Abstract: A vehicle door assembly has an inner sheet metal layer (16) which presents a substantially U-shaped structure. The inner sheet metal layer includes a latch mounting surface and at least one hinge mounting surface. An outer, substantially planar, sheet metal layer (14) is attached to the inner sheet metal layer to form a cavity. A structural reinforcement member (30) is disposed in the cavity to reinforce the inner and outer sheet metal layers, including reinforcements (44A, B and 28 A, B) for the latch and hinge mounting surfaces. A carrier assembly (60) is mounted to the structural reinforcement member, covering the U-shaped area, and a trim component (50) covers the carrier assembly. By incorporating the structural door member, the thickness of the inner and outer sheet metal layers can be reduced, for a net weight and reduced material cost savings.

Abstract: A vehicle door assembly has an inner sheet metal layer (16) which presents a substantially U-shaped structure. The inner sheet metal layer includes a latch mounting surface and at least one hinge mounting surface. An outer, substantially planar, sheet metal layer (14) is attached to the inner sheet metal layer to form a cavity. A structural reinforcement member (30) is disposed in the cavity to reinforce the inner and outer sheet metal layers, including reinforcements (44A, B and 28 A, B) for the latch and hinge mounting surfaces. A carrier assembly (60) is mounted to the structural reinforcement member, covering the U-shaped area, and a trim component (50) covers the carrier assembly. By incorporating the structural door member, the thickness of the inner and outer sheet metal layers can be reduced, for a net weight and reduced material cost savings.