Abstract: A reinforcement member for reinforcing an outer panel of a vehicle door includes an upper wall, an outer wall, a leg and a reinforcement beam. The leg extends between a lower end of the upper wall and an upper end of the outer wall. The reinforcement beam is formed at a lower end of the outer wall for reinforcing the outer panel of the vehicle door. A generally S-shaped flange is formed between the lower end of the upper wall and the leg. A portion of the S-shaped flange is substantially parallel with the upper wall so as to define a recess adjacent the S-shaped flange that provides enhanced retention of a door seal thereto.

Abstract: A reinforcement member for reinforcing an outer panel of a vehicle door includes an upper wall, an outer wall, a leg and a reinforcement beam. The leg extends between a lower end of the upper wall and an upper end of the outer wall. The reinforcement beam is formed at a lower end of the outer wall for reinforcing the outer panel of the vehicle door. A generally S-shaped flange is formed between the lower end of the upper wall and the leg. A portion of the S-shaped flange is substantially parallel with the upper wall so as to define a recess adjacent the S-shaped flange that provides enhanced retention of a door seal thereto.

Abstract: A reinforced structural component is manufactured by forming an intermediate structural member which defines a channel extending along at least a portion of its length. A support member is disposed in the channel and affixed to the intermediate structural member. A second forming operation is carried out on the combination of the intermediate structural member and support member so as to partially enclose and fixedly retain the support member therein. The method may be applied to metallic and nonmetallic structures, and may be utilized in conjunction with high speed metal forming processes such as roll forming. Disclosed herein are structures made according to the method as well as use of the method in the manufacture of structural components for motor vehicles.