Hybrid Motor Vehicle Door Base Support with Integrated Panelings
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Solution Overview
Problem
Existing composite components for motor vehicle doors are complex and costly to produce, with limited potential for weight reduction and simplification, due to the need for intricate fastening of multiple components.
Innovation Solution
A composite component design featuring a hybrid base support with integrated functional elements, where metal and plastic are combined through high-pressure forming and injection molding, allowing for simplified production and integration of reinforcements, reducing the need for separate attachments and enabling precise, cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components are used for door construction (base support, outer paneling, inner lining), then functional requirements can be met, but production complexity and costs increase significantly
Solution Approach 1:
The patent combines the base support, outer paneling, and inner lining into a single integrated door component. The base support serves as the structural core to which the outer and inner panelings are directly attached, eliminating the need for separate mounting brackets and fastening systems. This merging of components simplifies production and reduces assembly complexity while maintaining all necessary functional requirements.
Solution Approach 2:
The base support is designed as a multi-functional component that simultaneously provides structural strength, mounting surfaces for panelings, and integration points for door mechanisms. By making the base support universal and multi-functional, the patent reduces the total number of parts needed and simplifies the overall construction process.
2Productivity
If traditional fastening methods are used to attach panelings to base support, then components can be assembled, but production costs and manufacturing time increase
Solution Approach 1:
The outer and inner panelings are pre-attached to the base support during the molding process rather than being assembled separately later. This preliminary action of attaching components during manufacturing eliminates subsequent assembly steps, reduces production time, and lowers labor costs while maintaining assembly quality.
Solution Approach 2:
The patent replaces traditional mechanical fastening systems (screws, clips, adhesives) with an integrated molding approach where panelings are directly formed onto the base support. This substitution of mechanical assembly with a unified manufacturing process significantly improves productivity and reduces manufacturing costs.
3Weight of moving object
If weight reduction measures are implemented in composite components, then fuel efficiency improves, but structural strength and load-bearing capacity may be compromised
Solution Approach 1:
The base support is designed with varying wall thicknesses and reinforcement zones at specific locations where load-bearing requirements are highest. This local quality approach allows the door to be lightweight in non-critical areas while maintaining sufficient strength where needed, optimizing the weight-strength ratio.
Solution Approach 2:
The patent uses a composite construction combining the rigid base support with the outer and inner panelings. This composite structure achieves weight reduction compared to fully metal construction while maintaining adequate strength through the integrated design and strategic reinforcement of the base support in load-critical areas.
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
This approach results in a lightweight, precisely manufactured component with reduced production costs, improved load-bearing capacity, and simplified assembly, while allowing for optical adaptation across various models without significant changes to the base support.
Implementation Method 1
the metal support element is in the form of an internal high-pressure formed part. A metal support element of this type can namely be formed particularly precisely and in accordance with the load.
Implementation Method 2
the plastic has been applied at least partially to the metal carrier element in an injection molding process. Such an injection molding process can be integrated particularly well in a high-pressure forming process
Data Source
Figure 1a~2a
Figure 2b~3
Figure 4a~4d
AI summary
The compound component has a base support (10) which is connected to an outer cover section (12) on an outer side. The base support is connected to an interior lining part (14) facing the inner side of a motor vehicle interior. The base support is designed as a hybrid component, which has a metal support element partially fitted with plastic. An independent claim is also included for a method for manufacturing a compound component, particularly a door of a motor vehicle.