement 101a and the hinge pillar outer reinforcement 101b.

[0080] As shown in Figures 5, 10, and 11, particularly Figure 11, the rear edge portion 14 has a stepped horizontal cross section along the fore-and-aft direction as shown in Figure 11, which is made up of a first rear wall portion 161r extending mainly outward in the vehicle width direction from the rear edge portion 11rr of the main inner surface portion 11s via a rear first ridge portion 151r, a rear inner surface portion 11r extending rearward from the outer end of the first rear wall portion 161r in the vehicle width direction via a rear second ridge portion 152r, and a second rear wall portion 162r extending mainly outward in the vehicle width direction from the rear end of the rear inner surface portion 11r via a rear third ridge portion 153r, so as to define the rear surface of the door internal space 7.

[0081] 11, the rear first ridge portion 151r and the rear second ridge portion 152r each form a rear ridge portion 15r of the resin door inner panel 10. The first rear wall portion 161r and the second rear wall portion 162r each form a rear wall portion 16r of the resin door inner panel 10.

[0082] As shown in FIG. 10, when the door is closed, a center pillar 102 as a body frame member is provided inward in the vehicle width direction and near the rear side of the rear portion of the integrated door inner panel 5 so as to overlap with the rear portion of the integrated door inner panel 5 in the fore-and-aft direction of the vehicle.

[0083] The center pillar 102 comprises a center pillar inner reinforcement 102a, a center pillar outer reinforcement 102b with a hat-shaped cross section that opens inward in the vehicle width direction, and a center pillar outer panel 102c with a hat-shaped cross section that opens inward in the vehicle width direction, and a closed cross-sectional portion 102s extending in the vertical direction of the vehicle is formed between the center pillar inner reinforcement 102a and the center pillar outer reinforcement 102b.

[0084] As described above, the lower edge portion 12 of the resin door inner panel 10 has a plurality of lower ridge portions 15d extending in the front-rear direction and spaced apart in the vertical direction (see FIG. 5). Similarly, the front edge portion 13 of the resin door inner panel 10 has a plurality of front ridge portions 15f extending in the vertical direction and spaced apart in the front-rear direction. The rear edge portion 14 of the resin door inner panel 10 has a plurality of rear ridge portions 15r extending in the vertical direction and spaced apart in the front-rear direction.

[0085] As a result, the resin door inner panel 10 has a plurality of ridges 15d, 15f, 15r arranged radially from the door center outward on the outer periphery of the main inner surface portion 11s when viewed from the front of the door. The ridge portions 15d, 15f, and 15r provided on the resin door inner panel 10 are collectively referred to as the inner panel ridge portion 15.

[0086] Furthermore, as shown in Figure 5, the resin door inner panel 10 is formed so that at least the lower first ridge portion 151d of the multiple lower ridge portions 15d formed on the lower edge portion 12, at least the front first ridge portion 151f of the multiple front ridge portions 15f formed on the front edge portion 13, and at least the rear first ridge portion 151r of the multiple rear ridge portions 15r formed on the rear edge portion 14 are continuous with each other, including the corner portions of adjacent edges.

[0087] That is, the lower first ridge portion 151d, the front first ridge portion 151f, and the rear first ridge portion 151r are formed as a single continuous first ridge portion 151 in a substantially U-shape in a front view of the door along the outer peripheral edge excluding the upper edge of the main inner surface portion 11s. Note that, as shown in Figures 6 to 12, the cross section of the first ridge portion 151 taken orthogonal to the extending direction of the first ridge portion 151 protrudes in an arc shape inward in the vehicle width direction relative to the main inner surface portion 11s.

[0088] In this way, when viewed from the front of the door, multiple ridge portions 15 are arranged radially on the outer periphery of the resin door inner panel 10, and of these multiple ridge portions 15, at least the first ridge portion 151 located on the edge portions 11dd, 11ff, 11rr of the main inner surface portion 11s is formed continuously over the lower edge portion 12, the front edge portion 13, and the rear edge portion 14, thereby increasing the tensile strength and compressive strength of the outer periphery of the resin door inner panel 10 against collision loads input toward the passenger compartment against the front side door 1.

[0089] Furthermore, as shown in FIG. 5, the first ridge portion 151 is formed not only on the door body 2 but also on the door sash 3, and is formed continuously along the extension direction of the door sash 3 (the door sash front edge portion 3f and the door sash rear edge portion 3r).

[0090] 5, the first ridge line portion 151 of the door body 2 and the first ridge line portion 151 of the door sash 3 are integrally connected to each other at the upper edge of the front edge 13 of the door body 2 and the lower edge of the door sash front edge 3f, and are also integrally connected to each other at the upper edge of the rear edge 14 of the door body 2 and the lower edge of the door sash rear edge r. As a result, the first ridge line portion 151 extends continuously in a closed loop along the outer peripheral edge of the resin door inner panel 10, further increasing the tensile strength and compressive strength of the outer peripheral side of the resin door inner panel 10 against a collision load.

[0091] As shown in Figures 6 to 11, the outer peripheral edge of the resin door inner panel 10, excluding the upper edge, of the door body 2 is formed slightly smaller than the outer peripheral edge of the integrated door inner panel 5 when viewed from the front of the door, in consideration of reinforcing the outer peripheral side mainly with the reinforcing member 30.

[0092] In addition, the above-mentioned main inner surface portion 11s, lower inner surface portion 11d and rear inner surface portion 11r of the resin door inner panel 10 are collectively referred to as the inner surface portion 11 of the resin door inner panel 10, and the above-mentioned lower wall portion 16d, front wall portion 16f and rear wall portion 16r of the resin door inner panel 10 are collectively referred to as the wall portion 16 of the resin door inner panel 10.

[0093] The entire reinforcing member 30 is made of aluminum, which has a higher tensile strength than the plastic door inner panel 10, and as shown in Figures 3 and 4, when viewed from the front of the plastic door inner panel 10, it is provided mainly on the inside in the vehicle width direction relative to the plastic door inner panel 10, extending from the door body 2 to the door sash 3 in order to reinforce these.

[0094] Specifically, as shown in FIG. 3, the reinforcing member 30 includes a door body reinforcing portion 31 that reinforces the door body 2 and a door sash reinforcing portion 36 that reinforces the door sash 3.

[0095] As shown in FIG. 3, the door sash reinforcing portion 36 faces the resin door inner panel 10 of the door sash 3 so as to cover substantially the entirety from the inside in the vehicle width direction, thereby reinforcing the door sash 3 to increase its rigidity (mainly rigidity against vibration).

[0096] As shown in the same figure, the door body reinforcement portion 31 includes a lower edge reinforcement portion 32 that reinforces the lower edge portion 12, a front edge reinforcement portion 33 that reinforces the front edge portion 13, a rear edge reinforcement portion 34 that reinforces the rear edge portion 14, and a belt line reinforcement portion 35, and is integrally formed in a frame shape (annular shape) when viewed from the inside in the vehicle width direction.

[0097] The belt line reinforcement portion 35 extends in the fore-and-aft direction of the vehicle along the belt line BL so as to connect the upper portion of the front edge reinforcement portion 33 and the upper portion of the rear edge reinforcement portion 34, and reinforces the area around the belt line BL of the resin door inner panel 10.

[0098] As shown in Figures 3, 6, and 7, the lower edge reinforcement portion 32 is a portion that reinforces the lower edge portion 12 of the resin door inner panel 10, and includes a lower first reinforcing ridge portion 451d, a first lower wall reinforcement portion 461d, a lower second reinforcing ridge portion 452d, a first lower inner surface reinforcement portion 421d, a lower third reinforcing ridge portion 453d, a second lower wall reinforcement portion 462d, a lower fourth reinforcing ridge portion 454d, a second lower inner surface reinforcement portion 422d, a lower fifth reinforcing ridge portion 455d, a third lower wall reinforcement portion 463d, a lower sixth reinforcing ridge portion 456d, and a lower outer surface reinforcement portion 47d.

[0099] The lower first reinforcing ridge line portion 451d faces the lower first ridge line portion 151d of the resin door inner panel 10 from the inside in the vehicle width direction across a gap, and reinforces the lower first ridge line portion 151d.

[0100] The first lower-wall reinforcing portion 461d extends downward and outward in the vehicle width direction from the upper end of the lower-side reinforcing portion 32 via the lower-side first reinforcing ridge portion 451d, and faces the first lower wall portion 161d of the resin door inner panel 10 from below across a gap to reinforce the first lower wall portion 161d. The lower-side second reinforcing ridge portion 452d faces the lower-side second ridge portion 152d of the resin door inner panel 10 from below across a gap to reinforce the lower-side second ridge portion 152d. The first lower inner surface reinforcing portion 421d faces the first lower inner surface portion 111d of the resin door inner panel 10 from inside in the vehicle width direction across a gap to reinforce the first lower inner surface portion 111d.

[0101] Furthermore, the lower third reinforcing ridge portion 453d faces the lower third ridge portion 153d of the resin door inner panel 10 from the inside and below in the vehicle width direction, across a gap, to reinforce the lower third ridge portion 153d. The second lower wall reinforcing portion 462d faces the second lower wall portion 162d of the resin door inner panel 10 from the below, across a gap, to reinforce the second lower wall portion 162d. The lower fourth reinforcing ridge portion 454d faces the lower fourth ridge portion 154d of the resin door inner panel 10 from the inside and below in the vehicle width direction, across a gap, to reinforce the lower fourth ridge portion 154d.

[0102] The second lower inner surface reinforcing portion 422d faces the second lower inner surface portion 112d of the resin door inner panel 10 from the inside in the vehicle width direction across a gap, thereby reinforcing the second lower inner surface portion 112d. The lower fifth reinforcing ridge portion 455d faces the lower fifth ridge portion 155d of the resin door inner panel 10 from the inside and below in the vehicle width direction across a gap, thereby reinforcing the lower fifth ridge portion 155d.

[0103] Furthermore, the third lower wall reinforcing portion 463d faces the third lower wall portion 163d of the resin door inner panel 10 from below across a gap to reinforce the third lower wall portion 163d. The lower sixth reinforcing ridge portion 456d faces the lower sixth ridge portion 156d of the resin door inner panel 10 from below and inside in the vehicle width direction across a gap to reinforce the lower sixth ridge portion 156d. The lower outer surface reinforcing portion 47d faces the lower outer surface portion 17d of the resin door inner panel 10 from below across a gap in the vehicle width direction to reinforce the lower outer surface portion 17d.

[0104] The lower first reinforcing ridge portion 451d, the lower third reinforcing ridge portion 453d, and the lower fifth reinforcing ridge portion 455d are all formed to protrude inward in the vehicle width direction in response to the inward protrusion shapes of the lower first ridge portion 151d, the lower third ridge portion 153d, and the lower fifth ridge portion 155d of the resin door inner panel 10. The lower second reinforcing ridge portion 452d, the lower fourth reinforcing ridge portion 454d, and the lower sixth reinforcing ridge portion 456d are all formed to protrude outward in the vehicle width direction in response to the outward protrusion shapes of the lower second ridge portion 152d, the lower fourth ridge portion 154d, and the lower sixth ridge portion 156d of the resin door inner panel 10.

[0105] Furthermore, as shown in Figures 1, 2, 6 and 7, the lower outer surface reinforcement portion 47d protrudes downward from the vehicle widthwise outer edge of the third lower wall reinforcement portion 463d, as described above, but its lower edge 47dd extends in a flange-like manner downward from the vehicle beyond the lower edge 17dd of the lower outer surface portion 17d of the resin door inner panel 10 so as to form the lower edge 5dd of the integrated door inner panel 5.

[0106] As shown in the same figure, the tip of the lower outer surface reinforcement portion 47d is crimped and joined by a lower edge hem portion 6d (a portion that is hemmed and bent so that the lower edge of the door outer panel 4 is folded back approximately from the outside in the vehicle width direction to the inside in the vehicle width direction and upward) provided on the lower edge of the door outer panel 4.

[0107] 7, the first lower-wall reinforcing portion 461d is disposed so as to be gradually spaced downward from the first lower wall portion 161d toward the outer side in the vehicle width direction. A closed cross section 46s extending in the front-rear direction is formed between the first lower wall portion 161d, the first lower inner surface portion 111d, and the first lower-wall reinforcing portion 461d.

[0108] Furthermore, each of the lower first reinforcing ridge portion 451d, the lower second reinforcing ridge portion 452d, the lower third reinforcing ridge portion 453d, the lower fourth reinforcing ridge portion 454d, the lower fifth reinforcing ridge portion 455d, and the lower sixth reinforcing ridge portion 456d forms a lower reinforcing ridge portion 45 of the reinforcing member 30. Each of the first lower inner surface reinforcing portion 421d and the second lower inner surface reinforcing portion 422d forms a lower inner surface reinforcing portion 42d of the reinforcing member 30. Each of the first lower wall reinforcing portion 461d, the second lower wall reinforcing portion 462d, and the third lower wall reinforcing portion 463d forms a lower wall reinforcing portion 46d of the reinforcing member 30.

[0109] As shown in Figures 3, 4, 8 and 9, the front edge reinforcement portion 33 extends in the vertical direction along the front edge portion 13 (see Figure 5) of the resin door inner panel 10, and includes a main inner surface front reinforcement portion 41f, a front first reinforcing ridge portion 451f, a front wall reinforcement portion 46f, a front second reinforcing ridge portion 452f and a front outer surface reinforcement portion 47f.

[0110] 8 and 9, the main inner surface front reinforcing portion 41f is disposed opposite the front region 11fz of the main inner surface portion 11s from the inside in the vehicle width direction across a gap, reinforcing the front region 11f. The front first reinforcing ridge portion 451f is disposed opposite the front first ridge portion 151f from the inside in the vehicle width direction across a gap, reinforcing the front first ridge portion 151f.

[0111] The front wall reinforcing portion 46f faces the front wall portion 16f from the front side across a gap to reinforce the front wall portion 16f. The front second reinforcing ridge portion 452f is arranged facing the front second ridge portion 152f from the front and inner side in the vehicle width direction across a gap to reinforce the front second ridge portion 152f. The front outer surface reinforcing portion 47f is arranged facing the front outer surface portion 17f from the inner side in the vehicle width direction across a gap to reinforce the front outer surface portion 17f.

[0112] The front first reinforcing ridge portion 451f is formed to protrude inward in the vehicle width direction in response to the protruding shape of the front first ridge portion 151f of the resin door inner panel 10 protruding inward in the vehicle width direction. The front second reinforcing ridge portion 452f is formed to protrude outward in the vehicle width direction in response to the protruding shape of the front second ridge portion 152f of the resin door inner panel 10 protruding outward in the vehicle width direction.

[0113] As shown in Figures 3 and 4, the front wall reinforcement portion 46f of the front edge reinforcement portion 33 is arranged to face the front wall portion 16f from the front side, and also at the portions of the front wall portion 16f corresponding to the door hinge base portions 18 on each of the upper and lower sides, it is arranged to face the door hinge base portions 18 on each of the upper and lower sides (see Figure 5) from the front (outside the door internal space 7).

[0114] The front wall reinforcing portion 46f and the upper and lower hinge rains 95U, 95D (see FIG. 1) are arranged in overlapping surface contact with the door hinge base portion 18 on both the upper and lower sides so as to sandwich the door hinge base portion 18 from both the front and rear.

[0115] When the door side hinge brackets (not shown) of the upper and lower door hinges 80U, 80D (see Figure 1) are fastened to the door hinge base portion 18 from the front (outside the door internal space 7) via the front edge reinforcement portion 33, they are fastened together with the front wall reinforcement portion 46f of the front edge reinforcement portion 33 and the hinge rein 95 to the door hinge base portion 18.

[0116] Also, as shown in Figure 8, the front outer surface reinforcement portion 47f protrudes toward the front of the vehicle from the vehicle width direction outer edge of the front wall reinforcement portion 46f, as described above, but extends further toward the front of the vehicle than the front edge 17ff (see Figure 5) of the front outer surface portion 17f of the resin door inner panel 10 so that the front edge 47ff forms the front edge 5ff of the integrated door inner panel 5.

[0117] As shown in the same figure, the front edge 47ff of the front outer surface reinforcement portion 47f is crimped and joined by a front edge hem portion 6f provided on the front edge of the door outer panel 4 (a portion that is hemmed and bent so that the front edge of the door outer panel 4 is folded back approximately from the outside in the vehicle width direction to the inside in the vehicle width direction and toward the rear of the vehicle). As shown in FIG. 9, the front first reinforcing ridge portion 451f and the front second reinforcing ridge portion 452f each form a front reinforcing ridge portion 45f of the reinforcing member 30. As shown in FIG.

[0118] 10 and 11, the rear-side reinforcement portion 34 extends rearward and inward in the vehicle width direction from a front edge portion of the rear-side reinforcement portion 34, reinforcing the rear side portion 14 of the resin door inner panel 10 so as to cover the rear side portion 14 from the inside in the vehicle width direction. The rear-side reinforcement portion 34 includes a rear first reinforcing ridge portion 451r, a first rear wall reinforcing portion 461r, a rear second reinforcing ridge portion 452r, a rear inner surface reinforcing portion 42r, a rear third reinforcing ridge portion 453r, a second rear wall reinforcing portion 462r, a rear fourth reinforcing ridge portion 454r, and a rear outer surface reinforcing portion 47r.

[0119] The rear first reinforcing ridge portion 451r is disposed facing the rear first ridge portion 151r from the inside and rear side in the vehicle width direction, across a gap, to reinforce the rear first ridge portion 151r. The first rear wall reinforcing portion 461r is disposed facing the first rear wall portion 161r from the rear side, across a gap, to reinforce the first rear wall portion 161r. The rear second reinforcing ridge portion 452r is disposed facing the rear second ridge portion 152r from the inside and rear side in the vehicle width direction, across a gap, to reinforce the rear second ridge portion 152r.

[0120] The rear inner surface reinforcing portion 42r is disposed facing the rear inner surface portion 11r from the inside in the vehicle width direction across a gap, and reinforces the rear inner surface portion 11r. The rear third reinforcing ridge portion 453r is disposed facing the rear third ridge portion 153r from the rear side across a gap, and reinforces the rear third ridge portion 153r. The second rear wall reinforcing portion 462r is disposed facing the second rear wall portion 162r from the rear side across a gap, and reinforces the second rear wall portion 162r.

[0121] The rear first reinforcing ridge portion 451r and the rear third reinforcing ridge portion 453r are formed to protrude inward in the vehicle width direction in response to the respective protruding shapes of the rear first ridge portion 151r and the rear third ridge portion 153r of the resin door inner panel 10 protruding inward in the vehicle width direction. The rear second reinforcing ridge portion 452r is formed to protrude outward in the vehicle width direction in response to the protruding shape of the rear second ridge portion 152r of the resin door inner panel 10 protruding outward in the vehicle width direction. The rear fourth reinforcing ridge portion 454r is also formed to protrude outward in the vehicle width direction.

[0122] Also, as shown in Figure 10, as described above, the rear outer surface reinforcement portion 47r protrudes toward the rear of the vehicle from the vehicle width direction outer edge of the second rear wall reinforcement portion 462r, but the rear edge 47rr extends toward the rear of the vehicle further than the rear edge 162rr of the second rear wall portion 162r of the resin door inner panel 10 so as to form the rear edge 5rr of the integrated door inner panel 5.

[0123] As shown in the same figure, the rear edge 47rr of the rear outer surface reinforcement portion 47r is crimped and joined by a rear edge hem portion 6r (a portion that is hemmed and bent so that the rear edge of the door outer panel 4 is folded back approximately from the outside in the vehicle width direction to the inside in the vehicle width direction and forward) provided on the rear edge of the door outer panel 4.

[0124] Each of the rear first reinforcing ridge portion 451r, the rear second reinforcing ridge portion 452r, the rear third reinforcing ridge portion 453r, and the rear fourth reinforcing ridge portion 454r forms a rear reinforcing ridge portion 45r of the reinforcing member 30. Each of the first rear wall reinforcing portion 461r and the second rear wall reinforcing portion 462r forms a rear reinforcing ridge portion 45r of the reinforcing member 30.

[0125] As described above, the reinforcing member 30 includes a lower reinforcing ridge portion 45d that reinforces the lower ridge portion 15d of the resin door inner panel 10, a front reinforcing ridge portion 45f that reinforces the front ridge portion 15f, and a rear reinforcing ridge portion 45r that reinforces the rear ridge portion 15r. The lower reinforcing ridgeline portion 45d, the front reinforcing ridgeline portion 45f, and the rear reinforcing ridgeline portion 45r are collectively referred to as the reinforcing ridgeline portion 45. That is, the reinforcing ridgeline portion 45 reinforces the inner panel ridgeline portion 15.

[0126] As described above, the front-edge reinforcing portion 33, the bottom-edge reinforcing portion 32, and the rear-edge reinforcing portion 34 of the reinforcing member 30 also have a plurality of reinforcing ridges 45d, 45f, and 45r formed therein corresponding to the ridges 15d, 15f, and 15r of the front edge portion 13, the bottom edge portion 12, and the rear edge portion 14 of the resin door inner panel 10. As a result, as shown in Figures 3 and 4, the reinforcing member 30 has a plurality of reinforcing ridges 45 arranged radially from the center outward in a front view of the door.

[0127] Furthermore, the reinforcing member 30 has at least a lower first reinforcing ridge portion 451d, a front first reinforcing ridge portion 451f, and a rear first reinforcing ridge portion 451r formed continuously to one another in correspondence with the first ridge portion 151 of the resin door inner panel 10. That is, the first reinforcing ridge portion 451 (the lower first reinforcing ridge portion 451d, the front first reinforcing ridge portion 451f, and the rear first reinforcing ridge portion 451r) are formed continuously in a U-shape in a front view of the door along the front edge portion, the rear edge portion, and the rear edge portion of the one-piece door inner panel 5.

[0128] In this way, the reinforcing member 30 has multiple reinforcing ridge portions 45 arranged radially on the outer periphery when viewed from the front of the door, and at least the first reinforcing ridge portion 451 of the multiple reinforcing ridge portions 45 is formed continuously in a U-shape when viewed from the front of the door, thereby increasing the rigidity of the outer periphery of the resin door inner panel 10 against collision loads.

[0129] The inner panel ridge line portion 15 and the reinforcing ridge line portion 45 that reinforces the inner panel ridge line portion 15 protrude in the same direction, either inward or outward, in the vehicle width direction. For example, when the inner panel ridge line portion 15 and the reinforcing ridge line portion 45 are combined to protrude inward in the vehicle width direction, the inner panel ridge line portion 15 protrudes so as to fit into the reinforcing ridge line portion 45. On the other hand, when the inner panel ridge line portion 15 and the reinforcing ridge line portion 45 are combined to protrude outward in the vehicle width direction, the reinforcing ridge line portion 45 protrudes so as to fit into the inner panel ridge line portion 15.

[0130] The inner panel ridge portion 15 and the reinforcing ridge portion 45 that reinforces the inner panel ridge portion 15 are at least partially aligned in the vertical direction when viewed in a vertical cross section along the vertical direction, and are arranged to face each other with a gap in the vehicle width direction.

[0131] 6 to 11, particularly at the enlarged portions of portion X7 in Fig. 7, portion X9 in Fig. 9, and portions X11a and X11b in Fig. 11, inner panel ridge portion 15 facing reinforcing ridge portion 45 in the vehicle width direction is provided with a protrusion 60 that protrudes toward reinforcing ridge portion 45 (i.e., toward the inside in the vehicle width direction). Note that in this embodiment, of inner panel ridge portion 15 and reinforcing ridge portion 45, protrusion 60 is provided only on inner panel ridge portion 15.

[0132] In the following, the structure of the protrusion 60 and its surroundings will be described, but as shown in the enlarged portion of portion X7 in Figure 7, the protrusion 60 and its surroundings provided on the lower third ridge portion 153d will be used as an example.

[0133] As described above, the protrusion 60 protrudes inward in the vehicle width direction from the inner surface in the vehicle width direction of the lower third ridge line portion 153d serving as the inner panel ridge line portion 15, and is formed integrally with the inner panel ridge line portion 15 during molding of the resin door inner panel 10. The protrusion 60 protrudes with a gap 70a between the tip end 60a in the protruding direction (protrusion top surface 60aa) and the lower third reinforcing ridge line portion 453d serving as the reinforcing ridge line portion 45.

[0134] The protrusion 60 is formed as a continuous ridge along the extension direction of the inner panel ridge 15. Furthermore, the cross section of the protrusion 60 along the protruding direction of the inner panel ridge 15 is formed in a tapered shape (chamfered shape) in which the tip end 60a is narrower than the base end 60b in the protruding direction. Specifically, the protrusion 60 is formed in a truncated cone shape that gradually narrows in the protruding direction and has the tip end 60a having a flat protrusion top surface 60aa.

[0135] As shown in the figure, in a vertical cross section along the up-down direction, the protrusion top surface 60aa of the protrusion 60 is formed along the cross-sectional shape of the surface of the reinforcing member 30 that faces the protrusion top surface 60aa.

[0136] The integral door inner panel 5 is set so that the gap 70 (70a, 70b) between the inner panel ridge portion 15 and the reinforcing ridge portion 45 is smallest at the protrusion top surface 60aa of the protrusion 60 at least in the inner panel ridge portion 15 and its surrounding area 65 when viewed from the front of the door (ta <tb)。

[0137] As described above, the resin door inner panel 10 and the reinforcing member 30 are joined together via the adhesive 80. The adhesive 80 is interposed between the resin door inner panel 10 and the reinforcing member 30 that face each other in the vehicle width direction, and is provided on the inner panel ridge portion 15 and its surrounding area 65 when viewed from the front of the door of the integrated door inner panel 5 (in the up-down and front-rear directions).

[0138] In this embodiment, the adhesive 80 is provided only on the inner panel ridge line portion 15 and its surrounding area 65 in a front view of the door of the integrated door inner panel 5. More specifically, the adhesive 80 is provided continuously in the extension direction of the inner panel ridge line portion 15 only in the gap 70a between the inner panel ridge line portion 15 and the reinforcing ridge line portion 45, and in the gap 70b between the inner panel ridge line portion 15 and the reinforcing ridge line portion 45 in the surrounding area 65 of the inner panel ridge line portion 15.

[0139] 7, adhesive 80 is provided on each of the multiple inner panel ridge portions 15 and their surrounding areas 65. Meanwhile, a layer 68 where no adhesive 80 is present is provided between the multiple inner panel ridge portions 15. This layer 68 where no adhesive 80 is present is located between the multiple inner panel ridge portions 15 in a front view of the door. In this embodiment, the layer 68 where no adhesive 80 is present is hollow, with a gap between the resin door inner panel 10 and the reinforcing member 30 that face each other in the vehicle width direction, but the two members 10, 30 may also be in close contact with each other without a gap between them.

[0140] Here, since the inner panel ridge portion 15 has a protrusion portion 60, the gap 70a in the portion between the inner panel ridge portion 15 and the reinforcing ridge portion 45 and the peripheral region 65 of the intervening portion is set to be smaller (thinner) than the gap 70b in the portion corresponding to at least the protrusion top surface 60aa of the protrusion portion 60 when viewed from the front of the door. Therefore, the adhesive 80 is provided so that the thickness ta at the inner panel ridge line portion 15 is thinner than the thickness tb at the peripheral region 65 of the inner panel ridge line portion 15 when viewed from the front of the door.

[0141] Specifically, the protrusion 60 provided on the inner panel ridge portion 15 is formed in a tapered shape that gradually tapers from the base end 60b in the protruding direction toward the tip end 60a (protrusion top surface 60aa) as described above. Therefore, of the gaps 70a, 70b between the inner panel ridge portion 15 and its surrounding area 65 and the reinforcing member 30, the gap 70a in the area corresponding to at least the protrusion top surface 60aa of the protrusion 60 is set smaller (thinner) than the gap 70b in the area corresponding to the surrounding area 65 of the protrusion top surface 60aa, and is set to gradually become smaller from the gap 70b in the surrounding area 65 of the inner panel ridge portion 15 toward the gap 70a of the protrusion top surface 60aa of the protrusion 60.

[0142] Therefore, when viewed from the front of the door, the adhesive 80 provided continuously in the gaps 70a, 70b between the inner panel ridge portion 15 and its surrounding area 65 is set to gradually become thinner in thickness from the surrounding area 65 of the inner panel ridge portion 15 toward the top surface 60aa of the protrusion 60 provided on the inner panel ridge portion 15.

[0143] Next, an example of a manufacturing method for the front side door 1 of this embodiment will be described. The front side door 1 is manufactured by assembling a resin door inner panel 10 and a reinforcing member 30 together by bonding them with an adhesive 80 to manufacture an integrated door inner panel 5, and then assembling the integrated door inner panel 5 and a door outer panel 4.

[0144] When assembling the integrated door inner panel 5 and the door outer panel 4, as described above, the outer peripheral edge of the reinforcing member 30, which is made of the same aluminum as the door outer panel 4, is crimped and joined using the hem portions (e.g., 6f, 6d, 6r) provided on the outer peripheral edge of the door outer panel 4, thereby assembling both members 4, 5 together.

[0145] The manufacturing method of the integrated door inner panel 5 includes an adhesive application step and a door inner panel assembly step, which are carried out in this order. In the adhesive application process, the adhesive 80 is applied only to the inner panel ridge line portion 15 of the resin door inner panel 10 when viewed from the front of the door. In other words, the adhesive 80 is applied continuously along the inner panel ridge line portion 15 of the multiple convex stripes.

[0146] In the subsequent assembly process, the resin door inner panel 10 and the reinforcing member 30 are assembled so as to be close to each other in the vehicle width direction before the adhesive 80 dries. At this time, the reinforcing member 30 is assembled so as to be pressed from the inside in the vehicle width direction against the adhesive 80 applied only to the inner panel ridge portion 15 of the resin door inner panel 10.

[0147] Because the adhesive 80 has fluidity, when the reinforcing member 30 is pressed against it, it spreads to the peripheral region 65 of the inner panel ridge portion 15. More specifically, when the reinforcing member 30 is pressed against it, the adhesive 80 present in the gap 70a between the protrusion 60 of the inner panel ridge portion 15 and the reinforcing ridge portion 45 facing the protrusion 60 flows so as to be pushed out from the gap 70a into a larger gap 70b in the peripheral region 65 of the inner panel ridge portion 15 (i.e., the protrusion 60).

[0148] By the above-described assembly process, the resin door inner panel 10 and the reinforcing member 30 can be integrally assembled with the adhesive 80 to manufacture the integrated door inner panel 5. That is, the adhesive 80 can be provided only on the inner panel ridge line portion 15 and its surrounding area 65 between the resin door inner panel 10 and the reinforcing member 30, and can be provided so that the thickness ta at the inner panel ridge line portion 15 is thinner than the thickness tb at the surrounding area 65.

[0149] The above-described method for manufacturing the front side door 1 is an example, and the method for manufacturing the door structure of the present invention is not limited to the above-described method. For example, in the adhesive application step, the adhesive 80 is not limited to being applied only to the side of the resin door inner panel 10, but may be applied to at least one of the resin door inner panel 10 and the reinforcing member 30.

[0150] As shown in Figures 1 to 11, the front side door 1 of the vehicle of this embodiment comprises a door outer panel 4, a resin door inner panel 10 (door inner panel) made of resin having an inner surface portion 11 spaced widthwise inward from the door outer panel 4 and extending in the up-down and front-to-rear directions, and a wall portion 16 extending in the vehicle width direction from the end of the inner surface portion 11 via an inner panel ridge portion 15 (ridge portion), a reinforcing member 30 formed of a material different from the resin door inner panel 10 and facing at least the wall portion 161 and the inner panel ridge portion 15 of the resin door inner panel 10 in the vehicle width direction, and an adhesive 80 (see Figures 8 to 11) that bonds the resin door inner panel 10 and the reinforcing member 30.

[0151] Furthermore, for example, as shown in the enlarged portion of portion X7 in Figure 7, adhesive 80 is provided in the inner panel ridge portion 15 and in the peripheral region 65 of the inner panel ridge portion 15 (regions other than the inner panel ridge portion 15), and is characterized in that the thickness ta at the inner panel ridge portion 15 is thinner than the thickness tb at the peripheral region 65 of the inner panel ridge portion 15.

[0152] According to this configuration, as described above, the thickness ta of the adhesive 80 at the inner panel ridge portion 15 is set thinner than the thickness tb of the adhesive 80 at the peripheral region 65, so that the adhesive strength of the adhesive 80 at the inner panel ridge portion 15 can be made higher than that of the peripheral region 65, and in the event of a collision, the reinforcing member 30 adhered to the inner panel ridge portion 15 of the resin door inner panel 10 is less likely to peel off and break, thereby suppressing deformation of the inner panel ridge portion 15.

[0153] Furthermore, the thin adhesive 80 provided on the inner panel ridge portion 15 can increase the bonding strength even when bonding the resin door inner panel 10 to a reinforcing member 30 made of a different material, thereby reducing the amount of adhesive 80 used.

[0154] Furthermore, in the peripheral region 65 other than the inner panel ridge portion 15, the adhesive 80 can be provided so that the thickness tb is thicker than the thickness ta of the adhesive 80 provided in the inner panel ridge portion 15, thereby allowing for thermal deformation under normal conditions between the resin door inner panel 10 and the reinforcing member 30, which have different thermal expansion coefficients.

[0155] Therefore, while reducing the amount of adhesive 80 used to join the resin door inner panel 10 and the reinforcing member 30, which are made of different materials, it is possible to ensure the bonding strength of both members 10, 30 in the event of a collision and to tolerate thermal deformation of both members 10, 30 under normal conditions, which have different thermal expansion coefficients.

[0156] The above-described features of the front side door 1 of this embodiment will now be described in detail in comparison with the problems of conventional front side doors. Generally, when a resin door inner panel is used as the door inner panel for the purpose of weight reduction and its outer periphery is reinforced with a reinforcing member made of a material different from that of the resin door inner panel, the resin door inner panel and the reinforcing member made of different materials are bonded together with an adhesive. In this way, in order to bond the resin door inner panel and the reinforcing member made of different materials while ensuring the desired bonding strength, it is possible to increase the amount of adhesive applied, but this increases costs and may hinder the achievement of a door structure combining different materials.

[0157] Therefore, when the door structure displaces into the passenger compartment during a collision and comes into contact with surrounding body frame members such as side sills, hinge pillars, and center pillars, adhesive is provided only on the inner panel ridge and its surrounding area, where strong shear forces act as it comes into interlocking contact with the body frame members.This allows the resin door inner panel to be bonded to the reinforcing member with pinpoint accuracy at the inner panel ridge and its surrounding area, where strong shear forces act, and the amount of adhesive needed to be applied can be minimized.

[0158] 12(a), when a collision load Fc toward the inside of the vehicle cabin is input to the center of the front side door 110 as viewed from the front during a collision, the outer periphery of the door is displaced toward the inside of the vehicle cabin and comes into contact with the vehicle body frame members 100, 101, and 102 on the vehicle body side. If the rigidity of the outer periphery of the door is not sufficiently ensured, when the outer periphery of the door comes into contact with the vehicle body frame members 100, 101, and 102 as described above, the outer end of the door buckles and curls up outward in the vehicle width direction, as shown in the front side door 110 indicated by the imaginary line in FIG. 12(b), and this may prevent the collision load Fc input to the front side door 110 from being sufficiently transmitted and dispersed toward the vehicle body frame members 100, 101, and 102.

[0159] Therefore, in order to achieve the exoskeleton door concept of suppressing buckling that would cause the outer edge of the door to curl up during a collision and transmitting and dispersing the input collision load Fc to the body frame members 100, 101, and 102 arranged around the door periphery, it is important to ensure the rigidity of the door periphery, increase the support force for the body frame members, and generate the door in-plane tension Ft as shown by the thick arrow in Figure 12(b).

[0160] As mentioned above, providing adhesive 80 only on the inner panel ridge portion 15 and its surrounding area 65 is effective in that it allows for pinpoint bonding at points where strong shear forces act; however, if the thickness of the adhesive provided on the inner panel ridge portion 15 is set to be too thick, the relative displacement between the resin door inner panel and the reinforcing member in response to shear stress during a collision, i.e., shear deformation of the adhesive 80, will increase, which will be disadvantageous in terms of improving adhesive strength.

[0161] In contrast, the front side door 1 of this embodiment has a thin adhesive 80 provided on the inner panel ridge portion 15, so that even if shear stress acts on the inner panel ridge portion 15 of the plastic door inner panel 10 during a collision, the shear stress resistance of the adhesive 80 provided on the inner panel ridge portion 15, i.e., the adhesive strength with the reinforcing member 30 made of a different material, can be increased.

[0162] Therefore, when the front side door 1 displaces into the vehicle interior during a collision and comes into contact with the body frame members 100, 101, 102 arranged on the outer periphery of the front side door 1, deformation of the inner panel ridge portion 15 can be suppressed. For example, during a collision, the lower portion of the front side door 1 is displaced toward the vehicle interior from the state shown in FIG. 6 and comes into contact with the side sill 100, which is a vehicle body frame member, in the early stage of the collision as shown in FIG. 13(a).

[0163] As shown in Figures 13(b) and 13(c), the inner panel ridge portion 15 (15d) is not completely crushed from the early stage of the collision to the later stage of the collision, and the inner panel ridge portion 15 can maintain a state of interlocking contact with the side sill 100 (i.e., a hooked state).

[0164] In this way, the support force of the outer periphery of the front side door 1 against the body frame members 100, 101, and 102 can be secured, thereby achieving the exoskeleton concept of transmitting and dispersing the collision load Fc input to the front side door 1 during a collision to the body frame members 100, 101, and 102.

[0165] In addition, the thickness of the adhesive 80 in the area 65 surrounding the inner panel ridge line 15 is set to be thicker than that of the inner panel ridge line 15, so that the difference in the amount of thermal deformation under normal conditions between the resin door inner panel 10 and the reinforcing member 30, which are made of different materials and therefore have different thermal expansion coefficients, can be tolerated (absorbed) by the thick adhesive 80.

[0166] As a result, the resin door inner panel 10 and the reinforcing member 30, which are made of different materials, can be joined using a minimum amount of adhesive 80, while ensuring the bonding strength of both members 10, 30 in the event of a collision and allowing for thermal deformation of both members 10, 30, which have different thermal expansion coefficients, under normal conditions.

[0167] In one embodiment of the present invention, as shown in Figures 7, 9, and 11, a reinforcing ridge portion 45 is provided in the reinforcing member 30 at a portion facing the inner panel ridge portion 15 on the inside in the vehicle width direction, the reinforcing ridge portion 45 protruding in the same direction as the inner panel ridge portion 15 protruding inward in the vehicle width direction.

[0168] According to this configuration, the reinforcing ridge portion 45, which has the highest strength among the reinforcing members 30, reinforces the resin door inner panel 10, thereby enhancing the reinforcing effect of the reinforcing member 30 on the inner panel ridge portion 15.

[0169] This makes it even more difficult for the adhesive 80 applied to the inner panel ridge portion 15 to peel off during a collision, and even when the front side door 1 displaced into the passenger compartment comes into contact with the body frame members 100, 101, 102 arranged on its outer periphery, the inner panel ridge portion 15 is less likely to deform and can maintain contact with the body frame members 100, 101, 102. Therefore, the effect of dispersing the collision load input to the front side door 1 to the vehicle body frame members 100, 101, 102 can be further improved.

[0170] In one embodiment of the present invention, as shown in Figures 7, 9, and 11, the inner panel ridge portion 15 is provided with a protrusion 60 that protrudes toward the reinforcing ridge portion 45, and the protrusion 60 has a tip end 60a in the protruding direction that protrudes with a gap 70a between it and the opposing reinforcing ridge portion 45.

[0171] According to this configuration, by providing the protrusions 60 on the inner panel ridgeline portion 15 , it becomes easier to set the thickness ta of the adhesive 80 on the inner panel ridgeline portion 15 to be thinner than the thickness tb of the adhesive 80 in the peripheral region 65 .

[0172] In detail, the gap 70 between the inner panel ridge portion 15 and the reinforcing ridge portion 45 corresponds to the gap 70a between the tip 60a of the protrusion 60 provided on the inner panel ridge portion 15 and the reinforcing ridge portion 45, and therefore the thickness ta of the adhesive 80 provided in the gap 70a can be easily set to be thinner than the thickness tb of the adhesive 80 provided in the peripheral region 65 of the inner panel ridge portion 15.

[0173] In an embodiment of this invention, as shown in Figures 7, 9, and 11, the protrusion 60 is provided only on the inner panel ridge portion 15, so that it can be easily provided on the inner panel ridge portion 15 when molding the resin door inner panel 10.

[0174] In one embodiment of the present invention, as shown in Figures 1, 7, 9, and 11, the protrusion 60 is a convex ridge portion that continues along the ridge portion 15 of one of the inner panels, so that the adhesive 80 can be provided continuously along the protrusion 60 and the thickness of the adhesive 80 can be set thin. Therefore, the adhesive 80 provided along the protrusion 60 can increase the adhesive strength between the inner panel ridge portion 15 and the reinforcing member 30 during a collision.

[0175] In one embodiment of the present invention, as shown in Figure 7, the protrusion 60 has a cross section perpendicular to one of the inner panel ridge portions 15 (a cross section along the protruding direction of the protrusion 60) formed in a tapered shape (chamfer shape) in which the tip end 60a is narrower than the base end 60b in the protruding direction.

[0176] With this configuration, when assembling the resin door inner panel 10 and the reinforcing member 30, the tip end 60a of the protrusion 60 can extrude the adhesive 80 between the opposing reinforcing member 30 and toward the peripheral region 65 of the protrusion 60. This makes it possible to reduce the thickness ta of the adhesive 80 at the tip end 60a of the protrusion 60. Meanwhile, the adhesive 80 extruded toward the peripheral region 65 by the protrusion 60 flows from the tip end 60a of the protrusion 60 toward the base end 60b of the protrusion 60 in a swirling manner while clinging to the protrusion 60, so that the thickness tb of the adhesive 80 in the peripheral region 65 of the protrusion 60 can be reliably set to be thick.

[0177] Therefore, thick and thin portions of the adhesive 80 can be easily and reliably provided at the inner panel ridge portion 15 and its surrounding area 65, making it possible to ensure the bonding strength of both components 10, 30 at the inner panel ridge portion 15 in the event of a collision while also allowing for thermal deformation under normal conditions of both components 10, 30 which have different thermal expansion coefficients.

[0178] In one embodiment of the present invention, as shown in Figures 7, 9, and 11, in a cross section along the protruding direction of the protrusion 60, the tip 60a of the protrusion 60 is provided with a protrusion top surface 60aa that faces the reinforcing ridge 45, and the protrusion top surface 60aa is formed along the surface of the reinforcing ridge 45 that faces the protrusion top surface 60aa. Therefore, an adhesive 80 that is thinner than the surrounding region 65 can be reliably provided between the protrusion 60 and the reinforcing ridge 45 in accordance with the size of the protrusion top surface 60aa.

[0179] As shown in Figures 6 to 11, in one embodiment of the present invention, adhesive 80 is provided only on the inner panel ridge portion 15 and its surrounding area 65 of the inner surface portion 11, inner panel ridge portion 15, and wall portion 16 of the resin door inner panel 10.

[0180] This configuration makes it possible to bond the resin door inner panel 10 and the reinforcing member 30, which are made of different materials, with a minimum amount of adhesive 80 applied (used), while ensuring the bonding strength of both members 10, 30 in the event of a collision and allowing for thermal deformation of both members 10, 30, which have different thermal expansion coefficients, under normal conditions.

[0181] In detail, as shown in Figures 7, 9 and 11, when the front side door 1 displaces into the passenger compartment during a collision and comes into contact with the surrounding body frame members 100, 101, 102, the resin door inner panel 10 is provided with adhesive 80 that bonds to the reinforcing member 30 only at the inner panel ridge portion 15 and its surrounding area, where the load received from the body frame members 100, 101, 102 is likely to be concentrated, and the adhesive 80 is set so that the thickness ta at the inner panel ridge portion 15 is thinner than the thickness tb in the surrounding area 65 of the inner panel ridge portion 15. This makes it possible to bond the resin door inner panel 10 and the reinforcing member 30, which are made of different materials, with a minimum amount of adhesive 80 applied, while effectively increasing the bonding strength between the two members 10, 30 during a collision.

[0182] Furthermore, by providing the adhesive 80 so that the thickness tb at the peripheral region 65 of the inner panel ridge portion 15 is thicker than the thickness ta at the inner panel ridge portion 15, it is possible to tolerate thermal deformation under normal conditions of both components 10, 30, which have different thermal expansion coefficients.

[0183] In one embodiment of the present invention, as shown in Figures 6 to 11, multiple inner panel ridge portions 15 are arranged from the center of the resin door inner panel 10 in an out-of-plane direction when viewed from the front of the door, and adhesive 80 is provided on each of the multiple inner panel ridge portions 15, thereby further enhancing the above-mentioned effect of setting the thickness ta of the adhesive 80 thin at the inner panel ridge portions 15, i.e., the effect of increasing the adhesive strength of both components 10, 30 during a collision.

[0184] Therefore, when an object strikes the door outer panel 4, the front side door 1 is displaced into the passenger compartment and comes into contact with the body frame members 100, 101, 102 arranged on the outer periphery of the front side door 1, and the inner panel ridge portion 15 can be brought into engagement with the body frame members 100, 101, 102, thereby improving the efficiency of transmission of the collision load.

[0185] As an embodiment of this invention, as shown in Figures 7, 9, and 11, a layer 68 without adhesive 80 is provided between the resin door inner panel 10 and the reinforcing member 30 and between the multiple inner panel ridge portions 15, thereby significantly reducing the amount of adhesive 80 used and achieving cost reduction.

[0186] This makes it possible to realize the exoskeleton concept of transmitting the collision load input inward in the vehicle width direction during a collision to the surrounding body frame members 100, 101, and 102 in a front side door 1 in which a reinforcing member 30 made of a different material is joined to a resin door inner panel 10.

[0187] The manufacturing method of the front side door 1 of the vehicle of this embodiment involves carrying out, in order, an adhesive application process in which adhesive 80 is applied to the resin door inner panel 10 of the resin door inner panel 10 and the reinforcing member 30, and an assembly process in which the reinforcing member 30 is attached to the resin door inner panel 10 via the adhesive 80 so that they face each other in the vehicle width direction.

[0188] Then, in the adhesive application process, adhesive 80 is applied only to the inner panel ridge line portion 15 in the opposing portion in the vehicle width direction between the resin door inner panel 10 and the reinforcing member 30. Furthermore, in the assembling process, by pressing the reinforcing member 30 against the adhesive 80, the adhesive 80 is deformed (flowed) so as to spread from the inner panel ridge line portion 15 to the peripheral region 65 of the inner panel ridge line portion 15, and the thickness ta at the inner panel ridge line portion 15 is set thinner than the thickness tb at the peripheral region 65.

[0189] This manufacturing method makes it possible to manufacture a front side door 1 for a vehicle that can bond the resin door inner panel 10 and reinforcing member 30, which are made of different materials, with a minimum amount of adhesive 80 applied (used), while ensuring the bonding strength of both members 10, 30 in the event of a collision and allowing for thermal deformation of both members 10, 30, which have different thermal expansion coefficients, under normal conditions.

[0190] In the configuration of this invention and the correspondence between the above-mentioned embodiments, the vehicle corresponds to an automobile, and similarly hereinafter, The door structure corresponds to the front side door 1, The door inner panel is compatible with the resin door inner panel 10. The ridge line corresponds to the inner panel ridge line 15 The reinforcing member ridge portion corresponds to the reinforcing ridge portion 45, but the present invention is not limited to the configuration of the above-described embodiment, and many other embodiments can be obtained.

[0191] For example, in this embodiment, the protrusion 60 is provided only on the inner panel ridge portion 15 out of the inner panel ridge portion 15 and the reinforcing ridge portion 45, but the protrusion of the present invention is not limited to this embodiment and may be provided on the reinforcing ridge portion 45 side or on both.

[0192] Furthermore, the protrusion 60 is provided on almost all of the multiple inner panel ridge portions 15 that face the reinforcing ridge portion 45 in the vehicle width direction, but the protrusion of the present invention may be configured to be provided on at least one of the multiple inner panel ridge portions 15.

[0193] Furthermore, in a vertical cross-sectional view along the vertical direction of the integrated door inner panel 5, the protrusion portion of the present invention may be provided with a width such that at least the top surface 60aa of the protrusion is contained within the inner panel ridge portion 15, and the base end portion 60b (hem portion) in the protruding direction may be provided with a width that exceeds the width of the inner panel ridge portion 15 and reaches the peripheral region 65 of the inner panel ridge portion 15.

[0194] In this embodiment, the adhesive 80 is provided only on the inner panel ridge portion 15 and the peripheral region 65 of the inner panel ridge portion 15, and is arranged so that the thickness ta at the inner panel ridge portion 15 is thinner than the thickness tb at the peripheral region 65. However, in the present invention, for example, the region where the adhesive 80 is provided so that it is thicker than the thickness ta at the inner panel ridge portion 15 is not limited to the peripheral region 65 of the inner panel ridge portion 15, and may be set to a region other than the peripheral region 65.

[0195] In the present invention, the protrusion 60 does not necessarily have to be provided between the inner panel ridge line portion 15 and the reinforcing ridge line portion 45. However, in cases where the protrusion 60 is not provided between the inner panel ridge line portion 15 and the reinforcing ridge line portion 45, it is preferable that the gap 70 between the ridge line portions 15, 45 be set smaller than the gap in other regions. [Explanation of symbols]

[0196] 1...Front side door (door structure) 4...Outer door panel 10...Resin door inner panel (door inner panel) 11...Inner surface 15...Inner panel ridge (ridge) 16...Wall part 161...Wall part 30...Reinforcing member 45... Reinforcement ridge portion (reinforcement member ridge portion) 60…Protrusion 60a...Tip of the protruding portion 60aa...Top surface of protrusion 60b...base end portion in the protruding direction (of the protruding portion) 65...Area surrounding the ridge of the inner panel 68...Layer without adhesive 70a...gap 80...Adhesive ta...thickness at the ridge of the inner panel tb: Thickness of the area around the ridge of the inner panel

Claims

1. Door outer panel, a resin door inner panel having an inner surface portion extending in the up-down and front-rear directions and spaced inward in the width direction from the door outer panel, and a wall portion extending in the vehicle width direction from an end of the inner surface portion via a ridge portion; a reinforcing member formed of a material different from that of the door inner panel and facing at least the wall portion and the ridge portion of the door inner panel in the vehicle width direction; an adhesive that bonds the door inner panel and the reinforcing member, The adhesive is provided on the ridge line portion and in a region other than the ridge line portion, and is provided so that the thickness of the adhesive on the ridge line portion is thinner than the thickness of the adhesive on the region other than the ridge line portion. Vehicle door structure.

2. The ridge line portion is an inner panel ridge line portion, A reinforcing member ridge line portion is provided at a portion of the reinforcing member facing the inner panel ridge line portion on the inner or outer side in the vehicle width direction, the reinforcing member ridge line portion protruding in the same direction as the inner panel ridge line portion protruding inward or outward in the vehicle width direction. The vehicle door structure according to claim 1.

3. At least one of the inner panel ridge line portion and the reinforcing member ridge line portion is provided with a protrusion portion that protrudes toward the other ridge line portion, The protruding portion protrudes with a gap between the tip end in the protruding direction and the other ridge line portion. The vehicle door structure according to claim 2.

4. The protrusion is provided on the ridge of the inner panel. The vehicle door structure according to claim 3.

5. The protrusion is a continuous ridge along at least one of the ridge lines. The vehicle door structure according to claim 3.

6. The protrusion has a cross section of at least one of the ridge lines along the protruding direction formed in a tapered shape such that the tip end is narrower than the base end in the protruding direction. The vehicle door structure according to claim 3.

7. a protrusion top surface facing the reinforcing member is provided on a tip end side of the protrusion in the protrusion direction in a cross section along the protrusion direction, The top surface of the protrusion is formed along the shape of the surface of the reinforcing member that faces the top surface of the protrusion. The vehicle door structure according to claim 3.

8. the other region is a peripheral region of the ridge line portion, The adhesive is provided only on the ridge line portion and its surrounding area among the inner surface portion, the ridge line portion and the wall portion. The vehicle door structure according to claim 1.

9. The ridge line portion is arranged in a plurality of portions from the center of the door inner panel to an outward direction of the surface when viewed from the front of the door, The adhesive is provided on each of the plurality of ridge portions. The vehicle door structure according to claim 1.

10. A layer where the adhesive is not present is provided between the plurality of ridges between the door inner panel and the reinforcing member. The vehicle door structure according to claim 9.

11. Door outer panel, a resin door inner panel having an inner surface portion extending in the up-down and front-rear directions and spaced inward in the width direction from the door outer panel, and a wall portion extending in the vehicle width direction from an end of the inner surface portion via a ridge portion; a reinforcing member formed of a material different from that of the door inner panel, an adhesive application step of applying an adhesive to the door inner panel; an assembling step of assembling the reinforcing member to the door inner panel by bonding it to the door inner panel via the adhesive so as to face each other in the vehicle width direction; In the adhesive application step, the adhesive is applied only to the ridge line portion in the opposing portion between the door inner panel and the reinforcing member in the vehicle width direction, In the assembling step, the reinforcing member is pressed against the adhesive, thereby deforming the adhesive so as to spread from the ridge line portion to a peripheral region of the ridge line portion, so that the thickness of the ridge line portion is thinner than the thickness of the peripheral region. A method for manufacturing a vehicle door structure.

12. a protrusion portion is provided on the ridge line portion, the protrusion portion protruding toward the reinforcing member and having a tip end portion in a protruding direction protruding with a gap between the protrusion portion and the reinforcing member; The thickness at the ridge line portion is the thickness at the protrusion portion, and the thickness at the peripheral region of the ridge line portion is the thickness at the peripheral region of the protrusion portion. The method for manufacturing a vehicle door structure according to claim 11.

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