Hybrid Door Module Carrier with Reinforcement
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Solution Overview
Problem
The automotive industry faces challenges in manufacturing vehicle door assemblies with effective side impact resistance while minimizing weight and manufacturing complexity, as existing intrusion beams are bulky, heavy, and costly, complicating assembly and negatively affecting fuel efficiency.
Innovation Solution
An intrusion member is integrated into the carrier module of a vehicle door assembly, formed of high-strength materials that provide enhanced side impact resistance, manufactured using over-molding techniques to streamline production and reduce weight, thereby improving fuel economy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid steel intrusion beams are used to provide side impact resistance, then safety performance is improved, but weight increases and fuel economy deteriorates
Solution Approach 1:
The patent employs composite materials by integrating a lightweight carrier module (made from materials such as aluminum or plastic) with high-strength reinforcement members (such as steel or aluminum alloy bars). This composite structure achieves the required side impact resistance while significantly reducing the overall weight compared to traditional solid steel intrusion beams.
Solution Approach 2:
The intrusion protection system is segmented into discrete reinforcement members positioned at specific locations within the door assembly, rather than using a continuous solid steel beam. This segmentation allows for optimized material placement, reducing weight while maintaining safety performance at critical impact zones.
2Strength
If separate solid steel intrusion beams are fixed to the door panel, then side impact resistance is achieved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the carrier module and reinforcement members into a single integrated assembly. The reinforcement members are pre-positioned and secured within the carrier module, which is then installed as one unit onto the door panel. This integration eliminates the need for separate installation steps for the intrusion beam and carrier, significantly simplifying manufacturing and assembly processes.
3Strength
If traditional intrusion beams are used, then side impact protection is provided, but material cost and manufacturing cost increase
Solution Approach 1:
By using composite materials and optimizing the material selection for different components (lightweight carrier with strategic high-strength reinforcement), the patent reduces overall material costs while maintaining safety performance. The integrated design also reduces manufacturing complexity and assembly time, further lowering production costs.
Solution Approach 2:
The patent optimizes the parameters of the reinforcement members (such as material grade, cross-sectional dimensions, and positioning) to achieve the minimum necessary strength for side impact protection. This parameter optimization reduces material usage and manufacturing costs while meeting safety requirements.
Data Source
AI summary
A carrier module for a motor vehicle door assembly having inner and outer panels defining a door panel structure with the inner panel having an opening for selective access to an internal door cavity between the inner and outer panels is provided. The carrier including an outer periphery configured for attachment to the inner panel to substantially close off the opening, and at least one reinforcement member fixed to the carrier, the at least one reinforcement member being formed of a material having a resistance to loading that is greater than a resistance to loading of a material of the carrier.