Vehicle Door Module Organosheet Layout for Window-Frame Rigidity
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Solution Overview
Problem
Current door modules for vehicle doors rely heavily on organic sheets for structural support, but they often lack functional area differentiation in terms of material thickness and fiber orientation, which can lead to inadequate load distribution and rigidity, particularly around window openings.
Innovation Solution
The proposed solution involves using multiple types of organic sheets with varying material thickness, fiber orientation, and layer numbers to create distinct functional areas within the door module, such as a support area, reinforcement area, and frame area, where different types of organic sheets overlap and are connected with molded plastic to enhance rigidity and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single type of organic sheet is used for the entire door module, then manufacturing is simpler, but structural rigidity and load distribution are insufficient in specific areas like window openings
Solution Approach 1:
The patent applies local quality by using different types of organic sheets with varying material thickness, fiber orientation, and layer numbers in different areas of the door module. Specifically, areas requiring higher rigidity (such as around window openings) use thicker organic sheets with optimized fiber directions, while less critical areas use thinner sheets, thereby achieving localized structural optimization without increasing overall complexity
Solution Approach 2:
The patent employs composite materials by combining multiple types of organic sheets with different properties (thermoplastic or thermosetting matrices with reinforcing fibers) to create a multi-layered structure. This composite approach allows the door module to achieve superior overall strength and rigidity by leveraging the complementary properties of different materials in different regions
2Strength
If additional cladding components are added to enhance structural integrity, then strength improves, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges the structural reinforcement function directly into the organic sheet itself by varying its thickness and fiber orientation in different areas. This integration eliminates the need for separate cladding components, as the organic sheet's own structural design provides the necessary reinforcement, particularly around window openings, thereby maintaining strength while reducing component count
Solution Approach 2:
The organic sheet is designed to perform multiple functions simultaneously: it provides structural support, local reinforcement where needed, and serves as the base material for the door module. By making the organic sheet multi-functional through varied thickness and fiber orientation, the patent eliminates the need for additional specialized reinforcement components
Data Source
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AI summary
The invention relates in particular to a door module (1) for a vehicle door (T), having at least one region (10, 11, 12), which is substantially formed by an organosheet. In particular, according to the invention the door module (1) has at least two different types of organosheet, by means of which different regions (10, 11, 12) of the door module (1) are formed.