Vehicle Door Panel Quadrangle Reinforcement for Plastic Rigidity
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Solution Overview
Problem
The existing methods for manufacturing vehicle panel doors are costly and time-consuming, especially for small-quantity batch production, as they require large-sized press molds, which are not suitable for producing various types of vehicles, and using plastic materials results in insufficient rigidity.
Innovation Solution
A rigidity-improved vehicle panel door design where both end portions of a stabilizer and an impact beam are connected to support members in a height direction, forming a quadrangle structure, with one panel made of plastic and the other of metal, using injection molding for cost-effective production and enhanced rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic material is used for door panels, then manufacturing cost and time are reduced, but rigidity becomes insufficient
Solution Approach 1:
The patent uses a composite structure combining plastic external panels with metal reinforcement members (stabilizer, impact beam, and multiple reinforcers). This allows the door to benefit from the cost and manufacturing flexibility of plastic while gaining the rigidity and strength of metal components through strategic reinforcement at critical locations.
2Productivity
If large-sized press molds are used for mass production, then production efficiency is improved, but adaptability to various vehicle types and design changes is reduced
Solution Approach 1:
The door panel is segmented into an external panel and multiple separate reinforcement members (stabilizer, impact beam, hinge upper reinforcer, hinge reinforcer, latch reinforcer, latch lower reinforcer). This segmentation allows the external panel to be produced efficiently through injection molding while reinforcement members can be independently manufactured and attached, enabling flexible adaptation to different vehicle types and design variations without requiring new molds for the entire door assembly.
3Strength
If reinforcement members are added to improve rigidity, then structural strength is improved, but device complexity increases
Solution Approach 1:
Reinforcement members are strategically positioned at specific locations where structural support is most needed: stabilizer at the belt line, impact beam at the lower portion, hinge reinforcers at the front end, and latch reinforcers at the rear end. This localized reinforcement approach provides maximum rigidity improvement with minimal additional complexity, as each reinforcement member serves a specific structural function rather than uniformly strengthening the entire door.
Data Source
AI summary
A rigidity-improved vehicle panel door includes an external panel positioned, toward the outside of a vehicle, in a door of the vehicle, an internal panel, an external edge portion of the internal panel being joined to the external panel, and the internal panel being positioned, toward the interior of the vehicle, in the door, and a rigid structure in which a plurality of support members disposed in a longitudinal direction of the vehicle are coupled to a plurality of reinforcement members to form the shape of a quadrangle, the plurality of reinforcement members being provided on a front end portion of the door and a rear end portion of the door.