Abstract: A vehicle door assembly includes a door inner panel that has a header portion that at least partially defines a window opening. A reinforcement panel is configured to abut the door inner panel along the header portion and further defines the window opening. The door inner panel and the reinforcement panel each have a respective first flange extending at least partially outboard and a respective second flange extending at least partially inboard. The first flange of the door inner panel abuts the first flange of the reinforcement panel and the second flange of the door inner panel abuts the second flange of the reinforcement panel. A trim member is secured to the reinforcement panel and to the header portion to cover the second flanges without contacting the second flanges and has an inboard-facing planar portion as a furthest inboard extent of the trim member.

Abstract: In accordance with exemplary embodiments, a system for isolating magnesium components from fastener devices is provided to prevent corrosion. The system comprises an isolation member of a metal other than magnesium and configured within a hole for receiving the fastener formed in a magnesium component. A compressible sealing washer having a first diameter is positioned over the hole and an isolation washer having a second diameter being less than the first diameter, and consisting of a similar metal as the isolation member, is placed over the compressible sealing washer. The fastener passes through the isolation washer, the compressible sealing washer and the isolation member within the hole, where is it tightened to compress the compressible sealing washer between the isolation member and isolation washer forming a water-tight seal around the hole to resist corrosion of the magnesium component.

Abstract: A vehicle door assembly includes a door inner panel that has a header portion that at least partially defines a window opening. A reinforcement panel is configured to abut the door inner panel along the header portion and further defines the window opening. The door inner panel and the reinforcement panel each have a respective first flange extending at least partially outboard and a respective second flange extending at least partially inboard. The first flange of the door inner panel abuts the first flange of the reinforcement panel and the second flange of the door inner panel abuts the second flange of the reinforcement panel. A trim member is secured to the reinforcement panel and to the header portion to cover the second flanges without contacting the second flanges and has an inboard-facing planar portion as a furthest inboard extent of the trim member.

Abstract: A lock indicator arm for a door having a latch mechanism includes a rod portion connectable on a first end to the latch mechanism, and a knob portion located on a second end of the rod portion opposite the first end and formed as a one-piece structure with the rod portion. The rod portion may include a spring region configured to bias the rod portion against either an interior panel, an exterior panel, or both panels. The knob portion and the rod portion of the lock indicator arm may be formed from a matrix material and a filler material. The filler material may include a plurality of fibers, and the plurality of fibers may be oriented substantially longitudinally along the rod portion. The rod portion of the lock indicator arm may have one of an H-shape cross section and a W-shape cross section.

Abstract: In accordance with exemplary embodiments, a system for isolating magnesium components from fastener devices is provided to prevent corrosion. The system comprises an isolation member of a metal other than magnesium and configured within a hole for receiving the fastener formed in a magnesium component. A compressible sealing washer having a first diameter is positioned over the hole and an isolation washer having a second diameter being less than the first diameter, and consisting of a similar metal as the isolation member, is placed over the compressible sealing washer. The fastener passes through the isolation washer, the compressible sealing washer and the isolation member within the hole, where is it tightened to compress the compressible sealing washer between the isolation member and isolation washer forming a water-tight seal around the hole to resist corrosion of the magnesium component.

Abstract: A lock indicator arm for a door having a latch mechanism includes a rod portion connectable on a first end to the latch mechanism, and a knob portion located on a second end of the rod portion opposite the first end and formed as a one-piece structure with the rod portion. The rod portion may include a spring region configured to bias the rod portion against either an interior panel, an exterior panel, or both panels. The knob portion and the rod portion of the lock indicator arm may be formed from a matrix material and a filler material. The filler material may include a plurality of fibers, and the plurality of fibers may be oriented substantially longitudinally along the rod portion. The rod portion of the lock indicator arm may have one of an H-shape cross section and a W-shape cross section.