Adjustable Vehicle Door Sections Using Coupler Mechanism
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Solution Overview
Problem
The alignment and fit of multi-section vehicle doors are challenging due to variances in manufactured parts dimensions, leading to suboptimal compression of the weather seal between the door and vehicle body, affecting wind and water sealing.
Innovation Solution
The vehicle door design incorporates adjustable sections with projections and intermediate members, utilizing couplers for precise alignment and retention, allowing independent adjustment of each section to achieve optimal fit and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple door sections are used to provide flexibility and partial door operation, then adaptability is improved, but alignment precision and fit between sections deteriorate due to manufacturing variances
Solution Approach 1:
The door section is made dynamically adjustable through the coupler mechanism that allows relative movement between the first and second sections. The coupler can be positioned at different locations along the longitudinal edge, enabling the door to adapt its configuration while maintaining proper alignment despite manufacturing variances in the door sections and vehicle body.
Solution Approach 2:
The coupler acts as an intermediary element between the first door section and the second door section. It mediates the alignment and connection between sections, compensating for manufacturing tolerances and ensuring proper fit and finish while allowing the door to operate with partial sections removed.
2Manufacturing precision
If door sections are made adjustable to compensate for manufacturing variances, then fit and finish are improved, but device complexity increases due to additional adjustment mechanisms
Solution Approach 1:
The door is segmented into a first door section and a second door section that can be independently positioned and adjusted. This segmentation allows each section to be optimized separately while the coupler provides the connection mechanism, simplifying the overall adjustment system compared to making the entire door adjustable.
Solution Approach 2:
The coupler serves multiple functions: it connects the first and second door sections, allows for adjustment of their relative positions, enables the door to operate with partial sections, and maintains proper alignment. This multi-functionality reduces the need for separate adjustment mechanisms for each purpose.
3Ease of manufacture
If coupler positions are fixed during assembly, then manufacturing simplicity is maintained, but adaptability to different configurations is reduced
Solution Approach 1:
The coupler is designed with dynamic positioning capability along the longitudinal edge of the first door section. It can be adjusted to different positions and secured, allowing the door configuration to be changed after assembly while maintaining manufacturing simplicity through a straightforward adjustment and locking mechanism.
Data Source
AI summary
In at least some implementations, a vehicle door includes a first section having a first void, a second section having a first projection, a first intermediate member received within the first void and having an inner surface that defines an interior, wherein the first projection is received within the interior, and a first coupler coupled to the first projection. The interior of the first intermediate member has at least a portion that is larger than the portion of the first projection received within that portion of the interior to permit movement of the first projection relative to the intermediate member. The first coupler is coupled to the intermediate member to maintain the position of the first projection relative to the first section. In this way, the position of the second section may be adjusted relative to the first section and the adjusted position can be maintained.