Modular Vehicle Door Panel Sharing for Full and Half Doors

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Solution Overview

Problem

Existing vehicle door designs lack a common component that can be effectively used between full doors and half doors, leading to inefficiencies in design and production.

Innovation Solution

A vehicle door system that includes a common door component, specifically a door body with a first door panel, a cover, a door knob, a latch, and a hinge, which can be used for both full and half doors, allowing for shared components and reduced mold costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate door components are used for full doors and half doors, then each door can be optimized for its specific function, but the number of components increases and production costs increase

Engineering Contradiction:

Improvedoor component compatibilityVSAvoidcomponent count

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The first door panel is designed as a universal component that can be used in both full doors and half doors. The panel includes standardized mounting features such as door knob openings, latch openings, and hinge attachment points that accommodate both door types, eliminating the need for separate component sets.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The door assembly is segmented into modular components where the first door panel is a separate, reusable module. This allows the panel to be detached and reattached between full door and half door configurations, reducing overall system complexity while maintaining functional optimization.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If separate door components are used for full doors and half doors, then each door can be optimized for its specific function, but mold costs increase

Engineering Contradiction:

Improvedoor configuration flexibilityVSAvoidmold cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single mold is designed to produce the first door panel that serves both full door and half door applications. The mold creates a panel with standardized features including door knob receptacles, latch mounting points, and hinge attachment areas that work for both door configurations, eliminating the need for separate molds.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The door panel design incorporates adjustable parameters such as opening positions for door knobs, latches, and hinges that can be configured for different door types. This allows a single mold to produce panels adaptable to various door configurations through parameter variation rather than requiring different molds.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If a detachable upper portion is used in the door frame, then the same frame can be used for both full and half doors, but the water/dust sealing and appearance are compromised

Engineering Contradiction:

Improveframe reusabilityVSAvoidwater and dust sealing

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The first door panel is designed as a dynamic component that can be detached and reattached to the door frame. The panel includes standardized attachment features that maintain proper sealing and alignment when reinstalled, ensuring water and dust protection is restored after detachment and reattachment operations.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12194821B2Vehicle half door, vehicle full door, and vehicle door group

Publication Date: 2025.01.14 KAWASAKI MOTORS LTD

AI summary

A vehicle full door includes a door body having a first door panel and a second door panel formed separately from the first door panel and connected to an upper end of the first door panel; a window provided at the second door panel; an outer knob, an inner knob, and a latch provided at the first door panel; and a hinge provided at the first door panel to turnably support the door body.