Vehicle Door Module with Polymeric Foam Core

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Solution Overview

Problem

There is a need to reduce the weight of vehicle door modules while maintaining structural strength and functionality, as existing modules are typically made from heavy materials like metal and plastic.

Innovation Solution

A vehicle door module with a unitary frame that incorporates closed cell polymeric foam in its circumscribed areas, which can be overmolded or compression molded to provide structural support and reduce weight, using materials like polypropylene and glass fiber with thermoplastic elastomers or urethane foams.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If traditional metal and plastic materials are used for vehicle door modules, then structural strength and functionality are maintained, but weight is excessive

Engineering Contradiction:

Improveweight of vehicle door moduleVSAvoidstructural strength of door module

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies composite materials by combining a polymeric foam core with skin layers or reinforcement elements. The door module uses a multi-material construction where lightweight polymeric foam provides the base structure, and additional materials like metals, plastics, or fabric layers are integrated to provide necessary structural strength and functional properties. This composite approach allows weight reduction while maintaining required strength characteristics.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by varying material properties and structural characteristics at different locations within the door module. The polymeric foam may have varying density distributions, and reinforcement elements are strategically placed in areas requiring higher strength. The skin layers or covering materials are applied selectively to specific regions to provide localized structural support while keeping other areas lightweight.

Inventive Principle:

Principle #3Local quality

2Weight of moving object

If lightweight materials are used to reduce weight, then weight decreases, but structural integrity may be compromised

Engineering Contradiction:

Improveweight of vehicle door moduleVSAvoidstructural integrity of door module

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent uses composite materials to achieve both weight reduction and structural integrity. The polymeric foam core provides lightweight structure, while integrated skin layers, reinforcement elements, or combination with traditional materials ensure the necessary structural integrity and reliability for vehicle door applications.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies parameter changes by modifying the density, cell structure, or mechanical properties of the polymeric foam material. The foam may be engineered with specific density ranges, cell sizes, or cross-linking characteristics to optimize the balance between weight and structural integrity. Additional parameters like thickness, reinforcement distribution, and material composition are adjusted to meet reliability requirements.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11479091B2Vehicle door module

Publication Date: 2022.10.25 INTEVA PRODUCTS LLC

AI summary

A vehicle door module includes a unitary frame and areas circumscribed by the unitary frame wherein the circumscribed areas are filled with a material comprising a closed cell polymeric foam. The vehicle door module can be made by overmolding or compression molding.