Modular Skeleton Door Assembly for Open-Air Vehicle Conversion
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Solution Overview
Problem
Conventional vehicle doors do not allow for easy conversion to a skeleton door configuration that provides an open air experience while maintaining protection, and existing tubular open air doors are typically stored separately, leading to loss or damage.
Innovation Solution
A modular vehicle door assembly with a removable module, including intrusion beams and a frame member, that can be converted to a skeleton door by attaching a module hinge and latch assembly, allowing for secure attachment to the vehicle and easy storage of the conventional door.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional door with full outer skin is used, then protection is provided, but open air experience and visibility are compromised
Solution Approach 1:
The door assembly is segmented into a permanent door housing and a removable module containing intrusion beams. This allows the intrusion protection functionality to be separated from the conventional door skin, enabling conversion to a skeleton door configuration by removing the module while maintaining protection when installed
Solution Approach 2:
The door assembly transitions from a static conventional door to a dynamic configuration that can be converted between enclosed and skeleton modes. The removable module design enables the door to adapt its structure based on operational requirements, providing both protection and open air experience as needed
2Adaptability or versatility
If tubular open air doors are provided as separate optional doors, then open air experience is provided, but storage and security issues arise
Solution Approach 1:
The skeleton door module is merged with the conventional door housing as an integrated assembly. The module containing intrusion beams is permanently housed within the door structure, eliminating the need for separate storage and ensuring the components remain secure and organized within the vehicle
Solution Approach 2:
The door assembly serves multiple functions: it provides conventional door protection when the module is installed, enables open air experience when the module is removed, and maintains intrusion protection through the removable module design. This multi-functionality eliminates the need for separate optional doors
3Adaptability or versatility
If a removable module with intrusion beams is used, then conversion to skeleton door is enabled, but device complexity increases
Solution Approach 1:
The door assembly is divided into a permanent door housing and a removable module containing intrusion beams. This segmentation allows the complex intrusion protection system to be isolated in a separate, self-contained module that can be easily removed and installed without affecting the rest of the door structure
Solution Approach 2:
The intrusion beam module is extracted as a separate, removable component from the conventional door assembly. This extraction simplifies the conversion process by allowing the module to be removed as a single unit, reducing the complexity of converting between conventional and skeleton door configurations
Data Source
AI summary
A vehicle door assembly includes a door housing configured for covering a vehicle access opening. A frame member is disposed within the door housing. A module includes an intrusion beam coupled to the frame member and removable from the door housing. The module is configured to accept attachment of a module hinge and a module latch to provide a secondary door assembly. A modular vehicle door assembly and a method of assembling a door assembly to a vehicle are also disclosed.