Vehicle Door Panel Assembly With Living-Hinge Debris Shield

Solution Overview

Problem

Conventional vehicle panel assemblies require separately manufactured and attached plastic materials along the bottom edge to protect against road debris, which increases production costs and time.

Innovation Solution

A panel assembly with an integrally formed interior panel featuring a living hinge that allows the lower portion to fold over the exterior panel, eliminating the need for separate plastic components and reducing manufacturing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate plastic material is attached to the outside panel using clips and fasteners, then protection against road debris is provided, but production costs and manufacture time increase

Engineering Contradiction:

Improveprotection against road debrisVSAvoidproduction costs and manufacture time

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The interior panel and exterior panel are merged into a single integrated assembly. The lower portion of the interior panel is formed integrally with the upper portion, eliminating the need for separate plastic materials and their associated fasteners. This integration reduces the number of parts, simplifies assembly, and lowers production costs while maintaining protective function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lower portion of the interior panel is designed with a living hinge that allows it to move between an extended position (providing protection) and a folded position (allowing access). This dynamic design enables the protective element to be both functional and accessible, resolving the contradiction between protection and ease of service.

Inventive Principle:

Principle #15Dynamics

2Reliability

If separate plastic material is attached to the outside panel, then protection against road debris is provided, but the number of parts and assembly complexity increase

Engineering Contradiction:

Improveprotection against road debrisVSAvoidnumber of parts and assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The interior panel and exterior panel are merged into a single integrated assembly. The lower portion of the interior panel is formed integrally with the upper portion, eliminating the need for separate plastic materials and their associated fasteners. This integration reduces the number of parts, simplifies assembly, and lowers production costs while maintaining protective function.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the lower portion is folded over the exterior panel, then protection against road debris is enhanced, but access to the exterior panel becomes restricted

Engineering Contradiction:

Improveprotection against road debrisVSAvoidaccess to exterior panel

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The lower portion of the interior panel is designed with a living hinge that allows it to move between an extended position (providing protection) and a folded position (allowing access). This dynamic design enables the protective element to be both functional and accessible, resolving the contradiction between protection and ease of service.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20250026187A1Panel assembly for a vehicle

Publication Date: 2025.01.23 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A panel assembly for a vehicle door includes an interior panel that has an inner surface and an outer surface. The inner surface and the outer surface collectively define a body and a trim element that is integrally formed with the body with a living hinge disposed therebetween. The panel assembly also includes an exterior panel that has an inner surface that is coupled to the body at the inner surface of the interior panel and has an opposing outer surface that is coupled to the trim element in a folded position of the trim element.