Vehicle Door Cover Module Nesting Control Box

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Solution Overview

Problem

The existing vehicle door structures face an increase in thickness due to the assembly of control boxes, which affects the door's dimensions and functionality.

Innovation Solution

A vehicle door structure that incorporates a cover module with a recessed portion for the control box, allowing it to be fitted within the cover, thereby reducing the protrusion height and preventing an increase in door thickness, while maintaining electrical connectivity through integrated electric wires.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a control box is assembled to the inner panel to control electric components, then the control function is improved, but the door thickness increases

Engineering Contradiction:

Improvecontrol functionVSAvoiddoor thickness

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

The control box is nested within the recessed portion of the door trim, allowing the control components to be housed inside the trim structure itself rather than adding external bulk to the door assembly

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The recessed portion is formed in the vehicle width direction (thickness dimension) of the door trim, creating a three-dimensional space that accommodates the control box without increasing the overall door thickness in the vehicle width direction

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If a control box is assembled to the inner panel, then the control function is improved, but the door structure becomes more complex

Engineering Contradiction:

Improvecontrol functionVSAvoiddoor structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The door trim and control box are merged into a single integrated assembly where the control box is housed within the trim structure, eliminating the need for separate mounting brackets, fasteners, and alignment features that would be required if the control box were mounted separately to the inner panel

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The door trim serves multiple functions: it provides interior finishing, houses the control box, and maintains the original door structure integrity, thereby reducing the need for additional dedicated mounting structures

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3808581B1Vehicle door structure and cover module

Publication Date: 2022.04.20 YAZAKI CORP

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AI summary

A vehicle door structure includes an outer panel, an inner panel assembled to a vehicle width direction inner side surface of the outer panel so as to form a panel space with the outer panel, a cover assembled to the inner panel so as to close a service hole, which is a through hole formed in the inner panel in order to facilitate a work in the panel space, a control box assembled to the cover and configured to control input/output of electric power and/or control signal to/from at least one of electric components disposed on a vehicle door; and a door trim assembled to a vehicle width direction inner side surface of the inner panel so as to cover the cover and the control box.