Side intrusion beam with four points of connection

Abstract

A side intrusion beam is disclosed for mounting within a vehicle door to inhibit intrusion into the vehicle during a collision. The intrusion beam spans across substantially the entire main portion (i.e. non-window portion) of the door. Structural keys located on the four corners of the intrusion beam mate with complementary shaped receptacles on the door jamb when the door is closed to anchor the intrusion beam to the vehicle chassis. Preferably, the intrusion beam includes a framework of truss members which create an overall outwardly curved shape. In the preferred embodiment, the entire framework is constructed from two sheet metal stampings that are welded together, forming a void therebetween. A structural foam can be injected into the void to increase strength and deaden sound. The inventive intrusion beam can be used with conventionally hinged passenger doors (both front and rear), vertically sliding doors, rear minivan doors, utility vehicle lift-gates, tailgates, and cargo doors, trunks, sliding van doors, or any vehicle door opening where it is desired to limit intrusion into the vehicle during a collision.