Abstract: The invention relates to a motor vehicle tailgate of the type in which the tailgate carries a series of accessories, characterized in that a least some of the accessories are pre-mounted on a mounting plate which is attached to the tailgate on the inside of an external cladding panel of the tailgate and which carries a local managing circuit for connecting the accessories to electric circuits of the vehicle for supplying power to, controlling and monitoring the accessories.

Abstract: A window guide for a side window of a motor vehicle side door in the vicinity of a door frame includes a frame profile, an inner cladding, and an outer cladding. The frame profile is made Z-shaped throughout, with an inner Z-leg flanking the window glazing being secured to a parallel connecting flange of the inner cladding and an outer Z-leg pointing away from the window glazing being attached flush to a parallel inner surface of the outer cladding.

Abstract: An automotive door trim panel assembly including a plastic inner panel having a relatively thick, rigid, hollow retaining section which is designed for snap-fit installation of the assembly with a weather seal having a snap-on groove defined therein to thereby eliminate the need for additional fastening hardware while at the same time to provide increased rigidity and ease of tooling. The assembly also includes a contour door trim member for the inner panel.

Abstract: A vehicle door module including window glass is presented which includes a box section belt having an angled bolt attachment and a double overlap attachment to maintain strength and rigidity of the door assembly. The incorporation of the box section belt to the vehicle door module permits the inclusion of the window glass and various parts of the lift system. The angled bolt attachment provides for efficient load transfer between the belt and the door frame through load sharing face contact and a bolt. The double overlap attachment provides for efficient load transfer through a lap joint and clamping forces provided by a bolt. The double overlap attachment further includes features which facilitate assembly while compensating for manufacturing tolerances and build variability. An embodiment of the double overlap joining includes interlocking ridges which engage to further enhance load transfer capability.

Abstract: An outer panel which includes a panel body and an outer sash and an inner panel which includes a panel base for mounting door equipments, and an inner sash are joined together to form a door panel so as to confront the outer sash and the inner sash to form a sash, and a door trim is attached to the door panel to provide a vehicle door.

Abstract: A door for a vehicle having an equipment mounting panel. The equipment mounting panel includes various kinds of door equipment to perform door functions. The door panel is mounted in the door by being introduced into a space formed between an outer panel and an inner panel through a rear end opening in the rear end of the door.

Abstract: A guide member 10 made of an elastic material has an arcuate portion 10a which extends and contracts while twisting. A wiring harness D.multidot.W/H is arranged between a door and a body of a vehicle after being mounted on the guide member 10, and the opposite ends of the guide member 10 are fixed to the door and the body, so that the movements of the guide member and the wiring harness can follow the opening and closing movements of the door. The arcuate portion 10a is so configured as to construct a part of a torsion coil spring.

Abstract: A motor vehicle door consisting of an outer door panel, an inner door panel and an inner door trim as well as a window pane which can be displaced by means of a window lift. The inner door panel supports functional units, such as a window lift, lock, door handle and/or a side airbag. At least one assembly opening is provided in the inner door panel which is sealed against moisture or spray water by such a functional unit. Alternatively, a door module is provided to seal between the inner and outer door panels, and the door module includes at least one assembly opening to be sealed by such functional units.

Abstract: The invention relates to a Bowden tube window winder with compensation for cable length, which also compensates using simple means for a comparatively high level of cable elongation without excessive twisting of the cable loop. Said Bowden tube window winder is characterised in that a common locking member (10) is associated with the cable sockets and links the force of the two cable sockets (110) with the result that a movement to compensate for play of at least one cable socket can only occur when both cable sockets are substantially unloaded.

Abstract: A multi-functional vehicle door system includes a common lower door adapted to selectively cooperate with one of a door cassette and a side curtain assembly. The common lower door defines a cavity which opens adjacent an upper surface of the common lower door. The door cassette includes a frame defining a window opening and a lower portion adapted to be substantially inserted into the cavity of the common lower door. The side curtain assembly includes a frame and a flexible window. The frame includes a plurality of downwardly extending locating pins. One of the locating pins is adapted to engage an aperture provided in the upper surface of the common lower door. The other locating pins are adapted to engage apertures provided in a trim plug removably insertable into the opening of the common lower door.

Abstract: A method for mounting a carrier for a window-lifter mechanism in a shell of a vehicle door, the window lifter including at least one rail for guiding the window and the shell having an opening through which the carrier is introduced as well as, at its top, a well for the passage of the window; a) the rail is secured to its carrier with a mutual separation (d1) which is greater than the normal separation in the service position of the window lifter; b) the upper end of the rail is introduced into the shell; c) the upper end of the rail is made to enter the window well by raising the carrier and the window lifter; d) the lower end of the rail is passed over the lower rim of the opening; e) the carrier is pressed against a sealing border around the opening by lowering the assembly back down so that the lower end of the rail positions itself in the shell below the lower rim; f) and the rail is moved from its position of separation (d1) from the carrier into its normal service position (d2) by bringing it closer t

Abstract: An upper door extension for vehicle doors, where the door extension conforms with a door frame recess of a raised roof. The door extension includes a support member and a contoured cover member. The support member includes a rigid frame and a pair of attachment rails which are attached to side edges of the rigid frame, such that a portion of each attachment rail extends downwardly therefrom. The contoured cover member is made of composite material and integrally molded to the support member and covers the entire rigid frame to form the upper door extension. The door extension is mounted to the vehicle door by inserting the attachment rails into a top end opening of the vehicle door and attaching the attachment rails to the interior sidewalls of the vehicle door.

Abstract: A door frame for a vehicle includes a first supporting portion having a recess, a second supporting portion having an recess which is arranged opposite to the recess of the first supporting portion and a decorative portion having a gradually tapered edge so as to change a width of the decorative portion, the decorative portion extending parallel to the recesses. The first supporting portion, the second supporting portion and the decorative portion are formed in one piece from one sheet.

Abstract: A vehicle side door or hatchback structure incorporates at least one hydroformed component. In one configuration, a window frame, a door frame and a reinforcement member are press-fit together by pressurized fluid during a hydroforming process to join the frames and the reinforcement member together. In another configuration, a vehicle hatchback frame subassembly includes a one-piece hydroformed window frame with a central portion disposed between opposing end portions. Inner and outer panels are attached to each other and secured to the opposing end portions of the window frame. In yet another configuration, a vehicle door and window frame subassembly includes a hydroformed one-piece first door frame, a roll formed second door frame and a reinforcement member secured to the tubular one-piece first door frame. An outer front panel is attached to the reinforcement member by at least one mirror bracket.

Abstract: A deformable structure for occupant protection in vehicles has hollow energy-absorbing elements which are disposed between walls or other components. The hollow bodies are tube portions which are predeformed perpendicularly to their longitudinal axes and which are disposed with the tube axes parallel to the walls individually in a predeterminable arrangement or joined together in single-layer or multilayer fashion, and wherein the degree of predeformation is between 0.1% and 85% of the open width of the undeformed tube in the direction of the deformation impact force.

Abstract: A door frame for a vehicle includes a main member formed by one sheet and having a first supporting portion with an opening, a second supporting portion which has an opening oppositely arranged to the opening of the first supporting portion, a decorative portion which has a sloped edge portion that changes the width of the decorative portion, and a submember formed by one sheet and fixed to the main member so as to form an enclosed space between the main member and the submember. The cross-sectional area of the enclosed space gradually changes along the longitudinal direction of the door frame.

Abstract: A motor vehicle door having a door frame (2; 2') and a covering (3; 3'; 3"; 36) attached to the outer side of the door frame. To accomplish that the outer covering (3; 3'; 3"; 36) of the vehicle door can be mounted on the door frame (2, 2') easily, quickly and economically and that it can be replaced in a simple manner, the covering (3; 3'; 3"; 36) is positioned on the door frame via a horizontal sliding movement. For this purpose, the door frame (2, 2') is respectively provided with a respective horizontal guide rail (9, 13) on its side facing the top and bottom edge region (6, 11; 11') of the covering (3; 3'; 3"; 36) into which guide rail the bent-back portions (8, 12) of the corresponding U-shaped edge regions (6, 11) of the covering (3; 3'; 3"; 36) are engaged.

Abstract: A door frame for a vehicle includes a first supporting portion having a recess, a second supporting portion having an recess which is arranged opposite to the recess of the first supporting portion and a decorative portion having a gradually tapered edge so as to change a width of the decorative portion, the decorative portion extending parallel to the recesses. The first supporting portion, the second supporting portion and the decorative portion are formed in one piece from one sheet.

Abstract: Twin-shell vehicle door with a double-strand cable window lift mechanism pre-fitted on a support plate, which is preferably to be inserted in connection with a modular constructed motor vehicle door, wherein the support plate sealingly covers a cut-out in the door inner panel. The lower free end of the guide rail on the B-column side does not project right into the fixing area (cover area) of the inner door panel and support plate whereas the lower free end of the guide rail on the A-column side projects into this fixing area or beyond same. The upper edge of the cut-out section in the inner door panel in relation to the extension of the breast runs downwardly inclined in the direction of the A-column at least at such an angle .alpha. that when the support plate swivels about an imaginary swivel point S about the angle .alpha. in the direction of the breast the lower free end of the guide rail on the A-column side is lifted over the fixing area.

Abstract: A motor-vehicle door includes a door body composed of a door frame member and inner and outer door panels attached to opposite sides of the door frame member, and a window sash assembly connected to an upper part of the door frame member. The window sash assembly includes a sash body, a window panel vertically movably held in the sash body, and a window regulator mounted on a lower portion of the sash body for moving the window panel up and down and holding it in position. Since the window panel and the window regulator are assembled in the window sash assembly as an integral part of the window sash assembly, the motor-vehicle door having such window sash assembly is simple in construction and can be assembled easily, precisely and less costly. Methods of assembling the motor-vehicle door are also disclosed.

Abstract: Apparatus for adjusting a frameless window pane moved by a cable window lifter in an automobile. The apparatus includes a first guide rail which has an unlocked and a locked state, and a second guide rail. The first guide rail is freely movable to a limited degree in the unlocked state and fixed in the locked state. A window pane is connected between the first guide rail and the second guide rail such that movement of the second guide rail causes the first guide rail to move when in its unlocked state. A bolt is provided for moving the second guide rail and for locking the first guide rail.

Abstract: A window lift module includes front and rear lift rails, each having a guide block slidably mounted thereon for attachment to a window panel. A drive cable is routed through and between the lift rails and attached to the guide blocks so that motion of the drive cable in one direction will lower the guide blocks along the lift rails and motion of the drive cable in the other direction will raise the guide blocks to raise the window panel. A drive mechanism such as a hand crank or electric motor is mounted on one of the lift rails to move the cable.

Abstract: A door inner panel has a wall defining an opening for receiving a door hardware module. The wall has at least one cutout with upper and lower integrally bent flanges defining the upper and lower margins of the cutout of the door inner panel. The door hardware module includes a molded plastic frame having a network of molded plastic structural elements which support hardware mounting surfaces upon which various door hardware components is mounted. The structural elements include integrally molded receptacles having upper and lower slots which are adapted to interfit respectively onto the upper and lower integrally bent flanges of the wall cutout of the door inner panel so that the molded plastic frame becomes supported on the door inner panel in readiness for the installation of fasteners between the molded plastic frame and the wall of the door inner panel.

Abstract: A method of attaching a vehicle door handle to the outer skin of a vehicle door, and a door handle assembly to facilitate such attachment. The door skin is provided with a pair of apertures and a plurality of lugs are provided on an inner planar face of the door handle assembly together with a spring clip proximate one end of the planar surface. The door handle is mounted on the door by passing the lugs through the apertures while deflecting the spring clip inwardly and thereafter sliding the door handle assembly over the door skin to move web portions on the lugs into wedging engagement with respective edge portions of the apertures while moving the spring clip into latching engagement with a transverse edge portion of one of the apertures. Flange portions on the lugs are simultaneously positioned beneath respective inner surfaces on the skin to complete the attachment of the door handle to the skin.

Abstract: A connector connecting structure capable of smoothly connecting connectors, for example, on a vehicle door trim and on a door panel respectively, even in case of the door trim slantingly approaching the door panel. A projection having a terminal conductor is orthogonally arranged on a substrate and is rotatable about a flexible portion as a supporting point, while a slant guide corresponding to the projection is formed on a connector corresponding to the projection for enabling the projection to be inserted into the connector slidingly and rotatively along the slant guide. Practically, a vehicle door trim functions as a substrate and a connector is provided on a vehicle door panel for enabling a projection on the door trim to be inserted into the connector upon rotative assemblage of the door trim onto the door panel.

Abstract: A modular insert trim unit is provided for a motor vehicle door. The modular insert trim unit includes a one-piece molded plastic door cavity insert having a passenger-side aesthetic trim surface. The door cavity insert preferably is a hollow body structure formed by reaction injection molding and having unitary mounting bosses for structurally mounting functional door hardware and for mounting the modular insert trim unit to structural componentry of the door assembly. The modular insert trim unit preferably is preassembled as a self-supporting unit which can be inserted conveniently into a door cavity defined at least in part by an outer panel of the door assembly. Window regulator hardware, door lock and handle hardware, are thus installed into a motor vehicle door as an integrated unit with the door cavity insert, which further provides the aesthetic passenger-side trim surface generally required for motor vehicle doors.

Abstract: A vehicle door has a door housing and a door cassette that may be assembled off the manufacturing line and tested prior to assembling on the door housing. The door cassette has a cross member onto which a door frame is connected. The cross member and door frame assembly is pivotally connected to the door housing. The door frame has a lower door frame that is inserted into the door housing. A connection adjustably fastens the lower door frame in relation to the housing so that the frame may be easily adjusted to fit to the vehicle body.

Abstract: An apparatus for installing a window, a window drive mechanism, and a latch carrier mechanism within a vehicle door includes a one-piece cable regulator having a molded passage thereabout for guiding at least one length of cable between the window and the window drive mechanism, a molded vertical passage for guiding motion of the window, a molded cantilever beam for contacting and gradually reducing the downward motion of the window near a window stop position and a molded guide for slideable cooperation with the door latch carrier, whereby the door latch carrier, once slideably secured within the guide, may be shifted over the cable regulator to a compact shipping and installation position, and then may be shifted outward from the cable regulator to a final assembly position within the door.

Abstract: An anti-intrusion barrier comprising a corrugated metal sheet and at least one mounting flange integral with the sheet. The flange comprises extensions of the corrugations which have been collapsed inwardly upon themselves so as to provide a plurality of plateaus each defined by a pair of pleats formed by collapsed walls of the corrugations.

Abstract: In accordance with the present invention, the preferred embodiment of a multi-functional apparatus employing a flexible drive element for selectively actuating multiple output includes an electromagnetic device and a flexible drive element with a plurality of members thereon. In another aspect of the present invention, a flexible closed loop drive element in response to selective energization of an electric motor, and at least one rotatable member is coupled to one accessory such as a window wiper. The member attached to the drive element are arranged in a loop motion or discontinuous manner and selectively engage the rotatable member and thus actuate the attached accessory.

Abstract: A multi-functional automotive vehicle apparatus comprising: a rotatable member; an electromagnetic device operable to selectively rotate said rotatable member; a first motion transmitting member selectively moved in response to rotation of said rotatable member; and a second motion transmitting member selectively moved in response to rotation of said rotatable member.

Abstract: A motor vehicle door is made in the following way. A door main body is assembled by connecting an inner panel to a door panel. A window pane assembly is assembled by mounting into a guide frame a window pane and a power transmission mechanism for vertically moving the window pane. This guide frame is made by integrating an upper sash and a pair of front and rear lower sashes. The window pane assembly is inserted into the door main body through an upper edge opening portion of the door main body. The window pane assembly is fixed to the door main body in a condition in which the upper sash is positioned in a top of the door main body.

Abstract: A motor-vehicle door has an outer door panel, an annular inner door panel including a front frame member fixed to the outer door panel, a lower frame member fixed to the outer door panel, a separate upper frame member, and a rear frame member fixed to the outer door panel. The front, lower, and rear members together form an opening and the front frame member is formed with a pair of vertically spaced hinge holes each having a horizontal front part and a downwardly and rearwardly inclined rear part. An insert plate carries the upper frame member, fits in the opening, and is provided with hinge lugs engaged in the openings. The insert plate is pivotal about the lugs in the hinge holes between a raised position projecting inward from the door and a lowered position fitting in the opening. Mechanical, electromechanical, and electronic subassemblies are fixed on the insert plate, and fasteners retain the insert plate on the inner door panel in the lowered position of the plate.

Abstract: A door assembly for a motor vehicle. The door assembly comprises a molded door panel having a first side and a second side. The first side of the door panel is adapted to face into a passenger compartment of the motor vehicle. The second side of the door panel supports a belt line reinforcement, a lock and catch assembly, and a window lift assembly. The door assembly is adapted for joining with a door exterior.

Abstract: A door for an automobile having opposed molded plastic sides includes a steel door frame hingedly connected to the body. An outer panel is attached to the door frame, and a unitary injection-molded inner panel is also attached to the door frame to hide from view components such as latching mechanisms and window operators that are disposed between the panels. The inner panel is formed with a depression, and an elastic net covers the depression, to establish a storage compartment.

Abstract: A rod guide including an elongated strip base for connection with a vehicle door panel and to encircle an elongated control rod mounted adjacent the door panel, the strip base being spaced away from the rod; at least one mesh wing with a base end connected with the strip base, the mesh wing angularly extending from the strip base and the wing having a contact end for encircling contact with the control rod and dampening any transverse movement of the control rod while freely allowing generally linear movement of the control rod.

Abstract: A recites full view door in which the frame portion is totally molded. It may be molded in a number of processes from polypropylene or other materials, with or without additives, and other plastics suitable for large molded frames. There is an outside section of the frame and an inside section which are modified for securement each to the other. Provision is made in the interior edges of the frame for receiving the pane of glass, and then a holding assembly is provided, primarily four pieces being top, bottom and the two sides which snap-fits into the inside portion of the frame and secures the window in removable engagement to the door. In the method, means are provided on the outer half and the inner half for snap-fittingly or press-fittingly engaging each other. In addition, sonic welding, gluing, and other means for securing the outer half and the inner half of the door are contemplated.

Abstract: A mounting device is provided for mounting a window regulator drive unit on a molded plastic mounting panel. A plurality of flexible tabs are molded integral with the mounting panel and adapted to engage with the window regulator drive unit to retain the drive unit on the mounting panel. A molded plastic cap is adapted to fit over the drive unit and has integrally molded mounting fingers for engaging with complimentary integrally molded mounting fingers provided on the mounting panel so that rotation of the plastic cap causes inter-engagement of the mounting fingers and the drive unit is captured between the cap and the mounting panel. The cap has slots therein which become engaged with projecting lugs of the flexible tabs upon rotation of the cap relative to the mounting panel so that the flexible tabs become blocked and cannot be disengaged from their respective engagement with the drive unit.

Abstract: A vehicle door has a door trim panel to conceal a door inner panel. A rod is mounted on the inner panel and associated with the door latch to unlatch the door latch when the rod is pulled. A handle is pivotally mounted on the trim panel and has an arm projecting toward the inner panel. A plurality of door mounting hooks are provided on the lower edge portion of the trim panel for insertion into mating holes provided on the inner panel so that the trim panel is supported on the door in readiness and alignment for tilting of the trim panel into overlying relationship with the inner panel. A molded plastic guide track is mounted on the door inner panel, and a slider connected with the rod is slidably mounted on the guide track.

Abstract: A removable door cassette has a cross member having a lower door frame fixed thereto. The lower door frame has a first frame member fixed to the cross member and a second frame member defining a channel to receive the first frame member. The first frame member is separable from the second frame member. A pivot connection pivotally connects the second frame member to a door housing. A fastener fixedly secures the second frame member in relation to the door housing. A deformable button is preferably used to provide a mechanism to hold the lower door frame into the lower door frame channel and provide a release and locking mechanism between the first and second frame members.

Abstract: In accordance with the teachings of the present invention, a vehicle door including fiber reinforced plastic (FRP) members is provided. The vehicle door includes a fiber reinforced plastic outer skin member which is adhesively bonded to a fiber reinforced plastic intermediate shell including lateral side walls cooperating with inner and outer faces to define an open box-like structure with a hollow, interior cavity. The adhesively bonded outer skin member and intermediate shell define a door subassembly to which a hinge mechanism is coupled for securement to a body of a partially assembled vehicle. The door subassembly and the body of the partially assembled vehicle are simultaneously painted during the on-line assembly process.

Abstract: A motor vehicle door having a basic body (2; 22) and respectively an inside and an outside panel (4, 3; 23, 21; 27, 26), wherein the window-side circumferential edge (9) of the outside panel (3; 21; 26) is provided at least partially with an undercut (10) engaged by the corresponding regions of the circumferential edge of the basic body (2) or the inside panel (4), and wherein the outside panel (3) is provided with a folded section (16) at least at the end (15) of the circumferential edge (8) disposed opposite the window-side circumferential edge. To accomplish easy, quick and cost-advantageous mounting or replacement of the outside panel, the basic body (2; 22) or the inside panel (4; 23; 27) is connected by way of fastening means (18; 24; 28) to the wall region (20) of the folded section (14) of the outside panel (3; 21; 26), which wall region faces the door sill (14) of the corresponding motor vehicle.

Abstract: A vehicle door has a glass run channel extending vertically to guide vertical movement of a window glass. A bracket is mounted on the door adjacent the bottom of the glass run channel and has an upwardly opening slot therein. A threaded stud is carried by the bottom of the glass run channel. An annular roller of molded plastic construction is threaded onto the stud and has a circumferential groove by which the annual roller may be installed into the upwardly opening slot of the bracket to thereby mount the bottom of the glass run channel on the door. The stud is preferably threadably attached to the bottom of the glass run channel so that rotation of the threaded stud relative the glass run channel will adjust the position of the annular roller to adjust the bottom of the glass run channel relative to the door.

Abstract: A vehicle door module includes a door latch mounted on the module and has first and second bent wire rods pre-assembled on the door latch. The portion of the module to which the door latch is mounted is of molded plastic construction and has an integrally molded first receptacle in which the first bent wire rod is releasably snap-retained. A plastic mounting clip is attached to the door latch and has a molded second receptacle in which the second bent wire is releasably snap-retained. The first and second receptacles retain the first and second bent wire rods, respectively, to orient the bent wire rods to facilitate installation of the module into a vehicle door. The first and second receptacles permit release of the first and second bent wire rod therefrom to permit connection of the bent wire rods respectively to an outside door handle and an outside lock cyinder.

Abstract: A motor vehicle door has an outer panel and an inner panel. The outer panel is made up of a pair of double-walled, hollow structural members which are self-supporting. A door lock and door hinges are mounted on the outer panel. The inner panel, which is connected to the outer panel, carries all remaining accessories associated with the door, such as the operating mechanisms for a window mounted on the door.

Abstract: A vehicle door comprising an outer panel which is attached to a vehicle body so as to be openable and closable, an inner panel which has a peripheral dimension smaller than that of a panel portion of the outer panel, and which is attached to an interior side of the outer panel, door equipment including at least window glass, a regulator for raising and lowering the window glass, and a door lock, and an inner trim for covering an interior side of the inner panel, wherein the inner panel and the outer panel are secured together so as to form a space therebetween, the door equipment and the inner panel form a door module so that a side of the inner panel confronting the outer panel is provided with the door equipment in a one-piece unit, and the door module is attached to the outer panel so as to position the door equipment in the space by attaching the inner panel to the outer panel.

Abstract: A door cartridge assembly is provided to be installed into a vehicle door. The assembly includes a door hardware mounting panel having door components mounted thereon and being constructed and arranged to be fixedly mounted to a vehicle door; coupling structure carried by the mounting panel; and a door latch assembly constructed and arranged to be secured to a vehicle door to provide a latch for the vehicle door. The door latch assembly includes a latching member constructed and arranged to be movable between a latching position and a releasing position. The coupling structure is constructed and arranged to receive the latching member in latching relation therewith when the latching member is in the latching position thereof, thereby permitting the mounting panel to be transported with the door latch assembly connected thereto.

Abstract: Location pins are fitted into a plurality of sets of reference holes so that an inner panel, a hinge panel and a belt-like reinforcement which make up an inner panel assembly of a door panel are positioned in all directions with respect to each other. In addition, the inner panel assembly and an outer panel are mutually positioned using location pins, so that the mutual positions of all of the components of a door panel are fixed with a high degree of accuracy to produce a door panel of a high quality. Fittings may then be accurately mounted across the components of the door panel. With this arrangement, a door of high quality is ensured with less labor and fewer positioning members.

Abstract: A vehicle door frame has at least three, preferably four frame members (2, 3, 4, 5, or 2', 3', 4', 5') made of hollow tubular stock having a uniform cross-section substantially along the entire length, either of each individual frame member or along the entire frame, that forms a closed frame if four frame members are provided. Thus, the individual frame members or an entire frame length can be cut from extruded or rolled tubular stock having a uniform closed cross-section along its entire length. Hinges, having sections connected to the door frame permit mounting the entire door through its frame to the vehicle body. The frame forms a carrier for a door outer skin (31) and a door inner cover (30) and other door components, e.g. hinges and a lock. The door frame also forms a guide cage for a window pane (29). At least one frame member has a uniform cross-section substantially along its entire length and at least that frame member is cut from closed rectangular hollow tubular stock having a cross-section.

Abstract: A stamped beam for a vehicle door with improved structural strength while minimizing added weight to the vehicle. The beam includes a corrugated beam body with integral end brackets for mounting the beam in the vehicle door. The beam body has a sinusoidal cross-sectional configuration with a longitudinal valley allowing the entire beam to be stamped from an integral metal blank forming the mounting brackets. For additional strength, a tubular center member is welded within the longitudinal valley. The tube acts as a tuning mechanism by altering the thickness of the tube wall according to the application of the beam.