Automotive Door Locator Feature for Bumper Alignment

Solution Overview

Problem

Conventional vehicle interior door assemblies face complexity and issues such as noise, bounce-back, and improper latching due to potential misalignment of bumpers during the assembly process.

Innovation Solution

The interior door assembly incorporates an outer door panel with a bumper retainer and an inner door locator feature, which can be configured for snap-fit, friction fit, or screw-threaded fit, ensuring accurate positioning and retention of bumpers, thereby enhancing the fit and finish between the panels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If bumpers are mounted separately to the inner panel during assembly, then the door assembly can be constructed with modular components, but the complexity of the assembly process increases and bumper misalignment occurs

Engineering Contradiction:

Improvemodular component constructionVSAvoidassembly process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The bumper and inner panel are merged into a single integrated component. The bumper is formed as an integral part of the inner panel through injection molding, eliminating the need for separate mounting operations. This reduces assembly complexity while maintaining modular design benefits, as the integrated bumper-panel assembly can still be installed as a unit.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bumper position is predetermined and built into the inner panel design during manufacturing. The inner panel includes pre-formed bumper mounting features and positioning structures that ensure correct bumper placement before final door assembly. This preliminary positioning prevents misalignment during the final assembly process.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If bumpers are mounted separately to the inner panel, then modular construction is enabled, but bumper positioning precision deteriorates leading to misalignment

Engineering Contradiction:

Improvemodular component constructionVSAvoidbumper positioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The bumper and inner panel are merged into a single integrated component. The bumper is formed as an integral part of the inner panel through injection molding, eliminating the need for separate mounting operations. This reduces assembly complexity while maintaining modular design benefits, as the integrated bumper-panel assembly can still be installed as a unit.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bumper position is predetermined and built into the inner panel design during manufacturing. The inner panel includes pre-formed bumper mounting features and positioning structures that ensure correct bumper placement before final door assembly. This preliminary positioning prevents misalignment during the final assembly process.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If conventional separate mounting of bumpers is used, then component flexibility is maintained, but assembly time increases due to alignment requirements

Engineering Contradiction:

Improvecomponent flexibilityVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The bumper and inner panel are merged into a single integrated component. The bumper is formed as an integral part of the inner panel through injection molding, eliminating the need for separate mounting operations. This reduces assembly complexity while maintaining modular design benefits, as the integrated bumper-panel assembly can still be installed as a unit.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bumper position is predetermined and built into the inner panel design during manufacturing. The inner panel includes pre-formed bumper mounting features and positioning structures that ensure correct bumper placement before final door assembly. This preliminary positioning prevents misalignment during the final assembly process.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10246912B2Locator feature for automotive interior doors

Publication Date: 2019.04.02 FORD GLOBAL TECH LLC

AI summary

An interior door assembly for a vehicle includes an outer door panel including at least one bumper retainer associated with an inner door locator feature. The at least one bumper retainer is defined by an aperture dimensioned to receive a portion of a bumper therein. The assembly further includes an inner door panel including at least one aperture configured and dimensioned to engage the inner door locator feature.