A door panel that is light in weight and has sufficient strength is provided. A door panel has an outer panel, an inner panel, and a foamed material filling a space between the outer panel and the inner panel. The inner panel is formed by means of press molding so as to have an uneven surface with adhering portions and a raised portion. The adhering portions are affixed to the inner surface of the outer panel, and the space is formed between the raised portion and the outer panel. The outer panel has a thickness ranging from 1.2 to 5.0 times that of the inner panel. A hemmed portion is formed by folding the peripheral edge of the outer panel so as to curl over the peripheral edge of the inner panel and then pressing down the folded part.
1. A door panel comprising:
an outer panel;
an inner panel that is thinner than the outer panel and affixed to the inner surface of the outer panel so that a space is formed between the outer panel and the inner panel; and
a foamed material filling the space between the outer panel and the inner panel;
wherein the outer panel comprises a hemmed portion formed by folding the peripheral edge of the outer panel so as to curl over the peripheral edge of the inner panel and then pressing down the folded part; and
wherein the inner panel comprises a reinforcing deformed portion formed adjacent to an adhering portion that is formed at a location corresponding to the hemmed portion of the outer panel and adapted to be bonded, by an adhesive, to the outer panel so that the reinforcing deformed portion rises from a location close to the hemmed portion.
2. The door panel as claimed in claim 1 , wherein the inner panel further comprises:
a recessed adhering portion that is joined to the inner surface of the outer panel, and a raised portion bulging from the adhering portion.
3. The door panel as claimed in claim 1 , wherein:
the outer panel has a thickness ranging from 1.2 to 5.0 times that of the inner panel.
4. The door panel as claimed in claim 1 , wherein:
the outer panel and the inner panel are formed by using a galvanized steel sheet.