Abstract: A door assembly includes a carrier panel attachable to a vehicle door outer structure such that the carrier panel substantially covers an opening of the door outer structure. The carrier panel is configured to function as a water shield between the door outer structure and a vehicle occupant compartment. The carrier panel also includes an upper portion and a lower portion, and the lower portion defines a lower appearance surface. The assembly further includes a hardware component mounted to and supported by the carrier panel, and an upper trim panel arrangement that is attachable to the carrier panel after the carrier panel has been attached to the door outer structure. The upper trim panel arrangement is configured to substantially cover the upper portion of the carrier panel and defines an upper appearance surface.

Abstract: A structural member (1) has a body (2) with a cavity (3), plastic reinforcing ribs (4) in the cavity (3), and structure (10, 12) for fixing the ribs (4) to the body. The fixing structure includes discrete regions (12), set back from at least one outer edge (11) of the body (2), and blocks (10) that are part of the same moulding as the ribs (4). The blocks (10) envelop the outer edge (11) in its set-back regions (12).

Abstract: An anti-side intrusion assembly for a vehicle door includes a reinforcing beam. Anchoring members secured to the reinforcing beam anchor the reinforcing beam to the vehicle frame or chassis. The reinforcing beam extends across the vehicle door and is anchored to the chassis at each end. One of the anchoring members a door hinge, and the other of the anchoring member is a lug generally perpendicular to the reinforcing beam. When the door is closed, the lug extends into a recess provided in a rigid portion of the door frame or chassis. Substantial bending of the reinforcing beam upon side impact on the door is prevented by bearing the lug on the rigid sidewall of the recess.

Abstract: The invention concerns a device for reinforcing a vehicle, in particular, a vehicle equipped with a retractable roof comprising of a rigid ring (3) enclosing the vehicle passenger compartment (4), the rigid ring (3) comprising elements (5,6,7) secured to the fixed parts of a body of the vehicle and of mobile elements (8,9) integrated in an upper part of vehicle doors (1,2), the mobile elements (8,9) being located in an extension of the fixed elements (5,6,7) when the doors (1,2) are closed, each mobile element (8,9) comprising at each of its ends locking devices mobile between an unlocking position and a locking position wherein the mobile elements (8,9,) are rigidly linked to the fixed elements (5,6,7) and form together a ring (3) having a uniformly distributed rigidity about the vehicle passenger compartment (4).

Abstract: A door impact beam for a vehicle which includes a flange for receiving a load, a reinforcement body having approximately U shape in cross section and provided in one piece with the flange, a pair of separated side portions for connecting the reinforcement body to the flange, a bottom portion connected to the side portions via each curved portion, and the side portions having a configuration extended in an outward width direction while extended to the bottom portion direction.

Abstract: The invention relates to a motor vehicle door with a door inner shell and a door outer shell joined thereto. A large-area opening in the door inner shell can be covered in a sealed manner by a supporting plate by means of a sealing area, and with a channel seal, which forms the upper termination of the inner parapet area. The motor vehicle door is characterized in that the upper edge of the supporting plate supports the channel seal. The ends of the channel seal are connected to lateral sealing areas of the supporting plate.

Abstract: A mounting device for mounting a cable-operated window regulator for a vehicle to an inner panel of the vehicle, the cable-operated window regulator includes a guide rail for guiding a window glass; a reversible winding unit for raising and lowering the window glass by winding and rewinding at least one cable which is wound on upper and lower guide members provided at upper and lower ends of the guide rail, respectively; upper and lower fixing member which are integrally formed with upper and lower ends of the guide rail, respectively; and a service hole formed on the inner panel. The lower fixing member is fixed to an outer surface of the inner panel near a lower edge of the service hole. The upper fixing member is fixed to an inner surface of the inner panel near an upper edge of the service hole.

Abstract: A door intrusion beam is of laminated construction and has a base metal stamping with end flanges, with metal stamping being of an inverted generally U-shaped cross section. Slidable and nested on the base metal stamping are a plurality of slidable and stackable elongated plastic elements each having a generally M-shaped configuration. The first plastic element next to the metal stamping and all stackable elongated plastic elements are secured together by layers of adhesives where surfaces contact one another. The plastic elements are of varying length.

Abstract: A vehicle door includes various features that enable a thin door profile not achievable with the prior art. The vehicle door includes an inner panel, an outer panel, and a reinforcement member between the inner panel and the outer panel. Door hardware, including at least a window regulator, is connected to the reinforcement member such that the door hardware is outboard of a window, thereby enabling the inner panel to be positioned in close proximity to the window.

Abstract: A door for the operator's cab on an agricultural tractor is formed from a frameless single pane of transparent material pivoted at one edge on a pillar of the tractor. The pivot is formed of two hinges affixed to the pane and a reinforcing member extending generally parallel to the pivot axis and interconnecting the wings of the hinges that are affixed to the pane. The reinforcing member is arranged in line with the pillar on which the door is mounted, when viewed from the position of the driver of the vehicle, so as to minimize obstruction of the field of view of the driver. In another aspect of the invention, the surfaces on the hinges that mate with the pane are machined to match the contours of the pane while the reinforcing member and the hinges are in one piece.

Abstract: A double door structure which has front and rear doors opening outward to form an uninterrupted opening to front and rear seats has an impact load carrying assembly for forming a side body reinforcing structure for protecting passengers against a side collision. The impact load carrying assembly includes an impact bar extending to and overlapping a side sill of a vehicle body, an upper bracket fixedly mounted to the impact bar and located to overlap a roof side rail of the vehicle body and a lower bracket fixedly mounted to the impact bar. The upper bracket mounts a latch and a belt anchor of a seatbelt system thereon and the lower bracket mounts catch pins forming part of a door catch mechanism operative to prevent movement of the door upon an occurrence of a side collision.

Abstract: A vehicle door includes various features that enable a thin door profile not achievable with the prior art. The vehicle door includes an inner panel, an outer panel, and a reinforcement member between the inner panel and the outer panel. Door hardware, including at least a window regulator, is connected to the reinforcement member such that the door hardware is outboard of a window, thereby enabling the inner panel to be positioned in close proximity to the window.

Abstract: A vehicle power window and power door lock system includes a vehicle pillar adapted for use between openable and closable vehicle doors and a single lock actuation assembly in the pillar adapted for engagement with a front door lock latch assembly on a front door and a rear door lock latch assembly on a rear door for locking and unlocking the doors. The vehicle power window and power door lock system further includes a single reversible electric motor in the pillar adapted for selective engagement with a front window on an adjacent front door and a rear window on an adjacent rear door for driving the windows up and down. A vehicle side door assembly includes a door lock latch assembly, a latch rod operatively connected to the latch assembly, a window, and a driven gear operatively connected to the window. The latch rod is operably connectable to a lock actuation assembly located in a body pillar adjacent to the door when the door is positioned against the body pillar.

Abstract: A vehicle door beam of relatively small profile and high strength. The door beam is fabricated from a web and includes a beam portion and brackets extending from opposite ends of the beam portion. The beam portion includes two lateral portions of the web rolled inwardly into closed configurations, and the two lateral edges of the lateral portions are welded to the beam portion. In an alternative embodiment, a second web is included in the beam portion and is part of both of the closed configurations.

Abstract: A door intrusion beam is of laminated construction and has a base metal stamping with end flanges, with the base metal stamping being of an inverted generally U-shaped cross section. Slidable and nested on the base metal stamping are a plurality of slidable and stackable elongated plastic elements each having a generally M-shaped configuration. The first plastic element next to the metal stamping and all stackable elongated plastic elements are secured together by layers of adhesives where surfaces contact one another. The plastic elements are of varying length.

Abstract: A vehicle closure body structure is provided with an outer panel, an inner panel opposed to the outer panel, with the outer panel and the inner panel forming a hollow structure of a closure body adapted to be mounted to an opening portion of a vehicle body through a hinge secured to the inner panel, a reinforce joined to the inner panel, inside the closure body, in at least a hinge fixing area thereof at which the hinge is fixed, and a tunneled portion formed in the reinforce to form a passage between the tunneled portion and the inner panel so as to permit wiring harness to be arranged therein.

Abstract: An anti-intrusion beam for incorporation into a vehicle door assembly is manufactured from an outer skin formed from laminated layers of composite materials having fiber reinforcement oriented in a directional pattern in each respective layer. The anisotropic beam includes body members having an interior core formed of high density foam plastic. The transversely corrugated beam includes attachment areas that have the same corrugated configuration which are fastened to mounting lugs of an inner door panel arranged in a corresponding corrugation. Variations in the thickness and formation of the layers of the outer skin can be used to control the failure of the beam during impact to provide a progressive predicable failure pattern for the beam. A frame catcher can be inserted into the body portions of the anti-intrusion beam to permit the transfer of impact forces to the frame of the vehicle.

Abstract: An automotive door assembly (10) includes an inner door (30) having an inner panel (40). The inner panel (40) has a first seat (44) and a second seat (46) integrally formed therein. The first seat (44) has a first side member (50) fixedly attached thereto for separating an exterior of the door assembly (10) from a door cavity thereof. The first side member (50) also reinforces the automotive door assembly (10). Likewise, the second seat (46) a second side member (90) has fixedly attached thereto for separating the exterior of the door assembly (10) from the door cavity thereof. The second side member (90) also reinforces the automotive door assembly (10). The inner panel (40), the first side member (50), and the second side member (90) have an outer door (18) attached thereto for enclosing the door cavity.

Abstract: One large opening (1) formed in a car body side portion and continuous in a back-and-forth direction is opened and closed by front and rear side doors (11, 12). When the side doors (11, 12) are closed, a lap portion (15) is formed where a rear end of the front side door (11) overlaps a front end of the rear side door (12) externally in a direction of car width. A reinforcing member (25) extending in a vertical direction is disposed on the rear side door (12) in the vicinity of the lap portion (15). The rear end of a front impact bar (27) disposed in the front side door (11) extends to the lap portion (15). The front end of a rear impact bar (26) disposed in the rear side door (12) is connected to the reinforcing member (25).

Abstract: A vehicle door which can be used as a tailgate or a side door of a vehicle and a manufacturing method of this vehicle door is provided. A tailgate (1) which is a vehicle door is formed of an outer panel (2) on an outer side of a vehicle, an inner panel (3) on an inner side of the vehicle, and a module plate (4) to which door parts such as a wiper motor (18) are attached, and a lining (6). The inner panel (3) is in a frame shape with only a marginal portion (10) of the whole periphery left and with an opening (11) formed therein, which results in reduction in the weight of the tailgate (1).

Abstract: A side impact beam for incorporation in a motor vehicle, in particular in a vehicle door, includes a profiled section of sheet metal having at least two longitudinal beads in side-by-side disposition. Each bead has an apex and two flanks depending from the apex, thereby defining an inner flank and an outer flank, wherein the inner flanks of the beads confront one another. The inner flanks are interconnected by a center web and are disposed in V-shaped relationship at an angle from 25° to 60°.

Abstract: A mounting plate for an anti-intrusion reinforcement member includes securing features that secure the plate to a vehicle door. The mounting plate also includes a plurality of mounting interfaces for the reinforcement member. The plate can be fitted to different mounting points in the door and to different reinforcement members, simplifying the production of the mounting plate. An anti-intrusion assembly including the plate, and a door with the assembly are also provided.

Abstract: An anti-side intrusion assembly for a vehicle door includes a reinforcing beam. Anchoring members secured to the reinforcing beam anchor the reinforcing beam to the vehicle frame or chassis. The reinforcing beam extends across the vehicle door and is anchored to the chassis at each end. One of the anchoring members a door hinge, and the other of the anchoring member is a lug generally perpendicular to the reinforcing beam. When the door is closed, the lug extends into a recess provided in a rigid portion of the door frame or chassis. Substantial bending of the reinforcing beam upon side impact on the door is prevented by bearing the lug on the rigid sidewall of the recess.

Abstract: A vehicle side-door structure, in which a front door and a rear door cover a continuous opening with no partition in a side part of a vehicle so that the opening is opened and closed, the front door is pivotally attached on a hinge at its front part to a vehicle body so that the front door is opened and closed, and the rear door is pivotally attached on a hinge at its rear part to the vehicle body so that the rear door is opened and closed, includes: a front-door rear reinforcement, the front-door rear reinforcement being disposed at a rear end part of the front door and extending in the vertical direction along the rear end part.

Abstract: A combination energy absorption and environmental insulating barrier incorporated into a vehicle door trim panel assembly. A thermoformed and hardened shell has an exterior facing surface and an opposite recessed interior facing surface. A three-dimensional structural component is constructed of a durable plasticized and expanded foam material and exhibiting the properties of moisture imperviousness and impact resistance. The structural component has a specified length, width and thickness and is configured to substantially seat against the recessed interior facing surface of the shell. A dimensional misalignment tolerancing being established between the opposing facing surfaces of the thermoformed shell and the expanded structural component and owing to tolerancing vagaries associated with the expanded foam of the structural component. An exposed facing surface of the structural component secures against an inner associated surface of a vehicle door.

Abstract: A door for a vehicle includes an outer panel for forming the contour of the door, a door reinforcement formed in a perimeter shape shaped in conformity with the contour of the door, and a substantially U-shaped inner panel that is upwardly open. Front and rear edges and lower edges of the door reinforcement and the inner panel are respectively connected to each other by welding to form a box-shaped section. Both ends of a side impact bar are welded or fused to front and rear vertical walls and of the door reinforcement, and a door hinge is attached to the vertical wall.

Abstract: An impact absorbing structure for a vehicle side door which opens and closes an opening formed in a side part of a vehicle, the side door including: a door main body which has a door inner panel and a door outer panel joined to the door inner panel; and a door sash portion which extends upward from the door main body and supports a door window member, in which: a sash-side door trim which covers the door sash portion is provided in the door sash portion on the inside of a vehicle cabin; and an impact absorbing portion which absorbs an impact load when an occupant comes into contact with the sash-side door trim from the inside of the vehicle cabin is provided in a front longitudinal-side part of the sash-side door trim.

Abstract: A combination energy absorption and environmental insulating barrier incorporated into a vehicle door assembly, the assembly including an assembleable trim pad. A three dimensional structural component has a specified length, width and thickness and with at least one impact absorbing portion being designed into the structural component. A plurality of projections and recesses are defined in at least one of first and second faces of the structure component, the component further being molded into the desired three dimensional shape using an impact absorbing material. A moisture impervious barrier is placed upon an inner face of the trim pad and the structural component is adapted to being secured to an inner face of the trim pad and prior to installation of the trim pad against an opposing and inner facing side of the vehicle door.

Abstract: The present invention provides a structural member for a car capable of demonstrating excellent flexural strength and absorbed energy performance and, moreover, capable of realizing weight reduction and is a structural member for a car being formed with a high-tensile steel pipe having a material property of not less than 1,400 MPa in tensile strength and not less than 5% in elongation, and also having a closed section structure as the configuration of the cross section perpendicular to the direction of the longitudinal axis, the cross-sectional configuration satisfying the expression (1) below when defining a as the maximum length of said cross-sectional configuration in the longitudinal direction, when defining b as the maximum length thereof in the direction perpendicular to said direction, when defining L as the circumferential length thereof and when defining t as the wall thickness of the steel pipe,

Abstract: A motor vehicle door having a door inside part (19), a door outside part (20) and a supporting panel (3) which is connected in a tight-fitting manner to the door inside part (19).

Abstract: In a door structure for a vehicle provided with a door main body (4) having an opening (2) provided in an inner panel (3), a module base (7) in which a window regulator (6) for vertically moving a window panel (5) is assembled and a fastening portion (9a) provided near an outer periphery so as to be capable of closing the opening (2) is fixed to the inner panel (3) by a fastening member (10), and a handle (8a) provided in a room inside, the handle (8a) being fixed to the module base (7), reinforcing beads (19, 19a, 19b) are provided in the module base (7) along a line connecting a mounting portion (12) to which the handle (8a) is fixed and the fastening portion (9a) provided in a vertical direction of the mounting portion (12).

Abstract: A vibration reduction and damping system for use in automotive closure panels, such as doors, lift gates, or other operable hatches comprising an intrusion device and an expandable material, such as a polymer-based foam, disposed along at lease a surface of the intrusion device prior to final assembly of the vehicle by the vehicle manufacturer. The system is activated as the vehicle undergoes the final vehicle assembly process, which activates and transforms the expandable material, preferably during an automobile paint operation, to expand, bond and fill the door assembly structure for vibrational damping and noise reduction.

Abstract: A vehicle door has an inner panel (11) on which an outer panel is fitted. The inner panel is covered by a loose panel, the trim. The inner panel has a front end wall (12) and a rear end wall (13). A reinforcement beam (20) is fastened between the end walls for transmitting force from a door pillar (33) to which the door is attached to a door pillar (34) behind the door, in the event of a collision. The reinforcement beam has a high single hat profile (21) which is fastened to the upper part of the front end wall, and extends in a curve out towards the external part of the inner panel, where the profile height is lower. The profile height decreases continuously from the high profile height to the low profile height, and the single hat profile (21) extends into a double hat profile (22). The reinforcement beam also functions as a side impact guard.

Abstract: A trunk lid or back door of a vehicle includes an inner panel and an outer panel, and a gap is formed between the inner panel and the outer panels. A reinforcement member is provided outside the inner panel at a position corresponding to an attachment unit of a latch. An extending portion of the reinforcement member extends to the outer panel and is provided with an attachment portion which is fixed on the outer panel. The latch is provided inside the inner panel and a latch disengaging lever is attached to the latch at the outer side thereof in a rotatable manner. In addition, the extending portion of the reinforcement member is positioned directly above the latch disengaging member.

Abstract: A vehicle door has a supportive frame (10). A waist rail (14) and a side impact guard beam (22) are formed integrally with the supportive frame. The entire frame is made of high strength sheet steel. The door is produced by hot stamping a steel sheet blank into the shape of a supportive door frame that includes an integral waist rail (14) and a side impact guard beam (22), and hardening the shaped door frame while the frame remains in the shaping tools, and fastening an outer panel (31) to the finished door such that the side collision guard beam (22) of the frame will lie close to the outer panel (31).

Abstract: There is provided an impact absorption device that comprises an impact bar 24 extending in the longitudinal direction of a vehicle door 20 and a hollow impact absorption member 30 with an upper end rib 32 locked on the impact bar 24 and a lower end rib 34 locked on an internal wall of a door inner panel 22 via a long bracket 35. A fragile portion 36 is formed in the upper end rib 32, and an end 41 of the impact absorption member 40 provided on a door trim 23 is positioned opposite to the impact absorption member 30 with a gap 42 formed there between.

Abstract: A door intrusion beam is of laminated construction and has a base metal stamping with end flanges, with the base metal stamping being of an inverted generally U-shaped cross section. Slidable and nested on the base metal stamping are a plurality of slidable and stackable elongated plastic elements each having a generally M-shaped configuration. The first plastic element next to the metal stamping and all stackable elongated plastic elements are secured together by layers of adhesives where surfaces contact one another. The plastic elements are of varying length.

Abstract: Device for absorbing impact energy for a door of a motor vehicle, the door being in the form of a hollow box in which is arranged a glass panel (12) capable of sliding between a lowered position and a raised position, the absorbing device (30) being arranged in a lower region of the box and comprising two shock-absorbing blocks (32, 33) defining a passageway for the glass panel (12) therebetween. The device comprises movable members (39) for mechanical connection which are arranged between the shock-absorbing blocks (32, 33), the members (39) each assuming an active position, in the absence of the glass panel, in which they ensure mechanical continuity between the blocks (32, 33) and constitute a supplementary component for absorbing impact energy, and moving out of the way to assume an inactive position when the glass panel passes through.

Abstract: A lightweight tailgate assembly for pickup trucks and other motor vehicles includes several metal panels that are made from a single metal sheet and a plastic reinforcing module between inner and outer metal panels. The side panels of the tailgate are formed as part of the plastic reinforcing module. A preferred assembly may also include a hinge device for connection with a truck body and a latch mechanism for locking the assembly between opposed rear corner posts in a truck body. The hinge device may be integrally molded into the plastic reinforcing module. A particularly preferred tailgate assembly made with AA 6022 aluminum alloy sheet and a reinforcing module containing polymer and glass fibers may weigh less than half as much as a conventional steel truck tailgate. Metal cover plates can be used to obscure visibility of the plastic side panels from the exterior.

Abstract: A vehicle body frame hollow member has an external contour whose cross section forms a polygon and has a plurality of plates, each defining a circumferential wall of the hollow member, each of points of intersection being formed by intersecting prolongations from exterior surfaces of the adjacent two plates, ribs connecting respective apical angles of the polygon with a center shaft thereof; and an elongated projection projecting outwardly of a circle tangent to the points of intersection and extending along an edge of each of the apical angles.

Abstract: A side impact beam to be integrated in a motor vehicle includes at least one elongated bar, which has a trapezoidal cross section and terminates on both ends in ramp-like end portions, wherein the elongated bar has a central web, flanks diverging outwardly from the central web, and flanges connected to the extremities of the flanks, and terminal attachment zones. For manufacturing such a side impact beam, a semifinished flat blank is cut to size of constant width from a sheet metal material band of constant thickness and includes an elongated center portion of constant width and a length which is at least half a length of the blank, wherein the center portion terminates on opposite ends in tongue-shaped end portions.

Abstract: A body for a motor vehicle and a method of making same. The body includes a pair of side doors which are each provided with a reinforcing longitudinal frame part. The body includes an energy absorbing frame structure having cross members, forward, central and rearward side members, and a pair of A-columns and B-columns. First and second transmission devices are operatively arranged between the longitudinal frame part of each door and a respective A-column and B-column to achieve a closure between the door and the frame structure. The first and second transmission devices interact with the support structure to absorb and transmit forces acting upon the frame structure at least in the longitudinal direction of the vehicle.

Abstract: One large opening (1) formed in a car body side portion and continuous in a back-and-forth direction is opened and closed by front and rear side doors (11, 12). When the side doors (11, 12) are closed, a lap portion (15) is formed where a rear end of the front side door (11) overlaps a front end of the rear side door (12) externally in a direction of car width. A reinforcing member (25) extending in a vertical direction is disposed on the rear side door (12) in the vicinity of the lap portion (15). The rear end of a front impact bar (27) disposed in the front side door (11) extends to the lap portion (15). The front end of a rear impact bar (26) disposed in the rear side door (12) is connected to the reinforcing member (25).

Abstract: A hatchback for an automobile has an essentially peripheral supporting frame (1) designed as a hollow metal section, with a windshield area and a wall area, with a connecting section (2) arranged transversely in the supporting frame (1) at the transition of the windshield area and wall area, with a windshield (3) mounted on the supporting frame (1) in the windshield area and with an outside door panel (4) mounted on the supporting frame (1) in the wall area, whereby hinge brackets (5) that are movable with the supporting frame (1) are mounted on the upper edge of the supporting frame (1) in the windshield area and are pivotably connectable by at least one hinge element (8) each to stationary hinge blocks (7) mounted on a stationary body part (6) when the automobile hatchback is installed.

Abstract: A method of forming a vehicle component, particularly an elongated impact beam, having an open section structure, in a manner to provide predetermined strategically strengthened portions, comprising the steps of cold forming unhardened steel into a workpiece having mounting surfaces, selectively fixturing the mounting surfaces, static induction heating the workpiece with lengthwise surface eddy currents on selected portions, followed by quenching of the fixtured heated workpiece to form strengthened portions, and unfixturing the resulting component. Also disclosed is apparatus to accomplish this, and the resulting novel vehicle component.

Abstract: The reinforcement bar for motor vehicle body components, in particular an anti-intrusion bar for doors, has in cross-section at least one omega-shape element (10) comprising two horizontal base sections (12) from which extend respective vertical sections (14) joined at the top by a further horizontal section (16), or at least one inverted U-shaped element (28) comprising two vertical sections (14) joined at the top by a further horizontal section (16). The bar has respective longitudinally extending slots (18) in the vertical sections (14) at at least one end in such a way that it allows the end of the bar to be shaped in conformity with the assembly requirements of the motor vehicle body components to re reinforced.

Abstract: A vibration reduction and damping system for use in automotive closure panels, such as doors, lift gates, or other operable hatches comprising an intrusion device and an expandable material, such as a polymer-based foam, disposed along at lease a surface of the intrusion device prior to final assembly of the vehicle by the vehicle manufacturer. The system is activated as the vehicle undergoes the final vehicle assembly process, which activates and transforms the expandable material, preferably during an automobile paint operation, to expand, bond and fill the door assembly structure for vibrational damping and noise reduction.

Abstract: A door for a vehicle, in particular a motor vehicle, having a face designed to be orientated towards the interior of the vehicle or interior face, and a face designed to be orientated towards the exterior of the vehicle, or exterior face. The door permitting the installation of one or more fittings at least partially located, in particular, between the interior and exterior faces. The door is constituted by a reinforcement, capable of supporting the fitting or fittings, and by means for cladding the reinforcement, defining with the reinforcement, on either side thereof, interior and exterior compartments enabling the fitting or fittings to be accommodated.

Abstract: An anti-intrusion beam for incorporation into a vehicle door assembly is manufactured from an outer skin formed from laminated layers of composite materials having fiber reinforcement oriented in a directional pattern in each respective layer. The anisotropic beam includes body members having an interior core formed of high density foam plastic. The transversely corrugated beam includes attachment areas that have the same corrugated configuration which are fastened to mounting lugs of an inner door panel arranged in a corresponding corrugation. Variations in the thickness and formation of the layers of the outer skin can be used to control the failure of the beam during impact to provide a progressive predicable failure pattern for the beam. A frame catcher can be inserted into the body portions of the anti-intrusion beam to permit the transfer of impact forces to the frame of the vehicle.

Abstract: A two-piece doorbeam including a relatively low-cost, low-strength body and a relatively high-cost, high-strength insert. The insert is hat-shaped and crimped within the body. The insert provides improved impact strength where needed, providing the doorbeam the desired strength at relatively low weight and low cost.