Ford Global Technolgoies, LLC

Matthew Ammons

Zhibing Deng

Joseph Edward Abramczyk

Djamal Eddine Midoun

Robert Anthony Brancaleone

Prashant Agrawal

Richard Lee Matson

A vehicle door assembly includes a door structure having an inner panel and an outer panel defining an internal cavity that extends about a window surround above a vehicle waistline. The door assembly further defines mirror attachment holes and a plurality of collars affixed within the internal cavity. Each collar defines a bore in alignment with a mirror attachment hole of the door structure. The door assembly also includes a mirror assembly having a plurality of protruding fasteners attached to the door structure. The protruding fasteners compressively sandwich the collars within the internal cavity.

Automotive door structure for sail mounted mirrors

A strategically located door spacer block for transferring door beam bend/kink away from the occupant seating position is provided. The door spacer block is positioned between the door inner panel and the door outer panel and is aligned with the door beam. The door spacer block of the disclosed invention is placed between door inner panel and the door outer panel with the intention of minimizing the effect that the bend/kink in the door beam has on the occupant loading. The door spacer block engages the door beam and transfers the effective position of the kink of the door structure in a side impact away from the occupant seating position, thus freeing up crushable space in the occupant loading zone. The door spacer block of the disclosed invention eliminates or delays the loading of the beam surface to the pelvis bolster material, thus enabling additional free-crush space and allowing for a lower force transfer to the occupant.

Door spacer block design for side impact protection

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Plymouth, MI, United States of America

Matthew Ammons