Rear Door Mounting System for Reduced Clearance
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Solution Overview
Problem
Existing rear door mounting systems for small commercial vehicles require significant clearance behind the vehicle for complete opening, which is often not available, and they typically involve complex mechanisms with high friction and risk of accidental door unmounting.
Innovation Solution
A rear door mounting system with a first bracket hingedly engaged with an elongated rail for vertical movement, a second bracket connected to a piston for additional vertical movement, and a stopper element to allow rotational opening, utilizing wheels for reduced friction and easy re-engagement, allowing the door to open without fully opening the rear door, thus minimizing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional liftgate system or upright rear door panels are used, then the rear door can be opened for unloading goods, but a relatively large amount of free space behind the vehicle is required
Solution Approach 1:
The patent applies dimensionality change by transitioning the door opening motion from a horizontal swing (requiring lateral clearance) to a vertical lifting motion along guide rails. The door panel moves upward in the vertical dimension rather than outward in the horizontal dimension, eliminating the need for significant clearance space behind the vehicle while maintaining full unloading capability
2Area of stationary object
If a complex mounting mechanism is used to enable vertical door movement, then clearance space is reduced, but the device complexity increases
Solution Approach 1:
The patent extracts the essential function of vertical door support from a complex multi-component mechanism and implements it through simplified guide rails with rollers. By taking out only the necessary elements (guide rails, rollers, brackets) and eliminating unnecessary intermediate components, the design achieves vertical door movement with minimal complexity while reducing clearance requirements
3Ease of operation
If a wire winding mechanism with pulley is used to enable vertical door movement, then the door can open without projecting backward, but the mechanism complexity and friction increase
Solution Approach 1:
The patent replaces the complex wire winding mechanism with pulley with a direct roller-on-rail mechanical system. Instead of using flexible cables and rotating pulleys, the design uses rigid guide rails with rollers that move directly along the vertical path, substituting a multi-component flexible mechanical system with a simpler rigid guidance system that reduces friction and complexity
4Reliability
If traditional mounting systems are used, then the door can be mounted securely, but the risk of accidental door unmounting increases
Solution Approach 1:
The patent applies beforehand cushioning by incorporating safety features that prevent accidental unmounting before it can occur. The guide rails are designed with retention features that actively hold the rollers in place, and the bracket connections include anti-disengagement mechanisms that cushion against unintended separation, ensuring door security through preventive design rather than reactive measures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for efficient access and unloading with reduced space requirements, fewer components, lower friction operation, and reduced risk of accidental door unmounting, making it suitable for small commercial vehicles used for frequent deliveries.
Implementation Method 1
A wheel is provided inside the elongated rail and is movable along the elongated rail during the first and second movements
Implementation Method 2
a second bracket mounted to the rear door and being connected to a piston which is movably engaged with a cylinder
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A motor vehicle (1) comprising a rear door (2) mounted to the motor vehicle (1) using a mounting system (16) such that the rear door (2) is movable from a closed position to a fully open position via a first, mainly vertical movement (M1), and a second, mainly vertical movement (M2), and a third, rotational movement (M3). The mounting system (16) comprises a first holding means (3) comprising a first bracket (5) mounted to the rear door (2), the first bracket (5, 5a, 5b) being movably engaged with an elongated rail (6), the rail (6) being fixedly mounted to the vehicle (1). The mounting system (16) further comprises a second holding means (4) comprising a second bracket (7) mounted to the rear door (2), the second bracket (7) being connected to a piston (8) which is movably engaged with a cylinder (9), the cylinder (9) being hingedly mounted to a lower part of the vehicle (1). The present invention also relates to a method of operating a rear door (2) mounted to a motor vehicle (1).