Vehicle Door Outer Skin Module with Integrated Stiffening
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Solution Overview
Problem
Vehicle doors with existing outer skin modules are unstable, complex to manufacture, and heavy due to large-area sheet metal components, requiring additional stabilization measures and complex production processes.
Innovation Solution
A prefabricated outer skin module featuring a fiber-reinforced plastic door shell with a shell-shaped outer skin and a one-piece, formed stamped sheet metal mounting frame, side impact beam, and integrally formed stiffening struts, which are bonded together to enhance stability and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a large-area sheet metal outer skin is used, then the vehicle door achieves a smooth exterior surface, but the structure becomes unstable and handling becomes difficult
Solution Approach 1:
The mounting frame is divided into multiple segments with individual support elements distributed across the outer skin surface. Each support element provides localized stabilization, transforming the unstable large-area sheet metal structure into a series of stable smaller sections while maintaining the smooth exterior appearance.
2Stability of the object's composition
If additional stabilization measures are added to the outer skin module, then structural stability improves, but manufacturing complexity and effort increase
Solution Approach 1:
The mounting frame and support elements are combined into a single integrated component manufactured as one piece from sheet metal. This merging eliminates the need for separate stabilization components and their associated assembly operations, reducing manufacturing complexity while providing the necessary structural stability.
3Adaptability or versatility
If the outer skin module is designed as a separate component, then assembly flexibility is maintained, but the number of manufacturing process steps increases
Solution Approach 1:
The outer skin, mounting frame, and support elements are pre-assembled into a complete module before delivery to the vehicle assembly line. This preliminary assembly allows the entire stabilization system to be installed in a single operation, reducing the number of manufacturing process steps while maintaining the flexibility of modular assembly.
4Stability of the object's composition
If thicker sheet metal is used for the outer skin, then structural stability improves, but vehicle weight increases
Solution Approach 1:
Instead of uniformly thickening the entire outer skin, support elements are strategically positioned at specific locations where structural reinforcement is needed. This localized approach provides the necessary stability only where required, minimizing the overall weight increase while achieving the desired structural performance.
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 integrated design results in a more stable and lightweight vehicle door with reduced manufacturing complexity and improved handling and painting efficiency, allowing for thinner sheet metal usage and potential weight reduction.
Implementation Method 1
the at least one stiffening strut between the side impact beam and the mounting frame is bonded to the outer skin at least sectionally, preferably over its entire length
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to an outer skin module (10) of a vehicle door (12), comprising a side impact support (14) for stiffening the vehicle door (12), a shell-shaped outer skin (16) having a shell edge (18), and a peripheral mounting frame (20) on its edge, which is connected to the shell edge (18) of the outer skin (16) for fixing the outer skin (16) to a door shell (22) of the vehicle door (12), wherein the mounting frame (20) and the side impact support (14) are designed as one-piece module components (24). The invention further relates to a vehicle door (12) having such an outer skin module (10).