Vehicle Door Module Structure Using Region-Specific Organosheets
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Solution Overview
Problem
Existing vehicle door modules lack functional and structural optimization, particularly in the use of organo sheets, which are not tailored to specific regions based on their functions and loading, leading to inefficiencies and potential weaknesses.
Innovation Solution
The use of multiple types of organo sheets with varying material thickness, fiber alignment, and number of layers to form different regions of the door module, combined with a positively locking connection through injection-molded plastic material, allowing for region-specific reinforcement and decorative surfaces without additional cladding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single type of organo sheet is used for the entire door module, then manufacturing simplicity is maintained, but structural optimization and functional adaptation to different regions are compromised
Solution Approach 1:
The patent applies local quality by using different types of organo sheets with specific properties tailored to different regions of the door module. High-strength organo sheets are placed in load-bearing areas such as the sill region and window frame, while standard organo sheets are used in less critical carrier regions. This regional differentiation optimizes structural integrity where needed without unnecessarily complicating the overall design.
Solution Approach 2:
The door module is segmented into different functional regions (carrier region, sill region, window frame region), each equipped with appropriately tailored organo sheet types. This segmentation allows each region to be optimized independently for its specific functional requirements while maintaining overall manufacturing feasibility through modular assembly.
2Adaptability or versatility
If multiple types of organo sheet are used to optimize different regions, then functional adaptation and structural optimization are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple organo sheet types into a unified door module structure where they work together synergistically. Different organo sheet types are combined in overlapping or adjacent configurations to create a integrated structure that adapts to various functional requirements while being manufactured as a cohesive unit, reducing the practical manufacturing complexity despite the diversity of materials.
3Strength
If reinforcement is added to specific regions, then structural integrity is improved, but material usage and weight increase
Solution Approach 1:
Reinforcement is applied locally only where structurally necessary, such as in the sill region and window frame areas that require higher strength. The carrier region and other less critical areas use standard organo sheet thickness, avoiding unnecessary material addition and weight increase while maintaining overall structural integrity.
Data Source
AI summary
A door module for a vehicle door, having at least one region, which is substantially formed by an organosheet. In particular, the door module has at least two different types of organosheet, by means of which different regions of the door module are formed.