Inner panel assembly with integral energy absorber

• US 5,040,335 A
• Filed: 03/18/1991
• Issued: 08/20/1991
• Est. Priority Date: 03/18/1991
• Status: Expired due to Term

• Current Assignee: Collins & Aikman Floor Coverings Incorporated (Collins and Aikman Floor Coverings)
• Original Assignee: Davidson Textron Inc. (Textron Inc)
• Inventors: Grimes, John A.
• Primary Examiner(s): KANNAN, PHILIP
• Application Number:
  US07/670,767
• Time in Patent Office: 155 Days
• Field of Search: 49/502, 49/501, 296/188, 296/189, 296/905, 296/906, 296/146, 296/153, 296/152, 280/751
• US Class Current: 49/502
• CPC Class Codes: B60J 5/0451 Block or short strip-type elements beams B60J5/0443, position thereof B60J5/0423
• CPC Class Codes: B60J 5/0455 integrated in door structure or other door elements, e.g. beam-like shapes stamped in inner door panel
• CPC Class Codes: B60J 5/0481 plastic
• CPC Class Codes: B60R 2021/0407 using gas or liquid as energy absorbing means
• CPC Class Codes: B60R 21/0428 associated with the side doors or panels, e.g. displaced towards the occupants in case of a side collision

Abstract

An inner door panel assembly for a vehicle door is adapted to be connected to an outer door panel to form a space therebetween for a window and a window regulator; the inner door panel assembly is an all plastic composite assembly including an inner covering on the inner surface of a molded plastic substrate. The substrate includes first and second integrally formed hollow boxes thereon faced in the direction of the interior space to absorb side impact energy directed against the side of the outer door panel.

Claims

1. A composite plastic inner door panel assembly for connection to an outer door panel to define an interior space therebetween for housing window and window operator components comprising:

a molded plastic substrate having an inboard surface and having an outboard surface;

a layer of decorative material formed on said inboard surface including an inner plastic shell defining the full planar extent of the inner door panel assembly; and

a plurality of hollow boxes formed integrally in said molded plastic substrate directed therefrom into the interior space for absorbing side impact energy upon collapse of said outer door panel into the interior space.

2. A composite plastic inner door panel assembly adapted to be connected to an outer door panel of a motor vehicle to define an interior space between the inner panel assembly and the outer door panel for housing window and window operator components closing a window opening and the door dimensioned to close an opening between a vehicle roof and side and bottom rails of a vehicle frame comprising:

a molded plastic substrate having an inboard surface extending vertically from the window opening to the bottom rail and across the horizontal dimensions thereof;

said substrate including an outboard surface for defining the outer surface of the inner door panel assembly;

a layer of decorative material formed on said inboard surface including an inner plastic shell defining an aesthetically pleasing inner surface on the inner door panel assembly; and

a plurality of hollow boxes formed integrally of said molded plastic substrate directed therefrom into the interior space for absorbing side impact energy upon collapse of the outer door panel into the interior space.

3. A composite plastic inner door panel assembly adapted to be connected to an outer door panel of a motor vehicle to define an interior space between the inner panel assembly and the outer door panel for housing window and window operator components, said door panel assembly comprising:

a molded plastic substrate having an inboard surface and an outboard surface;

a layer of decorative material formed on said inboard surface including an inner plastic shell defining an aesthetically pleasing inner surface on the inner panel assembly; and

a plurality of hollow boxes integrally formed on said plastic substrate and including closed ends formed by said inboard surface of said substrate and further including open ends facing toward the interior space.

4. A composite plastic inner door panel assembly adapted to be connected to an outer door panel of a motor vehicle to define an interior space between the inner panel assembly and the outer door panel for housing window and window operator components, said door panel assembly comprising:

a molded plastic substrate having an inboard surface and an outboard surface;

a layer of decorative material formed on said inboard surface including an inner plastic shell defining an aesthetically pleasing inner surface on the inner panel assembly; and

a first plurality of hollow boxes integrally formed on said plastic substrate and including closed ends formed by said inboard surface of said substrate and further including open ends facing toward the interior space at the upper end of said inner plastic shell; and

a second plurality of integral hollow boxes integrally formed on said plastic substrate and including closed ends formed by said inboard surface of said substrate and further including open ends facing toward the interior space;

means forming a vertically opening space between said first and second plurality of hollow boxes;

said second plurality of hollow boxes being located below said first plurality of hollow boxes.

5. A composite plastic inner door panel assembly adapted to be connected to an outer door panel of a motor vehicle to define an interior space between the inner panel assembly and the outer door panel for housing window, window track and window operator components, said door panel assembly comprising:

a molded plastic substrate having an inboard surface and an outboard surface said molded plastic substrate having a inwardly curved segment thereon defining a cavity;

a layer of decorative material formed on said inboard surface including an inner plastic shell defining an aesthetically pleasing inner surface on said inner panel assembly;

a first plurality of hollow boxes integrally formed on said plastic substrate and including closed ends formed by said inboard surface of said substrate and further including open ends facing toward the interior space at the upper end of said inner plastic shell;

a second plurality of integral hollow boxes integrally formed on said plastic substrate within said cavity and including closed ends formed by said inboard surface of said substrate inside said cavity and further including open ends facing toward the interior space;

said second plurality of integral hollow boxes being located below said first plurality of integral hollow boxes in spaced relationship thereto; and

said first and second plurality of integral hollow boxes having inner edges thereon located substantially in the same plane inboard of the window and window track.