Title: Window assembly for a motor vehicle
Abstract: The liftgate for a motor vehicle includes a frame member, an inner panel, and an outer panel. The frame member is a U-shaped member formed by a cross member and a pair of spaced apart legs extending from the cross member. The inner panel is connected to the legs and extends part way up the legs of the frame member. The outer panel is connected to the inner panel and is positioned opposite the legs and an inner side of the inner panel. The outer panel also extends part way up the legs of the frame member. The frame member defines a window opening with the inner panel and the outer panel. The frame member forms the entire upper portion of the liftgate.
Patent Number: 7,011,357 Issued on 03/14/2006 to Seksaria, et al.
| Inventors:
|
Seksaria; Dinesh C. (Novi, MI);
Cobes; John W. (Lower Burrell, PA)
|
| Assignee:
|
Alcoa Inc. (Pittsburgh, PA)
|
| Appl. No.:
|
996784 |
| Filed:
|
November 24, 2004 |
| Current U.S. Class: |
296/146.2; 296/56; 296/154; 296/146.8; 296/146.12 |
| Current Intern'l Class: |
B60J 1/18 (20060101); B60J 5/10 (20060101) |
| Field of Search: |
296/56,154,146.2,146.8,146.11,146.12,91
|
References Cited [Referenced By]
U.S. Patent Documents
| 5449213 | Sep., 1995 | Kiley et al.
| |
| 5944373 | Aug., 1999 | Seksaria et al.
| |
| 5947536 | Sep., 1999 | Mizuki et al.
| |
| 6000747 | Dec., 1999 | Sehgal et al.
| |
| 6003931 | Dec., 1999 | Dancasius et al.
| |
| 6053562 | Apr., 2000 | Bednarski.
| |
| 6123384 | Sep., 2000 | Eustache et al.
| |
| 6234564 | May., 2001 | Kim.
| |
| 6659583 | Dec., 2003 | Scheid.
| |
| 6733063 | May., 2004 | Paiva et al.
| |
| 2002/0046505 | Apr., 2002 | Seksaria et al.
| |
| 2003/0085589 | May., 2003 | Oberheide.
| |
Primary Examiner: Morrow; Jason
Attorney, Agent or Firm: Maivald; David P., Eckert Seamans Cherin & Mellott, LLC
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATION
The present application is a divisional of and claims priority from U.S. Ser.
No. 10/310,322 filed Dec. 5, 2002, entitled "DOOR FOR A MOTOR VEHICLE," now U.S.
Pat. No. 6,860,537.
This application claims the benefit of U.S. Provisional Application Ser. No.
60/338,177 filed Dec. 5, 2001, and entitled "Lightweight Multiproduct Vehicle Liftgate,
Hinge and Method", the disclosure of which is incorporated fully herein.
Claims
What is claimed is:
1. A window assembly for a vehicle door, comprising:
a window for covering a window opening in the vehicle door;
at least one hinge comprising a first member, a second member configured to pivotally
connect the vehicle door to the body of a vehicle, a third member, and a spring
structured to provide a lift assist function for the window assembly, the first
and third members each individually pivotally associated with the second member; and
a valance connected to the window, the valance mounted to the third member for
enabling pivotal movement of the window and valance independent of the vehicle door.
2. The window assembly of claim 1, the valance comprising an integrally formed
air deflector extending downward along the window.
3. The window assembly of claim 1, further comprising at least one wiper motor
and blade assembly mounted through the window and connected to the valance.
4. The window assembly of claim 1, further comprising at least one wiper motor
and blade assembly mounted to the valance and positioned between the valance and
an outer side of the window.
5. The window assembly of claim 1, further comprising at least one window latch
mounted to the window for locking the window to the vehicle door.
6. The window assembly of claim 1, further comprising a brake light for a vehicle
mounted to the valance.
7. A method of assembling a window assembly for a vehicle door, comprising the
steps of:
providing a window for covering a window opening in the vehicle door;
attaching a valance to the window;
providing at least one hinge comprising a first member, a second member configured
to pivotally connect the vehicle door to the body of a vehicle, a third member,
and a spring structured to provide a lift assist function for the window assembly,
the first and third members each individually pivotally associated with the second
member; and
mounting the valance to the third member for enabling pivotal movement of the
window and valance independent of the vehicle door.
8. The method of claim 7, further comprising the steps of mounting at least one
wiper motor and blade assembly through the window and connecting the at least one
wiper motor and blade assembly to the valance.
9. The method of claim 7, further comprising mounting at least one wiper motor
and blade assembly to the valance between the valance and an outer side of the window.
10. The method of claim 7, further comprising the step of mounting at least one
window latch to the window for locking the window.
11. A window assembly for a vehicle door, comprising:
a window for covering a window opening in the vehicle door;
at least one hinge comprising a first member, a second member configured to pivotally
connect the vehicle door to the body of a vehicle, and a third member, the first
and third members each individually pivotally associated with the second member;
a valance connected to the window, the valance mounted to the third member for
enabling pivotal movement of the window and valance independent of the vehicle
door; and
at least one wiper motor and blade assembly mounted through the window and connected
to the valance.
12. A window assembly for a vehicle door, comprising:
a window for covering a window opening in the vehicle door;
at least one hinge comprising a first member, a second member configured to pivotally
connect the vehicle door to the body of a vehicle, and a third member, the first
and third members each individually pivotally associated with the second member;
a valance connected to the window, the valance mounted to the third member for
enabling pivotal movement of the window and valance independent of the vehicle
door; and
at least one wiper motor and blade assembly mounted to the valance and positioned
between the valance and an outer side of the window.
13. A method of assembling a window assembly for a vehicle door, comprising the
steps of:
providing a window for covering a window opening in the vehicle door;
attaching a valance to the window;
providing at least one hinge comprising a first member, a second member configured
to pivotally connect the vehicle door to the body of a vehicle, and a third member,
the first and third members each individually pivotally associated with the second member;
mounting the valance to the third member for enabling pivotal movement of the
window and valance independent of the vehicle door; and
mounting at least one wiper motor and blade assembly through the window and connecting
the at least one wiper motor and blade assembly to the valance.
14. A method of assembling a window assembly for a vehicle door, comprising the
steps of:
providing a window for covering a window opening in the vehicle door;
attaching a valance to the window;
providing at least one hinge comprising a first member, a second member configured
to pivotally connect the vehicle door to the body of a vehicle, and a third member,
the first and third members each individually pivotally associated with the second member;
mounting the valance to the third member for enabling pivotal movement of the
window and valance independent of the vehicle door; and
mounting at least one wiper motor and blade assembly to the valance between the
valance and an outer side of the window.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to motor vehicles, such as passenger
cars, light trucks, sport utility vehicles, mini-vans, and other similar vehicles.
More particularly, the present invention relates generally to liftgates for such
motor vehicles and, even more particularly, to a lightweight, aluminum, and thin
profile liftgate for motor vehicles.
2. Description of Related Art
Liftgates are installed in several types of motor vehicles including mini-vans,
sport utility vehicles, hatchback cars, and other similar vehicles. They are used
most prominently in mini-vans. Liftgates provide access to a rear storage compartment
generally found in these vehicles.
Current liftgates are typically assembled from two deep-drawn steel sheet
panels and a number of stamped steel sheet reinforcement panels, which are resistance
spot-welded to the deep-drawn steel sheet panels. This method of construction utilizes
the steel sheet panels primarily to meet required stiffness and strength requirements
for the liftgate. Liftgates made by this construction method are thick in cross
section, typically measuring five to six (5-6) inches at their thickest point.
The thickness of such prior art liftgates takes away from the available cargo space
in the rear storage compartment of the vehicle. Additionally, the increased weight
of the liftgate made by this construction method makes it difficult to open and
close the liftgate, which requires vehicle manufacturers to add various lift assist
devices to aid in raising the liftgate. Vehicle manufactures are extremely sensitive
to vehicle weight because of government mandates for fuel economy and emissions,
which makes the use of heavy liftgates disadvantageous.
The current method of construction for liftgates requires that the latch and
other hardware associated with the liftgate be installed on the liftgate by inserting,
fastening, and connecting a number of individual components in the cavity defined
between the steel sheet panels. Generally, the individual components are assembled
through holes punched in the steel sheet panels. This process is difficult, slow,
and is error prone, which results in significant repair and warranty costs, and
further results in dissatisfied customers. Additionally, the confined and narrow
spaces within which the assembly line workers or service technicians must operate
occasionally cause injuries to these workers.
A recent development in liftgate design incorporates a flip glass, which may
be
flipped upward for access to the rear storage compartment without having to lift
the heavy liftgate itself. A rear glass wiper motor assembly is typically mounted
along the bottom center edge of the flip glass. The flip glass requires a latching
mechanism to lock the flip glass to the liftgate. The latching mechanism is also
typically mounted along the bottom center edge of the flip glass. A safety brake
light is typically mounted along the top center edge of the flip glass. The flip
glass design currently used in the automotive industry further requires the use
of a second pair of hinges to attach the flip glass to the liftgate, as well as
an additional lift assist mechanism for pivoting the flip glass upward to allow
access to the rear storage compartment. The current flip glass design known in
the art results in a non-smooth surface in the rear of the vehicle, which negatively
effects vehicle styling and increases aerodynamic drag. Additionally, this type
of construction requires a large window frame, which reduces visibility through
the liftgate window. This reduces safety while driving the vehicle, for example,
when looking for vehicles approaching from the rear. The reduced visibility is
also a significant drawback when backing up the vehicle, for example, while parking
the vehicle.
Attempts have been made in the automotive industry to reduce the weight
of vehicle body panels by using lighter weight construction materials, such as
aluminum and plastic. For example, U.S. Pat. No. 5,449,213 to Kiley et al. discloses
an aluminum movable liftgate having a tubular frame located between a pair of inner
panels and a pair of outer panels. The frame functions as the load-bearing structure
for the liftgate. However, no provision is made in the disclosed liftgate for hardware
or for contour and other design preferences for a liftgate installed at the rear
of a vehicle. Further, this liftgate does not include flip glass and other design
features that are preferred by customers in the marketplace. The disclosure of
U.S. Pat. No. 5,449,213 to Kiley et al. is incorporated herein by reference.
Another example of an attempt to reduce the weight of vehicle body panels
is disclosed in U.S. Pat. No. 6,003,931 to Dancasius et al. This reference discloses
a swiveling or sliding hatchback for a vehicle that incorporates materials having
lower weight to reduce the overall weight of the hatchback. The hatchback includes
a continuous frame element and inner and outer skins mounted on the frame element.
The inner and outer skins are formed of light metal or plastic and are reinforced
with reinforcing ribs.
A further example of the trend toward reducing the weight of vehicle body panels
is disclosed in U.S. patent application Publication No. 2002/0046505A1 to Seksaria
et al., the disclosure of which is incorporated herein by reference. This publication
discloses a sliding door for a mini-van that is comprised of a rectangular shaped
space frame and inner and outer door panels attached to the space frame. Hardware
for operation of the sliding door is mounted on the exposed inside surface of the
sliding door.
Accordingly, a need remains for a thin, lightweight liftgate that maximizes
vehicle interior space but also allows ready access to the rear storage compartment
in a vehicle such as a mini-van, sport utility vehicle, hatchback car, and other
similar vehicles.
SUMMARY OF THE INVENTION
The present invention is a vehicle door, preferably in the form of a liftgate
for a vehicle such as a mini-van, sport utility vehicle, hatchback car, and other
similar vehicles. The vehicle door is generally comprised of U-shaped frame member,
an inner panel, and an outer panel. The frame member, the inner panel, and the
outer panel may be made from a variety of materials including aluminum, steel,
and plastic, with aluminum being preferred. The frame member is preferably U-shaped
and comprises a cross member and a pair of spaced apart legs extending from the
cross member. The frame member primarily carries the structural load in the vehicle
door. The inner panel has an inner side and an outer side. The outer side is connected
to the legs of the frame member. The inner panel preferably extends only part way
up the legs of the frame member. The outer panel is connected to the inner panel
and is positioned opposite the legs of the frame member and the outer side of the
inner panel. The outer panel preferably extends only part way up the legs of the
frame member.
The frame member generally performs the function of carrying the structural load
of the liftgate. The frame member also provides mounting locations for supporting
several functional components used on the liftgate, such as hinges and lift assist
mechanisms, as discussed further herein. The hinges attached to the frame member
are used to attach the vehicle door to the body of a vehicle. Once assembled, the
maximum thickness of the vehicle door is preferably about 35 millimeters. At least
one of the frame member, the inner panel, and the outer panel is preferably formed
from aluminum.
The frame member may comprise a tube, preferably a hydroformed steel or aluminum
tube. The tube may be formed with different cross sectional profiles along its
length, which provide convenient mounting locations for attaching the functional
hardware mentioned previously (i.e., hinges and lift assist mechanisms, etc.).
The inner panel may define at least one depression in the inner side for increased
strength and rigidity. The at least one depression forms at least one raised portion
on the outer side having at least one contact surface facing an inner side of the
outer panel. The vehicle door may further comprise at least one cushioning member
positioned between the at least one contact surface and the inner side of the outer
panel to connect the inner and outer panels. The outer side of the inner panel
may define a pair of recesses for receiving the legs of the frame member. Preferably,
the legs of the frame member are connected fixedly in the recesses.
The vehicle door may comprise a locking hardware assembly connected to the inner
side of the inner panel for locking the vehicle door to the vehicle body. The locking
hardware assembly may comprise a hardware carrier and a pair of door locking mechanisms
mounted to the hardware carrier, preferably substantially at opposite ends of the
hardware carrier. The hardware carrier is preferably connected fixedly to the inner
side of the inner panel.
The vehicle door may further comprise at least one hinge connected to the frame
member, for example the cross member. The at least one hinge may comprise a first
member, a second member configured to pivotally connect the vehicle door to the
vehicle body, and a third member. The first member is preferably pivotally associated
with the second member and mounted to the frame member. The third member is preferably
pivotally associated with the first member and supports a window assembly comprising
a window for covering a window opening in the vehicle door. The window opening
is defined by the frame member, the inner panel, and the outer panel. The third
member of the at least one hinge may pivotally associated with the first member
such that the window assembly is pivotal between a first position wherein the window
substantially closes the window opening, and a pivoted second position allowing
access to the window opening. A sealing gasket may be attached to an inner side
of the window for creating a seal between the window, frame member, and outer panel.
The window assembly may further comprise a valance connected to the window. The
valance may be mounted to the third member of the at least one hinge for enabling
pivotal movement of the window assembly independent of the vehicle door. The valance
may comprise an integrally formed air deflector extending downward along the window.
A brake light for the vehicle may be mounted to the valance.
The window assembly may further comprise at least one wiper motor and blade assembly,
which may be mounted through the window and connected to the valance. Alternatively,
the wiper motor and blade assembly may be mounted to the valance and be positioned
between the valance and an outer side of the window. The locking hardware assembly
may further comprise at least one window locking mechanism, which may be configured
to coact with at least one window latch mounted on the window to lock the window.
The window locking mechanism may be mounted to the hardware carrier along a top
end of the hardware carrier.
Additionally, the vehicle door may comprise at least one lift assist
mechanism connected to the frame member. The at least one lift assist mechanism
may have a first end connected to the frame member and a second end configured
for connection to the vehicle body. The lift assist mechanism may be a gas-assist
strut, a powered linear screw strut, and the like.
The present invention is also a window assembly for a vehicle door. The window
assembly generally comprises a window for covering a window opening in the vehicle
door, at least one hinge, and a valance connected to the window. The at least one
hinge preferably comprises a first member, a second member configured to pivotally
connect the vehicle door to the vehicle body, and a third member. The first and
third members may each be individually pivotally associated with the second member.
The valance is preferably mounted to the third member for enabling pivotal movement
of the window and valance independent of the vehicle door. The valance preferably
comprises an integrally formed air deflector extending downward along the window.
The window assembly may include at least one wiper motor and blade assembly mounted
through the window and connected to the valance. Alternatively, the wiper motor
and blade assembly may be mounted to the valance between the valance and the outer
side of the window. The window assembly preferably further comprises at least one
window latch mounted to the window for locking the window to the vehicle door.
Further, the window assembly may include a brake light for the vehicle. The brake
light is preferably mounted to the valance.
The present invention is also a method of assembling a vehicle door. The method
generally comprises the steps of: providing an inner panel having an inner side
and an outer side; providing an outer panel having an inner side and an outer side;
providing a U-shaped frame member comprising a cross member and a pair of spaced
apart legs extending from the cross member; fixing the legs of the frame member
to the outer side of the inner panel, such that the inner panel extends only part
way up the legs of the frame member; and fixing the outer panel to the inner panel
such that the inner side of the outer panel is positioned opposite the legs of
the frame member and the outer side of the inner panel, the outer panel extending
only part way up the legs of the frame member.
The outer side of the inner panel may define a pair of recesses. The step of
fixing the legs of the frame member to the outer side of the inner panel may comprise
positioning the legs of the frame member in the recesses, and fixing the legs in
the recesses. The step of providing the inner panel may comprise stamping the inner
panel from a sheet of material, preferably aluminum. The method may further comprise
the step of forming at least one depression in the inner side of the inner panel,
the at least one depression defining at least one raised portion on the outer side
of the inner panel having at least one contact surface. The method may further
comprise the step of placing at least one cushioning member between the at least
one contact surface and the inner side of the outer panel to connect the inner
and outer panels.
The step of providing the outer panel may comprise stamping the outer panel from
a sheet of material, preferably aluminum. The steps of providing the inner and
outer panels may comprise stamping the inner and outer panels in a single stamping.
The method may further comprise the step of stamping a hardware carrier for supporting
a pair of door locking mechanisms with the inner and outer panels in the single
stamping. The method may further comprise the steps of mounting the door locking
mechanisms substantially at opposite ends of the hardware carrier, and fixing the
hardware carrier to the inner side of the inner panel.
The step of providing the frame member may comprise hydroforming the frame member
from a tube. The step of hydroforming the frame member from the tube may further
comprise forming different cross sectional profiles along the length of the tube.
The tube may be formed from aluminum. The method may further comprise providing
a locking hardware assembly of the vehicle door, and fixing the locking hardware
assembly to the inner side of the inner panel.
The method of assembling the vehicle door may additionally comprise the steps:
of providing a window assembly of the vehicle door, the window assembly comprising
a window for covering a window opening in the vehicle door, at least one hinge
comprising a first member, a second member configured to pivotally connect the
vehicle door to the body of a vehicle, and a third member, the first and third
members each individually pivotally associated with the second member, and a valance
connected to the window and mounted to the third member; and connecting the first
member to the frame member to mount the window assembly to the vehicle door, such
that the window assembly is independently pivotal from the vehicle door.
Further, the method may comprise the step of attaching at least one lift
assist mechanism to the frame member. The lift assist mechanism may have a first
end connected to the frame member and a second end configured for connection to
the vehicle body.
Moreover, the present invention is a method of assembling a window assembly
for a vehicle door, which generally comprises the steps of: providing a window
for covering a window opening in the vehicle door; attaching a valance to the window;
providing at least one hinge comprising a first member, a second member configured
to pivotally connect the vehicle door to the body of a vehicle, the first and third
members pivotally associated with the second member; and mounting the valance to
the third member for enabling pivotal movement of the window and valance independent
of the vehicle door.
The method of assembling the window assembly may further comprise the steps of
mounting at least one wiper motor and blade assembly through the window, and connecting
the at least one wiper motor and blade assembly to the valance. Alternatively,
the at least one wiper motor and blade assembly may be mounted to the valance between
the valance and an outer side of the window. The method of assembling the window
assembly may further comprise the step of mounting at least one window latch to
the window for locking the window to the vehicle door.
A complete understanding of the invention will be obtained from the following
detailed
description when read in conjunction with the accompanying drawing figures wherein
like reference characters identify like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an external view of a vehicle door including a window assembly in
accordance with the present invention;
FIG. 2 is an internal view of the vehicle door of FIG. 1;
FIG. 3 is a front view of an inner side of an inner panel and a frame member
of the vehicle door of FIG. 1;
FIG. 4 is a perspective view of the frame member of the vehicle door of FIG. 1;
FIG. 5 is a front view of an outer side of an outer panel and the frame member
of the vehicle door of FIG. 1;
FIG. 6 is a side view of the vehicle door of FIG. 1;
FIG. 7 is an internal view of the vehicle door of FIG. 1, showing a locking
hardware assembly attached to the inner side of the inner panel and having the
window assembly of the vehicle door removed for clarity;
FIG. 8 is an internal view of the vehicle door of FIG. 7, with a hardware carrier
of the locking hardware assembly removed to show door locking mechanisms of the assembly;
FIG. 9 is an external view of the vehicle door of FIG. 7, with the inner panel
removed for clarity;
FIG. 10 is a perspective view of the locking hardware assembly and frame member
shown in FIG. 9;
FIG. 11 is a perspective view of the vehicle door of FIG. 1, showing a pair
of hinges connected to the frame member and having the window assembly of the vehicle
door removed for clarity;
FIG. 12 is a perspective view of the hinges of FIG. 11 shown detached from the
vehicle door of FIG. 11;
FIG. 13 is an exploded perspective view of one of the hinges shown in FIG. 12;
FIG. 14 is a perspective view of the vehicle door of FIG. 1, showing the window
assembly supported by the vehicle door;
FIG. 15 is a perspective view showing the internal side of the vehicle door
and the window assembly of FIG. 14;
FIG. 16 is a perspective view of the external side of the window assembly of
FIGS. 14 and 15;
FIG. 17 is a perspective view of the internal side of the window assembly of
FIGS. 14 and 15; and
FIG. 18 is a perspective view of the vehicle door of FIGS. 14 and 15, showing
a window of the window assembly in an open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of the description hereinafter, the terms "upper", "lower", "right",
"left", "vertical", "horizontal", "top", "bottom", and derivatives thereof shall
relate to the invention, as it is oriented in the drawing figures. However, it
is to be understood that the invention may assume various alternative variations
and step sequences except where expressly specified to the contrary. It is also
to be understood that the specific devices and processes illustrated in the attached
drawings and described in the following specification are simply exemplary embodiments
of the invention. Hence, specific dimensions and other physical characteristics
related to the embodiments disclosed herein are not to be considered as limiting.
Additionally, in this disclosure, the terms "inner" and "outer" and "internal"
and "external" are intended to define the side of an element that faces inward
toward the passenger compartment of a vehicle or facing outward toward the ambient
environment, respectively.
Referring to FIGS. 1-6, a vehicle door
2 in accordance with the
present invention is shown. The vehicle door
2 is preferably in the form
of a liftgate for attachment to the rear end of a motor vehicle, such as a mini-van,
sport utility vehicle, hatchback car, and other similar vehicles. The door
2
is comprised generally of an inner panel
4, an outer panel
6, and
a frame member
8 generally positioned between the inner and outer panels
4,
6. The door
2 is described hereinafter as being manufactured
from aluminum. However, this is not to be limiting as other suitable materials
may be used for the door
2 including steel, plastic, and combinations thereof,
which may include aluminum. The frame member
8 provides the structural support
for the door
2. The closure or panel functions of the door
2 are
provided by the inner and outer panels
4,
6. Thus, the inner and
outer panels
4,
6 are de-coupled from the structural function provided
by the frame member
8.
As stated, the door
2 is preferably in the form of a liftgate used to
enclose
the rear end of a vehicle (not shown), such as a mini-van, as is known in the art.
Specifically, the door
2 is used to enclose the rear storage compartment
of the vehicle. The door
2 of the present invention generally further comprises
a window assembly
10 supported by the frame member
8 and a locking
hardware assembly
12 used to secure or lock the door
2 to the body
of the vehicle, and further to lock the window assembly
10 to the body of
the door. The locking hardware assembly
12 is generally carried on the inner
panel
4 as described further hereinafter.
The inner panel
4 is generally rectangular-shaped and has an inner side
14 and an outer side
16. The inner side
14 generally faces
inward toward the passenger compartment of the vehicle when the door
2 is
mounted to the vehicle body. The outer side
16 of the inner panel
4
faces outward from the vehicle body when the door
2 is mounted to the vehicle
body. The outer side
16 defines a pair of transversely extending recesses
18. The recesses
18 are located generally at opposite lateral ends
20,
22 of the inner panel
4. The inner panel
4 is preferably
formed of aluminum, such as 6022T4E29 aluminum alloy, as designated by the Aluminum Association.
The frame member
8 is preferably in the form of a hydroformed aluminum
tube. The frame member
8 is comprised by a cross member
24 and a
pair of spaced apart legs
26 extending from the cross member
24.
As shown in FIG. 4, the hydroformed aluminum tube comprising the frame member
8
defines different cross sectional profiles
28 along the length of the tube,
which provides mounting locations for various components to be attached to the
frame member
8, as discussed further hereinafter.
The outer panel
6 is generally rectangular-shaped in a similar manner
to the inner panel
4. The outer panel
6 has an inner side
34
and an outer side
36. The inner side
34 generally faces inward toward
the passenger compartment of the vehicle when the door
2 is mounted to the
vehicle body. The outer side
36 of the outer panel
36 faces outward
from the vehicle body when the door
2 is mounted to the vehicle body. The
outer panel
6 is preferably formed of aluminum, such as 6022T4E29 aluminum
alloy as designated by the Aluminum Association. The inner and outer panels
4,
6 may be formed together in a single manufacturing step as discussed further herein.
The legs
26 of the frame member
8 are received in the recesses
18 formed in the outer side
16 of the inner panel
4. Preferably,
the legs
26 are fixed in the recesses
18 by conventional means. Such
conventional means may include, for example, mechanical fasteners, welds, adhesives,
and combinations thereof. As illustrated, the inner panel
4 extends only
part way up the legs
26 of the frame member
8. The outer panel
6
is connected to the inner panel
4 such that the frame member
8 is
located between the inner and outer panels
4,
6. Thus, the inner
side
34 of the outer panel
6 faces the legs
26 of the frame
member
8 and the outer side
16 of the inner panel
4. The outer
panel
6 also extends only part way up the legs
26 of the frame member
8, as illustrated. Thus, the frame member
8 forms the entire upper
portion of the door
2. The inner panel
4, outer panel
6, and
frame member
8 define a window opening
38 of the door
2, which
is covered by the window assembly
10, as discussed hereinafter. The outer
panel
6 is connected to the inner panel
4 along the lateral edges
and bottom edge of the respective panels
4,
6, preferably by hemmed
connections. Spot welding may be used to connect the top edges of the inner and
outer panels
4,
6 to generally form the vehicle door
2.
The inner panel
4 is preferably formed with one or more depressions
40
(shown in FIG. 8) in the inner side
14, which form one or more raised portions
42 on the outer side
16 of the inner panel
4. The raised portions
42 each have a contact surface
44 proximate to the inner side
34
of the outer panel
6. Cushioning members
46 are positioned between
the respective contact surfaces
44 and the inner side
34 of the outer
panel
6 to interconnect the inner and outer panels
4,
6. The
cushioning members
46 are preferably in the form of anti-flutter adhesive
drops, as discussed further hereinafter. The depressions
40 in the inner
panel
4 enhance the strength and rigidity of the inner panel
4, and
support the outer panel
6 when the door
2 is assembled. The inner
and outer panels
4,
6 may also be connected by conventional means
in a license plate area
48 of the door
2, such as by mechanical fasteners,
welds, adhesives, and combinations thereof.
The overall thickness of the door
2 at its widest point is approximately
35 millimeters in accordance with the construction of the inner and outer panels
4,
6 and frame member
8 described hereinabove. This thickness
dimension is in contrast to typical prior art liftgates, which ordinarily have
a thickness in the range of 130-150 millimeters at their deepest point and weigh
approximately twice as much as the door
2 of the present invention. The
small depth or cross sectional profile of the door
2 frees up additional
space in the rear storage compartment of the vehicle and the lighter weight makes
the door
2 easier to manipulate during opening and closing. The savings
in weight further helps to improve the fuel economy of the vehicle.
Referring to FIGS. 7-10, the locking hardware assembly
12 of the
door
2 is connected to the inner side
14 of the inner panel
4.
The locking hardware assembly
12 is comprised generally of a hardware carrier
50 and a pair of door locking mechanisms
52 mounted to the hardware
carrier
50. The hardware carrier
50 may be in the form of a sheet
or plate and may have depressions or recesses formed in the sheet or plate for
mounting elements of the locking hardware assembly
12 thereto and for increased
strength and rigidity. The door locking mechanisms
52 are mounted at opposite
lateral ends
54,
56 of the hardware carrier
50, preferably
on a side
58 of the hardware carrier
50 facing the inner side
14
of the inner panel
4. The hardware carrier
50 is preferably connected
fixedly to the inner side
14 of the inner panel
4 by mechanical fasteners
(i.e., screws). Two locking mechanism
52 are preferred to provide redundancy
and safety. For example, in the event of a rear end collision involving the door
2, two door locking mechanisms
52 provide redundancy in preventing
the door
2 from opening as a result of the collision. The use of two door
locking mechanisms
52 also provides an extra layer of defense against break-ins
to the vehicle.
The door locking mechanisms
52 each include a catch
60. The catches
60 of the door locking mechanisms
52 are engaged by respective latches
(i.e., latch loops, for example—not shown) mounted on the vehicle body to
lock the door
2 to the vehicle body in a known manner. Uniquely, however,
the catches
60 of the door locking mechanisms
52 include wedges
62,
which are connected to the frame member
8, in particular the legs
26
of the frame member
8, and add strength and rigidity to the door
2
in case of a rear impact, or attempted unauthorized entry into the rear storage
compartment of the vehicle. The locking hardware assembly
12 may be pre-assembled
and pre-tested for proper operation prior to being mounted to the door
2,
which improves the quality and reliability of door
2. The modular nature
of the locking hardware assembly
12 also makes maintenance of the locking
hardware assembly
12 easier should this be necessary, for example, at the
dealer level.
Referring to FIGS. 11-13, the door
2 preferably includes a pair
of double-pivoting hinges
70 for mounting the door
2 to the body
of the vehicle. However, the pair of hinges
70 may be replaced by one or
two conventional single-acting (i.e., single pivot axis) hinge in accordance with
the present invention. The hinges
70 are preferably double-pivoting hinges,
which permit independent pivotal movement by the window assembly
10 and
the door
2. Generally, the hinges
70 perform two functions for the
door
2. First, as stated, the hinges
70 mount the door
2 to
the vehicle body and permit the door
2 to pivot with respect to the vehicle
body to open and close the door
2. Second, the hinges
70 mount the
window assembly
10 to the frame member
8 and permit the window assembly
10 to pivot independent of the door
2, which permits access to the
rear storage compartment in the vehicle body without opening the door
2.
The hinges
70 each include a first member
71 configured to be mounted
to the cross member
24 of the frame member
8, preferably by mechanical
fasteners (i.e., screws), as shown. The first members
71 secure the hinges
70 to the frame member
8. The hinges
70 each further include
a second member
72 connected to the first member
71 by a linkage
73. The second members
72 in the hinges
70 are generally configured
to connect or mount the door
2 to the vehicle body. The second member
72
and linkage
73 in each of the hinges
70 are preferably pivotally
connected by mechanical fasteners (i.e., nuts and bolts, for example), as illustrated.
When the window assembly
10 is to be mounted to the vehicle body, the second
members
72 of the hinges
70 are initially mounted to the vehicle
body with, for example, mechanical fasteners (not shown) that cooperate with openings
74 formed in the base of the second members
72. Once the second members
72 are mounted to the vehicle body, the linkages
73 in the hinges
70 are pivoted into engagement with their corresponding second member
72.
The linkage
73 in each of the hinges
70 defines openings
75
in the base of the linkage
73 for receiving the same mechanical fasteners
(i.e., bolts, for example) used to connect the second members
72 to the
vehicle body. Additional mechanical fasteners (i.e., nuts—not shown) are
then used to fixedly connect the linkage
73 and second member
72
in each of the hinges
70. Thus, the base of the linkage
73 is fixedly
secured to the base of the second member
72 in each of the hinges
70.
The first member
71 is pivotally connected to the linkage
73 by a
pin
76 in each of the hinges
70. Hence, the first member
71
is pivotally connected to the second member
72 in each of the hinges
70
via the linkage
73.
The hinges
70 each further include a third member
77 connected
pivotally by the pin
76 to the linkage
73 and, hence, the second
member
72. The pin
76 enables independent pivotal movement by the
first member
71 and the third member
77 about the same pivot axis
(i.e., pin
76) in each of the hinges
70. The third members
77
are generally configured to support the window assembly
10, as discussed
hereinafter. Thus, the first and third members
71,
77 are pivotally
connected to the second member
72 through the linkage
73 in each
of the hinges
70 and pivot independently of each other about the same pivot
axis defined by the pin
76. Torsion springs
78 may be incorporated
into the hinges
70, preferably coaxial to the pins
76, which assist
in opening the window assembly
10, as discussed hereinafter. Additionally,
the third member
77 in each of the hinges
70 is preferably formed
with studs
79 for supporting additional elements of the window assembly
10, as also discussed hereinafter.
Referring to FIGS. 14-18, the window assembly
10 is attached to
the frame member
8 by the hinges
70. Specifically, the window assembly
10 is supported by the independently pivotal third members
77 of
the hinges
70. The window assembly
10 is generally comprised of a
glass rear window
80 and a valance
82. The window
80 is preferably
bonded to the valance
82. The valance
82 and window
80 may
be further connected by studs (not shown), which may be molded into the valance
182 and used to secure the connection between the window
80 and valance
82. The valance
82 is preferably located at the top or upper end
of the window
80. The window assembly
10, as stated, is supported
in the hinges
70 by the third members. In particular, the valance
82
is mounted to the third members
77 of the hinges
70 by the studs
79 (i.e., mechanical fasteners). The studs
79 may be integrally formed
with the third member
77. The valance
82 provides the support structure
for supporting the window
80 and several other elements of the window assembly
10, which are discussed hereinafter. The valance
82 may be formed,
for example, of plastic and may be reinforced with metal structural members.
The torsion springs
78 incorporated into the hinges
70 (i.e., substantially
coaxial to the pivot axis of the third members
77) provide the lift assist
function for the window assembly
10. Specifically, one part or portion
88
(i.e., ends or legs) of the torsion springs
78 acts against the linkage
73 and, hence, second member
72 in each of the hinges
70 and
another part or portion
84 (i.e., middle leg)
84 of the torsion springs
78 acts against the third member
77 to provide the desired lift assist
function. Traditional lift assist mechanisms such as those used in prior art liftgates
having a flip glass are not necessary in the door
2. The lift assist function
for the window assembly
10 is provided effectively by the torsion springs
78 incorporated into the hinges
70.
The window
80 is configured to cover the window opening
38 defined
by the frame member
8 and the inner and outer panels
4,
6.
A sealing gasket
86 may be provided on an inner side
88 of the window
80 for sealing against the frame member
8 and the outer side
36
of the outer panel
6 when the window
80 is in the closed position.
The gasket
86 provides a weather-tight seal for the window
80. FIG.
18 shows the window assembly
10 in an open position with the window
80
pivoted upward allowing access through the window opening
38 to, for example,
the rear storage area of a mini-van.
The valance
82 is generally located at the top or upper end of the window
80 on an outer side
89 of the window
80. The valance
82
preferably includes an integrally formed air deflector
90. The air deflector
90 generally extends downward along the window
80. The air deflector
90, in addition to performing an air-deflecting function for the window
assembly
10, also serves additional functions as discussed hereinafter.
The window assembly
10 preferably further includes a pair of rear window
wiper motor and blade assemblies
92, which are located at the upper end
of the window
80, preferably at the top corners of the window
80.
The wiper motor and blade assemblies
92 are each comprised of a wiper motor
94 and a wiper blade
96. In one embodiment, the wiper motors
94
are located on the inner side
88 of the window
80 and the wiper blades
96 are located on the outer side
89 of the window
80. The
wiper motors
94 and wiper blades
96 are preferably connected through
the window
80. Further, the wiper motor and blade assemblies
92 are
mounted to the valance
82 through the window
80. The valance
82
provides the structural support for the wiper motor and blade assemblies
92.
In particular, the wiper motors
94 have motor shafts
98 that extend
through openings in the window
80, and preferably through openings in the
valance
82. The motor shafts
98 are preferably secured to the valance
82 with mechanical fasteners, which further secures the window
80
and valance
82 in a fixed relationship. Appropriate connections are provided
to the electrical harness of the vehicle for providing power to the wiper motors
94.
In an alternative embodiment, as schematically illustrated in FIG. 16, the wiper
motor and blade assemblies
92 may be mounted directly to the valance
82
and located between the valance
82 and the outer side
89 of the window
80 (i.e., mounted on an inside side or surface of the valance
82
window
80). In this configuration, the motor shafts
98 of the wiper
motors
94 do not extend through the window
80. The wiper motor and
blade assemblies
92 in this embodiment are located entirely externally to
the window
80, again with appropriate connections to the electrical harness
of the vehicle for providing power to the wiper motors
94. In either embodiment
discussed hereinabove, the valance
82 has nozzles and tubing (not shown)
to provide washer fluid to the outer side
88 of the window
80.
The wiper blades
96 are mounted for pivotal movement on the motor shafts
98 in a known manner. Preferably, the wiper motor and blade assemblies
92
are configured such that the arcs of the wiper blades
96 are out of phase
with each other, but result in nearly 100% (i.e., over 90%) glass area cleaning
on the window
80. Additionally, the location of the wiper motor and blade
assemblies
92 provides advantages when opening the window assembly
10
independently from the door
2. In particular, the mass of the wiper motor
and blade assemblies
92 is located near the fulcrum of the window assembly
10 (i.e., proximate to the hinges
70), which reduces the effort required
to pivot the window assembly
10 upward to an open position. Thus, as indicated
previously, lift assist mechanisms such as those used in prior art liftgates having
a flip glass are not necessary. The lift assist function for the window assembly
10 is effectively provided by the torsion springs
78 incorporated
into the hinges
70 and the proximate location of the wiper motor and blade
assemblies
92 to the hinges
70.
The valance
82 preferably extends downward along the window
80
to substantially hide the wiper motor and blade assemblies
92 from view.
In particular, the integrally formed air deflector
90 of the valance
82
extends downward along the window
80 to hide the wiper motor and blade assemblies
92. The hinges
70 are likewise hidden by the valance
82 (i.e.,
air deflector
90) at the top or upper end of the window assembly
10.
The valance
82 with integral air deflector
90 thus improves the appearance
of the door
2 by hiding the functional elements of the window assembly
10.
When not in use, the wiper blades
96 are generally stored behind the valance
82 (i.e., air deflector
90), which prevents damage to the wiper blades
96 and improves the overall appearance of the vehicle incorporating the
door
2 of the present invention. The valance
82 is preferably made
of molded plastic and may include structural members made of metal for improving
the strength of the valance
82.
The locking hardware assembly
12 may further comprise a pair window locking
mechanisms
100 that coact with window latches
101 (i.e., latch loops,
for example) mounted on the inner side
88 of the window
80. The window
latches
101 are mounted on the window
80, preferably at the lower
corners of the window
80, by conventional means, for example with mechanical
fasteners or adhesives. The window locking mechanisms
100 are preferably
mounted to the hardware carrier
50 and coact in a conventional manner with
the window latches
101 to lock the window
80 to the body of the door
2. The window locking mechanisms
100 prevent unauthorized entry into
the vehicle through the window assembly
10. Once again, the use of two window
locking mechanisms
100 provides redundancy and safety in the case of an
accident involving the door
2 and increases the difficulty in breaking into
the vehicle. The locations of the window locking mechanisms
100 and window
latches
101 may be reversed in accordance with the present invention.
The door
2 may further comprise one or more lift assist mechanisms
102
to assist a driver or passenger of the vehicle in lifting the door
2 to
the open position. FIGS. 15 and 18 illustrate two possible lift assist mechanisms
102 for the door
2 in accordance with the present invention. The
left side lift assist mechanism
102 is in the form of a conventional gas-assist
strut. The right side lift assist mechanism
102 is illustrated as a powered
linear screw strut. Either lift assist mechanism
102 may be used in the
door
2 of the present invention. For example, the door
2 may include
one or two gas-assist strut lift assist mechanisms
102, or one or two powered
linear screw strut lift assist mechanisms
102 in accordance with the present
invention. Additionally, the door
2 may include one gas-assist strut lift
assist mechanism
102 and one powered linear screw strut lift assist mechanism
102. The powered linear screw strut embodiment of the lift assist mechanism
102 must be connected to a source of electrical power (i.e., the vehicle's
electrical harness), and may be used to remotely open the door
2. The lift
assist mechanisms
102 each include a first end
104 that is mounted
to the frame member
8 and, preferably, the cross member
24 of the
frame member
8. The first end
104 is preferably pivotally connected
to the frame member
8. A second end
106 of the lift assist mechanisms
102 is preferably configured to connect the lift assist mechanism
102
to the vehicle body. The frame member
8, as discussed previously, is preferably
formed with different cross section profiles
28, which provide locations
for mounting various components of the door
2 to the frame member
8.
Such elements include, for example, the hinges
70 and the lift assist mechanisms
102 discussed hereinabove.
The assembled door
2 of the present invention is approximately 35 millimeters
in thickness at its thickest point, which is significantly thinner than prior art
liftgates as indicated previously. Additionally, the use of lightweight aluminum
for the various components of the door
2, particularly the inner and outer
panels
4,
6 and frame member
8, provides a significant saving
in weight in comparison to prior art liftgates that are primarily made from steel
stampings. When installed on a vehicle, such a thin and lightweight door
2
provides more interior space within the vehicle thereby creating additional cargo
carrying capacity.
Further, the door
2 of the present invention is more easily manufactured
than prior art liftgates, particularly during the mounting of the locking hardware
to the door
2. All mechanical aspects of the locking hardware assembly
12
are pre-assembled in a "cassette" or "module", the components of which may be tested
and adjusted for performance, quality, and reliability before the locking hardware
assembly
12 is mounted to the inner side
14 of the inner panel
4.
Once the locking hardware assembly
12 is mounted to the inner side
14
of the inner panel
4, a decorative finishing trim panel (not shown) made
of fabric, plastic, and the like is easily mounted to the inner side
14
of the inner panel
4 to cover the locking hardware assembly
12.
Moreover, the window assembly
10 of the present invention provides
a convenient and user-friendly way of accessing the window opening
38 defined
by the frame member
8 and the inner and outer panels
4,
6.
The valance
82 of the window assembly
10 is formed to hide the functional
aspects of the window assembly
10, such as the wiper motors
94, wiper
blades
96, and the hinges
70, further enhancing the overall appearance
of the door
2. Other components of the vehicle, such as a rear brake safety
light
108, may also be incorporated into the window assembly
10.
For example, the brake light
108 may be connected to the valance
82
(i.e., air deflector
90) of the window assembly
10. The components
of the window assembly
10, such as the wiper motor and blade assemblies
92, window locking mechanisms
100, and brake light
108 may
be pre-tested on the window assembly
10 prior to attaching the window assembly
10 to the door
2. Thus, the window assembly
10 is a distinct
module in a similar manner to the locking hardware assembly
12, which may
be pre-assembled and pre-tested prior to being assembled to the door
2.
The "modular" nature of the window assembly
10 and locking hardware assembly
12 improves the overall quality and reliability of the door
2 of
the present invention.
The present invention is also a method of assembling the door
2. The method
may comprise the steps of (1) providing the inner and outer panels
4,
6;
(2) providing the U-shaped frame member
8; (3) fixing the legs
26
of the frame member
8 to the outer side
16 of the inner panel
4,
such that the
