Vehicle Rear Door Plastic Interior Member Sealing
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Solution Overview
Problem
Existing vehicle rear doors are heavy, costly to assemble, and suffer from differential heat expansion issues due to their metal frame construction, which affects sealing and structural integrity.
Innovation Solution
A vehicle rear door design featuring a plastic interior door member with a metal profile frame glued to its exterior, where the interior door member forms the support surface against the vehicle body gasket, reducing weight and assembly complexity, and compensating for heat expansion differences between materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal frame is constructed wide to provide support surface for the vehicle body gasket, then sealing capability is improved, but weight increases considerably
Solution Approach 1:
The door is divided into separate functional components: a lightweight plastic interior door member that provides the sealing support surface, and a metal frame that provides structural strength. The plastic member is attached to the frame, allowing each material to perform its optimal function without compromising the other.
Solution Approach 2:
The door assembly combines plastic and metal materials in a composite structure. The plastic interior door member provides the sealing function while the metal frame provides structural support, creating a lightweight yet reliable door assembly that resolves the contradiction between sealing capability and weight.
2Strength
If a metal frame is used to provide structural support, then strength is improved, but differential heat expansion causes shifting of door parts
Solution Approach 1:
The door is segmented into a metal frame for structural support and a plastic interior door member for sealing and alignment. The plastic member acts as a buffer that compensates for differential heat expansion between metal and plastic components, maintaining stable door part alignment across temperature variations.
3Ease of manufacture
If the window glass is mounted directly on the metal frame from the outside, then assembly is simplified, but sealing reliability deteriorates
Solution Approach 1:
The mounting function is segmented between the metal frame (structural support) and the plastic interior door member (sealing and window mounting). The window glass is mounted on the plastic member, which provides integrated sealing features, while the frame remains dedicated to structural support.
4Device complexity
If exterior paneling is attached directly to the frame from the outside, then device complexity is reduced, but heat expansion differences cause misalignment
Solution Approach 1:
The exterior paneling is attached to the plastic interior door member rather than directly to the metal frame. This segmentation allows the plastic member to absorb differential heat expansion, maintaining panel alignment while keeping the overall assembly structure relatively simple.
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 design results in a lighter, cost-efficient, and easily assembled rear door with improved sealing and reduced weight, allowing for various vehicle body configurations and simplified electrical connections, while minimizing heat expansion issues.
Implementation Method 1
a vehicle rear door design featuring a plastic interior door member with a metal profile frame glued to its exterior
Data Source
AI summary
The invention relates to a vehicle rear door, in particular a drop-down door or a revolving door having an inner door member with a metal profile frame glued to it, exterior paneling and a window pane, wherein the inner door member and/or the window pane exclusively constitute a support surface which bears against a gasket on the vehicle body.