Abstract: A vehicle door system includes a door with a door module and a hinge module. The hinge module is attached to the vehicle body. The door module is attached to the hinge module. The hinge module includes a hinge bracket attached to the vehicle body, and a pair of arms extending from the hinge bracket that can pivot relative to the hinge bracket and a cross brace attached at the ends of the arms. The door module attaches to the cross brace. The door module moves along with the cross brace, which moves along with the arms as they pivot relative to the hinge bracket. The door module includes a latch mechanism at a bottom edge, with the latch mechanism engaging with the vehicle body. A lateral edge of the door may seal against a lateral edge of the second door without a latch interface.

Abstract: A vehicle door system includes a door with a door module and a hinge module. The hinge module is attached to the vehicle body. The door module is attached to the hinge module. The hinge module includes a hinge bracket attached to the vehicle body, and a pair of arms extending from the hinge bracket that can pivot relative to the hinge bracket and a cross brace attached at the ends of the arms. The door module attaches to the cross brace. The door module moves along with the cross brace, which moves along with the arms as they pivot relative to the hinge bracket. The door module includes a latch mechanism at a bottom edge, with the latch mechanism engaging with the vehicle body. A lateral edge of the door may seal against a lateral edge of the second door without a latch interface.

Abstract: A door assembly for a vehicle is provided. The door assembly includes an inner panel and an outer panel which are joined together to define a central space therebetween. The central space has a front which faces towards the front of a vehicle and a back which faces towards a back of the vehicle. Both the inner and outer panels are made of aluminum, and at least one reinforcement beam made of steel is disposed in the central space between the aluminum inner and outer panels to provide the door assembly with increased impact resistance.

Abstract: The invention provides a method of joining dissimilar materials, such as aluminum to steel, by applying low pressure and heat to minimize distortion of the materials and the heat affected zone. The method includes applying current to a weld element, at least partially melting a portion of the first material with the heated weld element, and passing through the at least partially melted portion of the first material with the weld element. The method further includes contacting the second material with the heated weld element, and melting a portion of the weld element and a portion of the second material in contact with one another to form a weld. The weld element is designed with a head to trap the first material between the head and the second material, and a vent for receiving the at least partially melted first material as the weld element passes through.

Abstract: A door assembly for a vehicle is provided. The door assembly includes an inner panel and an outer panel which are joined together to define a central space therebetween. The central space has a front which faces towards the front of a vehicle and a back which faces towards a back of the vehicle. Both the inner and outer panels are made of aluminum, and at least one reinforcement beam made of steel is disposed in the central space between the aluminum inner and outer panels to provide the door assembly with increased impact resistance.