Abstract: In a vehicle door structure, a beam member (21) having a S-shaped cross section and extending in a fore-and-aft direction of a vehicle body is attached to an inner panel (15), and the upper edge of the inner panel (15) is formed by the beam member (21). Thereby, a crash load of a frontal crash is transmitted in a favorable manner, and energy of a side impact is adequately absorbed without incurring a cost increase or a weight increase owing to the use of the door beam.

Abstract: In another embodiment of the disclosure, there is provided an access door assembly for joining to a structure. The access door assembly has an access door with at least one access door nonlinear edge. The access door assembly further has a support structure with at least one support structure nonlinear edge. The access door assembly further has a doubler element attached to an interior side of the support structure. The support structure nonlinear edge is designed to interlace with the access door nonlinear edge to form an access door assembly for joining to a structure, the access door assembly having an interlaced nonlinear edge interface. A diameter of the doubler element of the access door assembly is preferably reduced as compared to a diameter of a doubler element of an access door assembly having a linear or circular edge, such that the reduced diameter preferably results in an overall reduced weight of the access door assembly and the structure to which the access door assembly is joined.

Abstract: A motor vehicle is provided with a sliding door, which has an inner side facing the vehicle interior, on which a protruding armrest is disposed. The sliding door can be displaced from a closed position in which the entry opening is closed by the sliding door, within the scope of an opening process via an intermediate position in which the sliding door is outwardly offset with respect to an adjoining vehicle wall, into an open position in which the inner side of the sliding door is disposed opposite to the outer side of the vehicle wall. Within the scope of the opening process the protruding armrest can be moved automatically from a usage position into a non-usage position in which the protruding armrest is set back with respect to the usage position in the direction of the inner side of the sliding door.

Abstract: A rear edge side window catch assembly for a vehicle side window may include a rear edge side window guide and a side window catch bracket. The rear edge side window guide may include an upper end, a lower end and a substantially U-shaped channel formed by an exterior side wall and an interior side wall connected by a back wall. The channel may extend substantially the entire length between the upper end and the lower end. The side window catch bracket may include a connection section and a catch section, wherein the connection section may connect to the rear edge side window guide and the catch section may extend from the rear edge side window guide along the exterior side wall in a direction towards an opening of the channel.

Abstract: A door assembly for a vehicle includes an exterior panel and an impact beam coupled to the exterior panel and spaced from an interior surface of the exterior panel a gap distance. A bracket is attached to the impact beam via a snap fit connection. The bracket includes an outboard surface disposed between the impact beam and the interior surface to at least partially span the gap distance. The snap fit connection allows for repositioning and removal of the bracket from the door assembly without negatively affecting the structural integrity of the impact beam.

Abstract: Disclosed herein is a sealing device disposed between a vehicle door and a vehicle body and a vehicle door sealing rubber strip thereof. The sealing rubber strip is sleeved on a door pipe of the vehicle door. The vehicle door sealing rubber strip is an annular rubber body constituted by a drain segment and a non-drain segment. The annular rubber body includes a hollow rubber ring made of foaming rubber and a groove-shaped rubber ring made of compacted solid rubber and provided with a pipe body mounting groove at the inner side of the groove-shaped rubber ring. An air hole is provided in the hollow rubber ring, and a small water flowing trench is provided at the bottom surface of the pipe body mounting groove of the groove-shaped rubber ring. A fixing groove with a broad bottom and a narrow opening is provided on one external side of the groove-shaped rubber ring.

Abstract: A dual channel window lift assembly is provided, the assembly having: a door bracket; a pair of guide rails each being rotationally mounted to the door bracket for rotational movement in a predetermined range; and a cable assembly secured to the door bracket wherein at least one cable of the cable assembly is not received within a conduit and the at least one cable is secured to as least one pulley rotationally mounted to the one of the pair of guide rails and the at least one cable remains on the at least one pulley as the pair of guide rail each rotate within the predetermined range.

Abstract: A door for a vehicle including a cast upper door frame having an upper halo portion including a central web. A glass run flange is connected to the central web by an intermediate connector. A door flange extends from the central web substantially orthogonally thereto. A stamped aluminum lower inner panel is operably connected to the cast upper frame.

Abstract: A door assembly for a vehicle includes an outer panel configured for defining an exterior surface of the vehicle, and an inner panel matable to the outer panel to define a cavity therebetween. The inner panel includes a lower portion having a first longitudinal axis and a B-pillar assembly extending from the lower portion. The B-pillar assembly includes a casting having an external surface configured for defining the exterior surface of the vehicle, an internal surface spaced apart from the external surface, a length, and a second longitudinal axis. The casting extends from the portion along the second longitudinal axis, and the second longitudinal axis is substantially perpendicular to the first longitudinal axis.

Abstract: A door opening and closing device for a vehicle that can remove an object attached to operation surface of a door handle with a simpler structure is provided. The device includes a door handle. The door handle includes a grip and a deflective portion. The grip protrudes outward and defines a space between the outer surface of the door outer panel and the grip to allow gripping by a user. The deflective portion is located at an end of the grip and extends from the outer surface of the grip along the outer surface of the door outer panel in a direction crossing front and rear directions of the vehicle to direct air flow flowing along the outer surface of the door outer panel to flow through at least the space of the grip to the operation surface.

Abstract: A method and system for disengaging a drive rod in a door after an impact to the door. An automobile having a door with a door handle, a drive rod, a latching system, a striker, and a drive rod striking member. The drive rod striking member can be positioned adjacent the drive rod. Upon impact to the door, the drive rod is disengaged from the door handle and/or the latching system through inertia, through the drive rod striking member impacting the drive rod, or through any other means of disengagement. The drive rod striking member prevents the drive rod from re-engaging with the latching system. The disengagement of the drive rod prevents the drive rod from controlling the latching system to disengage from the striker, either through deformation of the door, or through actuations by the door handle.

Abstract: In a vehicle body side structure, an impact beam (116) is mounted to a door inner panel (110) by an impact beam extension (118). A part of the impact beam extension (118) that extends from an impact beam fixing part (126) to the door inner panel (110) serves as a load transmission part (128) capable of transmitting a load from the impact beam (116) to the door inner panel (110), and the extension line therefrom is directed at the centroid C2 of the body pillar (106). With a simple structure such as this, at the time of a side impact it is possible to transfer a load from the impact beam (116) in a straight line to the centroid C21 of the body pillar (106) while suppressing the twisting moment of the body pillar (106).

Abstract: An impact beam that absorbs an impact of a vehicle collision is provided in a vehicle door, at a position between an inner panel and an outer panel. The impact beam has a wavy portion that undulates in the height direction of the vehicle door. The center axis of the wavy portion extends along the longitudinal direction of a vehicle.

Abstract: A rear door structure in which a rear door is openably and closably provided on a rear portion of a vehicle body, including a door panel, wherein: the door panel includes an upper door panel and a lower door panel provided on the lower portion of the upper door panel; and a lower edge portion of the upper door panel and an upper edge portion of the lower door panel mutually overlap so as to form a lateral beam having a closed cross section and extending in a vehicle width direction.

Abstract: A motor vehicle door has a triangular pane, a lowerable side pane, and a guide rail for guiding the lowerable side pane being provided between the triangular pane and the lowerable side pane. Here, the guide rail is fixedly connected to a window frame, to an inner window slot and to a mirror reinforcement.

Abstract: The invention concerns a window assembly in a vehicle having a window pane that is fixed in a window frame that is also used for movable windows, and a method for mounting the fixed window pane in the window assembly. The method may include: mounting a window mounting assembly to a vehicle structure adjacent to the window opening; sliding the window pane into run channels of the vehicle window frame; mounting a lower edge of the window pane onto a peripheral support surface of a window support cam of the window mounting assembly; rotating a cam lobe of the window support cam into contact with the lower edge of the window pane until the window pane slides upward into a fully closed position; and locking the window support cam, against rotation allowing the window pane to lower, as the window pane is lifted into the fully closed position.

Abstract: A system and method is provided to index the door window glass of a vehicle to disengage the glass from the window sealing interface prior to opening the door. A door latch including an unlatching lever selectively connectable to the inside and outside door handles is configured such that moving either handle to actuate the latch causes an initial change in the position of the unlatching lever prior to latch release. A sensor in the latch detects the initial change in position of the unlatching lever and signals an indexing mechanism to move the glass to the indexed position prior to latch release, such that the glass does not substantially interfere with the sealing interface when the door is moved from a closed position. The system may be configured such that the door lock mechanism must be unlocked prior to the indexing mechanism moving the window to an indexed position.

Abstract: A mirror assembly includes a reflective element portion and a molded portion formed of a multi-void, lightweight structure. The multi-void, lightweight structure may be formed by injecting a gas into an injection mold while the molded portion is being molded, resulting in a multi-void aerated molded structure having multiple-voids introduced during the molding step. A window assembly for a vehicle may include an outer frame portion, an inner frame portion hingedly attached to the outer frame portion, and at least one sealing element established along a sealing portion of the outer and/or inner frame portions. The outer frame portion may be pivoted relative to the inner frame portion and about the hinge portions to a closed position. The outer frame portion may be connected to the inner frame portion when in the closed position to secure the at least one sealing element therebetween.

Abstract: A fastening arrangement is provided for mounting a decorative panel on a vehicle door that includes, but is not limited to a frame profile forming an opening for a side window of the vehicle door, on which the decorative panel for covering the profile is mounted with a fastener. The fastener includes, but is not limited to an elongate fastening piece passing through an opening in the frame profile and a fastening counterpiece connected to the fastening piece. The fastening counterpiece is connected to the decorative panel. The elongate fastening piece extends perpendicular to a door plane and can be connected to the fastening counterpiece from a door inner side.

Abstract: A motorized door opener for a vehicle (such as a military or security vehicle), featuring a sensor system that determines door position to prevent door damage while the opener is in operation. The opener features an offset gear system that effectively changes the door's rotation point. Mechanical advantage is gained by using a lengthened lever arm with the gear system, providing increased leverage and allowing the motor to provide enough force to open and close a heavily armored door. The opener can use existing door hinges, and can be provided so as not to protrude into the door space, in order to facilitate passenger and equipment entry/exit through the doors. A safety release mechanism is included in some embodiments, allowing the door to be manually opened or closed.

Abstract: A vehicle door frame includes first and second door frame members which are positioned end-to-end to be butt-welded to each other, wherein each of the first and second door frame members includes a design part, an enclosed section provided on a vehicle interior side, a connecting part which connects an inner surface of the design part with the enclosed section; and first and second dam protrusions which project from the inner surface of the design part and are positioned on opposite sides of the connecting part, respectively. Molten metal is present in the first and second spaces after the molten metal has melted and passed through the inner surface of the design part from the outer surface thereof upon butted ends of the first and second door frame members being butt-welded to each other from the outer surface of the design part.

Abstract: An automobile door containing a door frame, a door module for the incorporation of functional supports such as loudspeakers or the like, and a door soft trim for the aesthetically pleasing finish of the door on the inside of the automobile. The door soft trim and the door module have corresponding catching elements for the attachment of the door soft trim and door module in a predetermined configuration aligned with each other, and with the door module and the door soft trim containing corresponding recesses that are arranged flush to one another with the engagement of the aforementioned catching elements for the incorporation of one of the fixing elements that is to be connected to the door frame. The automobile door presents a stabile and easy to produce automobile door that satisfies the highest standards in manufacturing tolerances.

Abstract: In a four-seat coupe, it is inconvenient for a rear-seat occupant to get in/out of the vehicle while a front-seat occupant is seated. In the present invention, the length of each door of the four-seat coupe is set, so that the rear-seat occupant can get off/on the vehicle while the front-seat occupant is seated. The door is provided with detachable first opening/closing mechanisms at its front and rear end portions. The first opening/closing mechanism at the front end portion of the door is adapted to be released when the front-seat occupant gets off/on the vehicle to allow the first opening/closing mechanism at the rear end portion of the door to support the door so that opening/closing motion can be performed.

Abstract: A center-channel protector for a vehicle sash door is arranged between a main sash and a center channel. A body of the protector has an H-shaped upper-end surface which is compatible to cover the upper end of the center channel. The body integrally includes a pair of branch covering portions corresponding to a pair of branch portions constituting the center channel and a middle covering portion disposed between the branch covering portions so as to connect the both branch covering portions therewith. An engaging portion is provided with the body and is mechanically engaged, in a direction intersecting a vertical direction, with an engaged portion which is provided with a center channel side. In collaboration with the engaged portion, the engaging portion constitutes a fastening mechanism by which the protector is fastened on the center channel.

Abstract: Vehicle door structure includes: a door body openably and closably mounted to a vehicle body; a door sash provided on the door body and including a vertical sash section extending in a vertical direction of the door body, and an upper sash section formed continuously with an upper end portion of the vertical sash section and bent relative to the vertical sash section; and a garnish provided on the door sash and including a base section covering the vertical sash section and fixed to the vertical sash section, an extension section formed continuously with an upper end portion of the base section, bent relative to the base section and covering the upper sash section, and an engaging section provided on the extension section and engaging with the upper sash section.

Abstract: An outer door panel 2 defines a lower edge of a door window portion 8. An outer waist reinforcement 4 is disposed along the lower edge of the door window portion 8 on the inner side, in a vehicle-width direction, of the outer door panel 2, and fixed onto the inner side surface, in the vehicle-width direction, of the outer door panel 2. A door beam 5 is disposed in a front-rear direction below the outer waist reinforcement 4, and fixed onto the inner side surface, in the vehicle-width direction, of the outer door panel 2. A mirror-support stay is disposed on the outer side, in the vehicle-width direction, of the outer door panel 2, and supports a mirror. A mirror mounting member 30 is fixed to a front end portion of the outer waist reinforcement 4 and a front end portion of the door beam 5 while straddling these two front end portions to connect the two, and supports a lower end of the mirror-support stay.

Abstract: A method and tool for mass manufacturing convertible roofs having an outer shell, a frame and lateral linkage parts for supporting the outer shell, the outer shell including at least two outer shell parts is provided. The method includes the steps of providing an upper tool fixture and a lower tool fixture, aligning and assembling the frame and outer shell in the lower tool fixture such that the frame and outer shell are upside down, aligning and assembling connection members onto the frame part so the roof can fittingly engage the windshield frame when the roof is in a closed position, and lowering the lateral linkage parts onto the assembled frame and outer shell using the upper tool fixture.

Abstract: A garnish has an upper mounting projection concealed by a corner pad and a lower mounting projection concealed by a lower end of a vertical sash portion. The upper mounting projection is mounted in an upper mounting hole of the vertical sash portion. The lower mounting projection is mounted in a lower mounting hole of an outer panel. The upper mounting hole is concealed by the corner pad, and the lower mounting hole is concealed by the lower end of the vertical sash portion. This ensures a high quality appearance of the garnish without employing additional materials or components. Also, the garnish is mounted in a front door without reducing the surface area of the corresponding window of the vehicle.

Abstract: In a window regulator 10, when a pin bolt 42 provisionally attached to a pulley 22 and a pulley support 54 is fastened to a door panel 14 by a nut 52, the pulley 22 and the pulley support 54 are supported on the pin bolt 42 and attached to a predetermined position on the door panel 14. Here, in the above-described provisionally attached state, the pin bolt 42 is held in the pulley 22 by pin member holding claws 74 of the pulley 22, and the pulley 22 is held in the pulley support 54 by pulley holding claws 68 of the pulley support 54. Consequently, when the pin bolt 42 is to be fastened to a body panel, the pulley 22, the pulley support 54, and the pin bolt 42 can be handled as a single part. Thus, the work of attaching a pulley and a pulley support to a body panel of a vehicle can be facilitated.

Abstract: A door structure of a vehicle, having an effective space within a vehicle compartment increased, is provided. The door structure has a carrier plate (4) fixed to an inner panel (3) for closing an opening portion (3a) formed in the inner panel (3); and a plurality of trim members (7, 8, 9) for covering an inside of the carrier plate (4) within a vehicle compartment, the plurality of trim members (7, 8, 9) including a belt line trim (7) disposed along a belt line in an upper end portion of the inner panel (3), a pocket trim (8) disposed in the vicinity of a lower portion of the inner panel (3), and an arm rest trim (9) disposed between the belt line trim (7) and the pocket trim (8).

Abstract: A door structure includes a door for opening and closing a door opening formed in a vehicle body. The door has a side impact bar extending in the backward and forward direction of the vehicle body and a window regulator for lifting and lowering a glass of the door. The window regulator is mounted on the side impact bar and is disposed within a sectional width area of the side impact bar in a vehicle width direction.

Abstract: A front door 20 includes a first door component 22 and a second door component 34. The first door component 22 forms an inner side portion of a door main body 21, and the second door component forms an inner side portion of the door main body 21 and has functional parts located inside the vehicle. The first and second door components 22, 34 have honeycomb structural bodies 23, 41, respectively. The honeycomb structural bodies 23, 41 are entirely formed of synthetic resin. The honeycomb structural bodies 23, 41 include honeycomb portions 24, 42, which are composed of numerous tubular cells 26, 44, 45 separated by partition walls 25, 43, and sealing plate portions 27, 28, 46, 47 that are located on the outer side and the inner side of the honeycomb portions 24, 42 and seal the cells 26, 44. The door components 22, 34 are joined to each other at least at a part of the adjacent sealing plate portions 28, 46 of the honeycomb structural bodies 23, 41.

Abstract: A glass supporting assembly for a motor vehicle door with an unframed upper edge is provided with a fixed structure and a frame, which has at least one guide to support and guide a glass and is connectable to the door in such a way as to make it tiltable about a substantially horizontal axis of adjustment; a slot is obtained in a tangential direction in relation to the axis of adjustment in one of either the fixed structure or the frame, and is slidingly engaged by a pin with an axis orthogonal to the tangential direction; the pin is carried by the other of either the fixed structure or the frame, carries a screwed locking nut, and is axially rotatable; the rotational motion of the pin is converted into translational motion by a positioning device to position the pin along the slot.

Abstract: A structural door module for a motor vehicle door, comprising of a carrier plate with a plurality of door hardware components mounted to the dryside and wetside surfaces of the carrier plate. The carrier plate includes a number of preformed components that allow door subsystems to be pre-mounted to the door module and tested prior to mounting the structural door module in the motor vehicle door body. An energy absorbing area is molded into the carrier plate. Additionally, a protruding arm rest support is designed to collapse during a side-impact collision.

Abstract: A vehicle door frame includes a door sash, a belt-line reinforcement member, and a bracket which connects the door sash and the belt-line reinforcement member to each other and is fixed to a door panel. The bracket is welded to the belt-line reinforcement member at a plurality of welding portions, each of the welding portions defining a welding line, wherein extended lines of a plurality of the welding lines do not coincide with one another.

Abstract: A trim attachment structure includes a door frame, trim and a clip. The door frame has an attachment part, which is formed by a single plate, and a fitting hole. The fitting hole has a square shape in which the diagonals thereof are aligned with specific directions. The trim has a pair of ribs which extend towards the inner side in the width direction of the vehicle, respectively facing a pair of end parts of the fitting hole. The clip is installed in the fitting hole. The clip includes a head part, a tube part and a latching hook. The tube part has a tip end part which projects from the fitting hole to the outer side of the attachment part in the width direction of the vehicle. Angled parts of the tip end part are held between the ribs. The latching hook is latched at the peripheral edge of the fitting hole on the outer side of the attachment part in the width direction of the vehicle.

Abstract: A device for displaceably holding a glass pane (1) in a sliding rail has at least one fastening part (2) to which a hot-melt adhesive cushion (7) is fitted and which has at least one locking element (10, 11). Furthermore, there is an elongate holding rail (3) which can be brought into engagement with the or each locking element (10, 11). The or each locking element (10, 11) can be moved between a locking position, in which the or each fastening part (2) is connected fixedly to the holding rail (3), and a release position in which the engagement with the holding rail (3) is released and the glass pane (1) can be removed from the holding rail (3). As a result, repair due to wear of the holding rail (3) is less cost-intensive, since the glass pane (1) is connected releasably to the holding rail (3).

Abstract: A module covers an opening in a motor vehicle door and supports a door inner trim. The module comprises a base body including a base and at least one bracket movable with respect to the base. The bracket includes a supporting surface contacting an edge of the opening. The bracket includes at least one fixation point for fastening to the door inner trim.

Abstract: An automotive door comprises an outer metal panel and an inner metal panel which are coupled with each other to constitute a door base construction. The door base construction has therein a clearance that is defined between the outer and inner metal panels. A module base is incorporated with the inner metal panel and has a swelled portion that is projected into the clearance. Due to provision of module base having such swelled portion, rigidity of the door is increased.

Abstract: A vehicle door assembly includes an outer handle assembly, a latch mechanism, a rod, and a contact surface. The outer handle assembly includes a moveable handle. The latch mechanism includes a latch for engaging a striker and an outer handle lever operably connected to the latch. The rod connects the outer handle assembly to the latch mechanism. The contact surface is associated with the vehicle door and is inwardly offset from the rod. The contact surface is positioned with respect to the rod such that inward lateral movement of the handle during an outer handle intrusion event results in the rod moving laterally inward and impacting the contact surface. Impact with the contact surface by the rod inhibits the rod from moving the outer handle lever in an unlatching direction.

Abstract: A car door is constituted by a main body which includes an outer panel and an inner panel combined together, a door lower half, and a rising part extending upward from the door lower half and facing with a side edge of a roof via an upper part thereof; and a bracket-shaped sash assembly constituted by a front vertical sash whose bottom edge is joined to a front upper end of the door lower half, and a roof-facing sash extending from an upper part of the front longitudinal sash and joined to an upper end of the rising part.

Abstract: A window surround module (10) for installation to the perimeter of a window opening (120, 248) in a motor vehicle door panel (118, 244) comprises individual window surround components that are fabricated into a unitary structure. The individual components include two or more of a header molding (16, 130), a bell molding (18, 132), a mirror base (12, 28, 140), a B-pillar trim piece (14, 134), a glass run channel (150, 260), a wire harness (264), a wire harness support (262), seals (24, 200, 202, 2004), a mirror (30, 114), and a window (122, 246). At least some of the components are molded together to form a unit to which other components are mounted.

Abstract: A door assembly for a vehicle includes an outer panel. A support panel is operatively connected to the outer panel and configured such that the support panel provides bending resistance to the outer panel when the outer panel is deflected toward the support panel during a first deflection distance of the outer panel. A cable is operatively connected in the door assembly between a first end and a second end of the outer panel such that the cable provides additional bending resistance to the outer panel when the outer panel is deflected toward the support panel during a second deflection distance of the outer panel, greater than the first deflection distance.

Abstract: A door module of a vehicle includes: a panel of door glass including an upper peripheral edge and a lower peripheral edge; a lift plate coupled to the lower peripheral edge of the door glass such that a regulator may move the door glass between a full-up position and a full-down position within the door module via the lift plate; and a position block movable within the door module to: (i) a first position below the lift plate such that the lift plate rests on the position block and the door glass is at a position above the full-down position when the door glass is inserted into the lift plate during manufacture, and (ii) after such insertion, a second position that permits the lift plate to move further downward such that the door glass is at the full-down position.

Abstract: A structural door module for a motor vehicle door, comprising of a carrier plate with a plurality of door hardware components mounted to the dryside and wetside surfaces of the carrier plate. The carrier plate includes a number of preformed components that allow door subsystems to be pre-mounted to the door module and tested prior to mounting the structural door module in the motor vehicle door body. An energy absorbing area is molded into the carrier plate. Additionally, a protruding arm rest support is designed to collapse during a side-impact collision.

Abstract: A back door structure of a vehicle comprises an inner panel and an outer panel of a back door, a latch provided at a central portion, in a vehicle width direction, of a lower side portion of the back door, a latch opening portion formed at a latch attachment portion of the lower side portion, a reinforcing member provided at the lower side portion, the reinforcing member reinforcing a periphery of the latch opening portion, and side wall portions provided on both sides of the reinforcing member, in the vehicle width direction, the side wall portions extending in a vehicle longitudinal direction between the inner and outer panels of the back door and connecting the inner panel to the outer panel.

Abstract: A door for a vehicle including a cast upper door frame having an upper halo portion including a central web. A glass run flange is connected to the central web by an intermediate connector. A door flange extends from the central web substantially orthogonally thereto. A stamped aluminum lower inner panel is operably connected to the cast upper frame.

Abstract: A door frame for a vehicle includes a door frame, a window regulator mounted to the door frame for opening and closing a window pane, and a door lining mounted to the door frame. A plurality of mounting apertures is defined in the door frame, including at least one first mounting aperture for mounting the window regulator and at least one second mounting aperture for mounting the door lining. An isolating aperture is defined in the door frame between the at least one first aperture and the at least one second aperture for isolating the at least one second aperture from the at least one first aperture to thereby reduce lateral forces imparted to the door frame from the window regulator from transferring to the door lining.

Abstract: A blank for a vehicle door includes components arranged in the form of a blank for a front door or a rear door, each component including an edge that is adjacent to an edge of another one of the components, and welds produced by a laser, connecting the components along weld lines at the adjacent edges, each weld line of the blank for a front door being collinear with a corresponding weld line of the blank for a rear door.

Abstract: The attachment of a modified upper rear door hinge patch to the outside surface of a center pillar stiffener creates an energy absorbing cavity that: 1) reduces the chances that the center pillar stiffener will buckle or kink in a side impact collision, and 2) improves door mounting accuracy apart from the center pillar stiffener, and 3) improves the formability of the steel used in the manufacture of center pillar stiffeners.