Modular Vehicle Door with Plastic Window Module
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Solution Overview
Problem
Conventional vehicle doors are heavy due to the use of steel materials and have a large number of parts, which increases weight, cost, and assembly time.
Innovation Solution
The door is modularized with a first metal door module forming the skeleton and a second lightweight plastic module forming the door window, reducing the number of parts and weight, and incorporating a door trim for assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel material is used for door internal panel and door frame, then collision stability and structural integrity are improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining steel (for the door external panel and impact beam requiring high strength) with plastic material (for the door internal panel and door frame where lower strength is acceptable). This composite approach reduces overall door weight while maintaining collision stability in critical areas through the steel components.
2Ease of manufacture
If door internal panel and door module are separately manufactured, then manufacturing flexibility is improved, but number of parts increases and assembly complexity increases
Solution Approach 1:
The patent merges the door internal panel and door frame into a single integrated door module made of plastic material. This consolidation reduces the number of separate parts and simplifies assembly procedures while maintaining manufacturing flexibility through modular design, where the integrated module can still be produced independently and then assembled with other door components.
3Adaptability or versatility
If multiple separate parts are used for door assembly, then functional specialization is improved, but assembly time and cost increase
Solution Approach 1:
The patent combines multiple functional elements (door internal panel, door frame, and associated mounting structures) into a single integrated plastic door module. This merger maintains functional specialization through design features like integrated mounting bosses and structured cavities, while dramatically reducing assembly time by eliminating the need to separately assemble multiple discrete parts.
Data Source
AI summary
A door of a vehicle may include a first door module forming a door skeleton and a second door module coupled with the first door module, wherein the second door module includes a door window and may include a relatively lightweight material as compared to the first door module and a hollow portion is formed along an edge portion of the second door module forming the door window, reducing weight and cost of the door.