One-Piece Door Module Pull Handle Support
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Solution Overview
Problem
Existing vehicle door modules lack sufficient resistance to pulling forces, causing deformation of the pull handle and perceived lack of robustness, and require additional material and complex assembly processes when integrating a support element with the metal lining.
Innovation Solution
A one-piece door module with a U-shaped pull handle support element made from polypropylene reinforced with glass fibers, featuring two branches connected by a pulling element, which provides robustness without needing a modified door lining and integrates the support function within the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a pull handle support element is fixed to the metal lining of the door, then the robustness to pulling force is improved, but the device complexity and weight increase due to requiring a modified lining with additional material and complex assembly
Solution Approach 1:
The support element is merged with the door module by being formed in one piece with it through injection molding. This integration eliminates the need for a separate support element and its complex connection to the metal lining, while maintaining the required robustness through the integrated structure's inherent strength
Solution Approach 2:
The door module is designed to serve multiple functions: it provides structural support, houses the support element for the pull handle, and integrates the window lift system. This multi-functionality eliminates the need for separate components and modifications to the metal lining
2Strength
If a support element is added to the metal lining to receive the pull handle, then the resistance to pulling force is improved, but the weight of the door increases due to additional material in the lining
Solution Approach 1:
The support element is combined with the door module in a single injection-molded component. This integration eliminates the need for additional material in the metal lining, thereby avoiding the weight increase that would result from adding a separate support element to the lining
Solution Approach 2:
The support element is designed with optimized geometric parameters including two branches extending from the support face and connected by a pulling element. This configuration provides sufficient resistance to pulling forces while maintaining minimal mass through efficient structural design
3Reliability
If the metal lining is modified to receive a support element, then the pull handle robustness is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The support element is manufactured as an integral part of the door module through injection molding. This eliminates the need to modify the metal lining and simplifies assembly, as the support element is already positioned and integrated when the door module is installed on the door
Solution Approach 2:
The support element is pre-formed and integrated into the door module during its manufacturing process. This preliminary integration eliminates the need for subsequent modifications to the metal lining and simplifies the overall assembly process when installing the door module
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution offers significant resistance to pulling forces, maintaining the door's light weight while ensuring robustness and simplifying assembly by eliminating the need for additional metal reinforcement and complex lining modifications.
Implementation Method 1
The door module is made from a single injected plastic material, preferably a plastic material based on polypropylene reinforced with glass fibres
Data Source
Figure 1
Figure 2
AI summary
The door module (1) is made as a single piece and comprises a substantially planar support face (2). The door module further comprises a door pull-handle support element (16) made as one piece with the module, said element (16) comprising two branches (28) projecting out from the support face (2), said branches (28) being joined together by a pull element (34) running substantially parallel to the support face (2).