Motor Vehicle Door Module Guide Rail Design
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Solution Overview
Problem
Current door modules for motor vehicles are inefficient in producing a guide rail that effectively maintains the window support device in multiple directions while being easy to produce, as existing designs are either fragile or require complex molds and additional production steps.
Innovation Solution
A door module with a guide rail that extends in at least two planes from the supporting face, integrated into the lateral end parts of the module, allowing for robust support in multiple directions without the need for additional mold components or sealing rings, using a single injection process with polypropylene-based plastic reinforced with glass fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple rib structure is used for the guide rail, then the manufacturing process is simple, but the support device may leave the rib in case of impact, making the support too fragile
Solution Approach 1:
The guide rail is designed to extend in at least two planes different from the plane of the supporting face, creating a three-dimensional structure that provides support in multiple directions. This dimensional extension prevents the support device from leaving the rail during impact while maintaining manufacturing simplicity through single-piece injection molding.
2Reliability
If a sealing ring is added to ensure sealing with the door, then sealing effectiveness is improved, but the production process becomes more complex and expensive
Solution Approach 1:
The sealing function is merged with the guide rail structure itself. The rail extends beyond the plane of the supporting face to form an integrated sealing structure that combines mechanical support and sealing functions in a single component, eliminating the need for separate sealing rings and complex mold drawers.
Solution Approach 2:
The guide rail is designed to perform multiple functions simultaneously: it provides mechanical support for the window regulator system in multiple directions, ensures sealing with the door, and maintains structural integrity. This multi-functionality eliminates the need for separate sealing components.
3Reliability
If moving drawers are added to the mold to create a complex rail shape, then the guide rail can effectively maintain the support device, but the production time increases and costs rise
Solution Approach 1:
The guide rail extends in at least two planes different from the plane of the supporting face, creating a complex three-dimensional shape that effectively maintains the support device in multiple directions. This dimensional complexity is achieved through single-piece injection molding without requiring moving drawers, thus maintaining high production speed.
Data Source
AI summary
The invention relates to a door module (1) of the type formed by a single part and from a single injected material, which module comprises a substantially flat supporting face (2) and at least one guide rail (34) of a window regulator system, said rail (34) being intended to guide and maintain a motor vehicle window supporting device (32). The rail (34) forms at least part of one of one of the side end parts (4) of the supporting face (2), said rail (34) extending continuously with the rest of the module (1) and forming a projection (40) in relation to the supporting face (2). The rail (34) extends in at least two planes different from the plane of the supporting face (2).