Vehicle Door Storage Compartment Structural Reinforcement
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Solution Overview
Problem
Vehicle door storage compartments are prone to cracking when used to close the door, and the use of separate reinforcement brackets increases costs and causes an objectionable feel due to contact with different materials.
Innovation Solution
The door inner structure features a design with a lip, vertical ribs, and horizontal ribs that are completely covered by a skin, forming a smooth contact surface and providing structural rigidity to prevent cracking and discomfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate reinforcement brackets are used to prevent cracking, then the structural strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The reinforcement features (vertical ribs, horizontal ribs, and lip) are merged into the door inner structure itself, eliminating the need for separate reinforcement brackets. This integration maintains structural strength while reducing device complexity and manufacturing cost.
Solution Approach 2:
The reinforcement features are pre-formed as integral parts of the door inner structure during the molding process. This preliminary action prevents cracking before it occurs by having the structural reinforcements already in place, rather than adding them as separate components.
2Strength
If separate reinforcement brackets are used to prevent cracking, then the structural strength is improved, but the manufacturing cost increases
Solution Approach 1:
The reinforcement features are combined with the door inner structure in a single integrated component. This merging eliminates the need for separate manufacturing and assembly processes for reinforcement brackets, thereby reducing manufacturing cost while maintaining structural strength.
Solution Approach 2:
The door inner structure serves multiple functions: it provides the basic door panel structure, incorporates reinforcement features to prevent cracking, and offers a smooth contact surface for user interaction. This multi-functionality reduces the need for additional components and lowers manufacturing cost.
3Device complexity
If the storage compartment structure is simplified, then the device complexity is reduced, but the structural strength decreases
Solution Approach 1:
The door inner structure features localized reinforcement through vertical ribs, horizontal ribs, and a lip structure at critical areas prone to cracking. This local quality approach maintains simplicity in the overall design while providing targeted structural strength where needed.
Solution Approach 2:
The reinforcement structure is segmented into multiple functional elements (vertical ribs, horizontal ribs, and lip) that work together to prevent cracking. This segmentation allows each element to perform its specific reinforcement function while maintaining overall structural integrity without excessive complexity.
Data Source
AI summary
A door inner structure includes a first vertical wall, a second vertical wall, a floor, a lip, and a plurality of vertical ribs. The second vertical wall is disposed laterally inboard of the first vertical wall. The floor extends between and is connected to the first vertical wall and the second vertical wall. The first vertical wall, the second vertical wall, and the floor cooperate to define a storage compartment. The storage compartment has an open end that provides access to the storage compartment. The lip extends from a top edge of the second vertical wall toward the first vertical wall. The plurality of vertical ribs is disposed below the lip and extends from the second vertical wall. Each of the plurality of vertical ribs is connected to an outer surface of the second vertical wall and to an underside surface of the lip.