Modular Vehicle Door With Reinforced Lightweight 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 separate parts, increasing weight, cost, and assembly time.

Innovation Solution

The vehicle door is modularized with a first door module made of metal and a second door module made of lightweight plastic, reducing the number of parts and weight, and incorporating a reinforcement member to enhance structural integrity, while simplifying assembly by reducing the number of components to be assembled.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If steel materials are used for door internal panel and door frame, then collision stability and structural rigidity are improved, but door weight increases

Engineering Contradiction:

Improvestructural rigidityVSAvoiddoor weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent uses a composite structure combining metal (steel) and plastic materials. The door internal panel and door frame are made of metal material for strength, while the door module housing is made of lightweight plastic material. This composite approach maintains structural rigidity where needed while reducing overall door weight.

Inventive Principle:

Principle #40Composite materials

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

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidnumber of parts

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent integrates the door internal panel, door frame, and door module into a unified door assembly where these components are coupled together. The door module is coupled to the door internal panel, and the door frame is coupled to the door internal panel, creating an integrated structure that reduces the number of separate parts while maintaining manufacturing flexibility through modular coupling design.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple separate parts are used in door construction, then functional requirements are met, but assembly time and cost increase

Engineering Contradiction:

Improvefunctional requirementsVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent divides the door into segmented modules: a door module containing the window regulator mechanism, a door internal panel, and a door frame. These segments are designed to be coupled together through standardized interfaces, allowing for efficient assembly while meeting all functional requirements for door operation, window regulation, and structural support.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS10960737B2Door for vehicle

Publication Date: 2021.03.30 HYUNDAI MOTOR CO LTD

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 and forming a door window; wherein the second door module includes a relatively lightweight material as compared to the first door module; a reinforcement member is inserted along an edge portion forming the door window of the second door module; and a stepped portion is formed at the reinforcement member, reducing weight and cost of the door of the vehicle.