Vehicle Door Module Rail Locking for Window Regulator Stability
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Solution Overview
Problem
Existing door modules for vehicle doors face challenges in stabilizing the cable deflection region of the window regulator, leading to reduced mechanical strength, increased mechanical stress due to leverage, and potential noise issues from undesired movements or contact with the window pane.
Innovation Solution
A door module design where the cable deflection region has a joining contour that is permanently form-lockingly inserted into a receiving contour of the door structure, providing mechanical stabilization and eliminating the need for additional fastening elements like screws or bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cable deflection region is left exposed without fastening elements, then the mounting process is simplified and manufacturing cost is reduced, but the mechanical strength and stability of the window regulator are reduced and mechanical stress is increased
Solution Approach 1:
The joining contour is integrated directly into the cable deflection region as a single piece structure, merging the fastening function with the structural component. This eliminates the need for separate fastening elements (screws, bolts) while maintaining mechanical strength, thereby simplifying the mounting process and reducing manufacturing cost without sacrificing structural integrity
Solution Approach 2:
The joining contour is pre-formed as an integral part of the cable deflection region during manufacturing. This preliminary preparation allows the component to be directly installed into the receiving contour without requiring additional fastening steps, simplifying the mounting process while ensuring mechanical strength is maintained through the pre-integrated design
2Stability of the object's composition
If the cable deflection region is mechanically coupled to the door structure using screws or bolts, then the mechanical stability is improved, but an additional mounting step is required during door assembly
Solution Approach 1:
The joining contour integrates the fastening function directly into the cable deflection region structure, merging the structural component with the mounting feature. This eliminates the need for separate fastening elements and additional mounting steps, maintaining mechanical stability while simplifying the overall mounting process
Solution Approach 2:
The cable deflection region is designed with an integrated joining contour that performs the fastening function autonomously without requiring external fastening elements. The component serves its own fastening needs through the pre-formed joining contour, eliminating the need for additional mounting steps and reducing mounting process complexity
3Ease of operation
If the cable deflection region is not connected directly to the door structure, then the mounting process is simplified, but movements and bending or deformation of the cable deflection region occur during operation generating noise
Solution Approach 1:
The joining contour merges the structural support function with the mounting feature, creating an integrated connection between the cable deflection region and door structure. This eliminates unwanted movements and noise during operation while maintaining mounting process simplicity through the single-piece design that requires no additional fastening steps
4Strength
If bearing points are penetrated by bolts or screws to stabilize the cable deflection region, then the mechanical coupling is improved, but the structural integrity of the bearing point is compromised
Solution Approach 1:
The joining contour integrates the fastening function directly into the cable deflection region structure, merging the structural component with the mounting feature. This eliminates the need for separate fastening elements that would penetrate and compromise the bearing point, maintaining both mechanical coupling strength and structural integrity through the integrated design
Data Source
AI summary
A vehicle door module includes a carrier plate inside the vehicle door. A cable window regulator has a guide rail and is mounted onto the carrier plate. A door structure, which is separate from and configured to be joined to the carrier plate, has a receiving contour. The guide rail has a cable deflection region extending beyond the outer edge of the carrier plate. The cable deflection region has a joining contour protruding from and formed in one piece with the cable deflection region. The joining contour is permanently form-lockingly inserted in the receiving contour as a door subassembly of the vehicle door upon assembling the door. The joining contour is inserted in the receiving contour in a rail longitudinal direction, oriented approximately parallel to a height direction. The joining contour engages behind the receiving contour, holds and stabilizes the cable deflection region perpendicular to the cable deflection region.