Two-Piece Vehicle Door Garnish for Concealed Sensor Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle door designs face challenges in mounting sensors without compromising the fit and finish quality, as adding sensor mounting structures to a one-piece door garnish can complicate molding, lead to paint defects, and impact the connection quality between the garnish and door skin.
Innovation Solution
A two-piece door garnish system is used, comprising an inner and outer panel, where the sensor is mounted within a housing on the inner panel, concealed by the outer panel, and secured using clips and adhesive tape, eliminating the need for doghouses and datums, simplifying molds and reducing surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sensor is mounted in the space between the door skin and the main panel, then the sensor can be installed, but the fit and finish of the door garnish and other components is compromised
Solution Approach 1:
The door garnish is divided into two separate panels: an inner panel that provides mounting space for the sensor, and an outer panel that provides the aesthetic exterior surface. This segmentation allows the sensor to be mounted on the inner panel while the outer panel maintains the desired fit and finish appearance, resolving the contradiction between ease of sensor installation and manufacturing precision of the garnish.
2Ease of operation
If the installation area is accessed between the door skin and the main panel, then the sensor can be installed, but the fit and finish of the door garnish is adversely affected
Solution Approach 1:
By segmenting the door garnish into inner and outer panels, the sensor can be installed on the inner panel in a controlled manner without compromising the outer panel's aesthetic appearance. The inner panel serves as the installation surface while the outer panel maintains the desired fit and finish.
Solution Approach 2:
The inner panel acts as an intermediary element between the door skin/main panel structure and the outer aesthetic panel. It provides a dedicated mounting surface for the sensor while being concealed by the outer panel, thus facilitating sensor installation without adversely affecting the visible fit and finish.
3Device complexity
If a one-piece door garnish is used, then the construction is simple, but there is insufficient space and difficulty accessing the installation area for the sensor
Solution Approach 1:
The door garnish is segmented into an inner panel and an outer panel. The inner panel is designed with appropriate thickness and internal space to accommodate sensor mounting, while the outer panel provides the aesthetic finish. This segmentation creates sufficient installation space and accessible areas for sensor mounting without significantly increasing overall device complexity.
Data Source
AI summary
The presently disclosed subject matter includes a vehicle door that can include two separate panels (an inner panel and an outer panel) for providing a trim finish for the door. The door can include an exterior panel that includes a first outer surface, the inner panel mounted onto the first outer surface The outer panel can be mounted onto and cover the inner panel. The outer panel can have a second outer surface, and the outer panel can cover a first portion of the first outer surface and expose a second portion of the first outer surface such that the second outer surface and the second portion of the first outer surface form an exterior surface of the vehicle door. A plurality of connectors can be fixed to and protrude from the inner panel and be connected to the exterior panel. A sensor can be mounted on the inner panel.