Vehicle Door Inner Support Panel Hardware Mounting
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Solution Overview
Problem
Conventional vehicle door assemblies face challenges in efficiently integrating and securing mechanical and electrical hardware modules within the door structure, leading to complexity and reduced design flexibility for window glass packaging.
Innovation Solution
The use of a stamped-metal inner support panel with a multi-sided attachment interface, featuring a header section for the window frame and a shell section with hinge and latch pillars, along with three mounting interface zones, allows for secure and flexible mounting of the door hardware module, shifting the pulley position to increase window glass drop length and enhance structural robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hardware components are preassembled onto a unit carrier to form a door hardware module, then assembly time and complexity are reduced, but the structural integration and securing of the module within the door structure become more challenging
Solution Approach 1:
The inner support panel is divided into distinct functional zones: a header section for window frame support and a shell section with mounting interface zones for the hardware module. This segmentation allows the hardware module to be preassembled separately and then integrated into the door structure through defined mounting zones, reducing overall assembly complexity while maintaining structural integrity.
Solution Approach 2:
The inner support panel acts as an intermediary component between the door hardware module and the door structure. The panel's mounting interface zones provide standardized attachment points that facilitate the integration of the preassembled hardware module, simplifying the connection process while ensuring structural security.
2Strength
If the hardware module is securely integrated into the door structure, then structural robustness is improved, but design flexibility for window glass packaging is reduced
Solution Approach 1:
The inner support panel concentrates structural reinforcement at specific mounting interface zones where the hardware module attaches, rather than requiring the entire door structure to be overly robust. This localized quality approach maintains structural integrity at critical points while preserving design flexibility in other areas, particularly for window glass packaging configurations.
Solution Approach 2:
The shell section of the inner support panel extends in multiple directions with mounting interface zones positioned at different locations and orientations. This multi-dimensional arrangement of mounting zones provides structural robustness through distributed attachment points while allowing flexible positioning options for the hardware module, thereby maintaining design flexibility for various window glass packaging requirements.
3Adaptability or versatility
If multiple mounting interface zones are provided on the inner support panel, then mounting flexibility and structural support are improved, but manufacturing complexity increases
Solution Approach 1:
The header section and shell section of the inner support panel are integrally formed as a single component, combining multiple functional zones (window frame support, hardware module mounting interfaces) into one manufactured part. This merging approach provides mounting flexibility through multiple interface zones while avoiding the added manufacturing complexity of assembling multiple separate components.
Data Source
AI summary
A door inner support panel for a vehicle door assembly includes a header section with a window frame for receiving a windowpane. A shell section is attached to the header section and mounts to a door frame of a body of a vehicle. The shell section has a hardware frame for mounting a hardware module. The hardware frame includes: a mounting interface on the an inboard surface of the shell section for coupling to an outboard surface of the hardware module; a mounting interface on a flanged surface of the shell section for sealingly attaching to a peripheral surface of the hardware module; and a mounting interface on the outboard surface of the shell section for coupling to an inboard surface of the hardware frame. A method of making the door inner support panel is also disclosed.