Rear Module Shaper Element for Light Unit Alignment

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Solution Overview

Problem

The complex and time-consuming process of positioning the bodywork skin relative to light units on motor vehicle rear doors, which can lead to inadequate clearances and flush configurations, and requires additional steps for assembly and impact absorption.

Innovation Solution

A pre-fitted rear module with a shaper element that positions and shapes the bodywork skin around the light unit, using indexing means and impact absorber ribs to ensure precise alignment and absorption of impacts, while also serving as a reinforcement to prevent denting and reduce the thickness of the skin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the bodywork skin is positioned relative to light units during assembly, then the clearances and flush configuration can be improved, but the assembly process becomes more complex and time-consuming

Engineering Contradiction:

Improveclearance and flush configurationVSAvoidassembly process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The shaper element is pre-formed with a specific geometry that corresponds to the desired final position and shape of the bodywork skin around the light unit. This preliminary shaping action eliminates the need for complex positioning operations during assembly, as the skin naturally conforms to the pre-shaped element, achieving precise clearances and flush configuration automatically.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If additional positioning steps are added to assemble the bodywork skin and light units, then the positioning precision can be improved, but the assembly time increases

Engineering Contradiction:

Improvepositioning precisionVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The shaper element combines multiple functions into a single component: it provides the positioning reference for the bodywork skin, defines the clearance geometry, and guides the flush configuration. By merging these separate positioning functions into one integrated element, the assembly process requires only a single installation step rather than multiple sequential positioning operations.

Inventive Principle:

Principle #5Merging (Combining)

3Weight of moving object

If the bodywork skin is made thinner to reduce weight, then the weight can be reduced, but the skin becomes more susceptible to denting and deformation

Engineering Contradiction:

Improveskin weightVSAvoidresistance to denting

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The shaper element creates localized reinforcement zones in the bodywork skin through its geometric design. The pre-formed geometry induces controlled stress distribution and structural reinforcement at critical areas around the light unit, providing dent resistance exactly where needed while allowing the rest of the skin to remain thin and lightweight.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9211782B2Motor vehicle rear module intended to be affixed to a rear hatch module

Publication Date: 2015.12.15 OPMOBILITY SE

AI summary

A motor vehicle rear module for fastening on a structure of a rear door, the module has a light unit, an outer bodywork skin, this skin being adjacent at least in part to the light unit, and a shaper element arranged so as to shape the skin around the light unit.