Composite door assembly

DETAILED DESCRIPTION The present invention is primarily concerned with greatly reducing the total number of parts necessary to make vehicle doors which are structurally sound, attractive, and easy to manufacture.
In accordance with the teachings of the present invention, the composite vehicle door assembly has substantially fewer parts than conventional vehicle door assemblies.
The composite vehicle door structure includes a tailored steel inner panel, a composite or plastic outer body panel, as well as a belt-line reinforcement member which separates the inner and outer door panels along the bottom edge of the window opening and an intrusion beam.
The tailored inner panel and plastic outer panel can be adhered together in various ways under the present invention.
The belt-line reinforcing member is disposed between the inner and outer door panels to enhance the shock absorbing characteristics of the vehicle door during a collision.
The reinforcing member also provides for proper spacing between the inner and outer door panels.
One of the advantages of the present invention, therefore, is a decrease in the unit cost of the vehicle door.
By reducing the number of parts which make up the vehicle door structure and the assembly of parts, the amount expended for producing the vehicle door structure, as well as labor costs, will be reduced.
Another advantage of the present invention is a reduction inventories and inventory costs.
Yet another advantage of the present invention is a reduction in the weight of the vehicle door structure.
This translates into better fuel efficiency which, in turn, means cost savings to the consumer.
It is still another advantage of the present invention to provide an improved reinforcing construction of a vehicle door which has the ability to absorb or distribute deformation loads which result from collisions.