Vehicle Side Door Cover Projection for Collision-Safe Handle Operation
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Solution Overview
Problem
In vehicle side doors, differential deformation of inner and outer panels during collisions can lead to unexpected contact between the outer panel edge and the door handle, causing erroneous operation due to differences in material properties or shapes, even if the panels are made of the same material.
Innovation Solution
A cover with a projection is attached to the inner panel, extending into the space between the door handle and the outer panel, which restricts the movement of the outer panel's opening, preventing contact with the door handle by projecting into the space between the door handle and the outer panel in the vehicle's front-rear direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer panel is made of resin material with wider elastic region, then the outer panel can restore original shape after collision, but the door handle may contact the opening edge of the outer panel due to differential deformation with the inner panel
Solution Approach 1:
A cover is introduced as an intermediary component between the inner panel and outer panel. The cover includes a projection that extends into the space between the door handle and outer panel, acting as a mediator to prevent direct contact between the door handle and outer panel opening edge during collision-induced differential deformation.
Solution Approach 2:
The projection on the cover provides preliminary anti-action by preemptively blocking the path of the outer panel opening edge toward the door handle. Before contact can occur, the projection restricts the movement of the outer panel opening, preventing the harmful contact that would cause erroneous door handle operation.
2Adaptability or versatility
If the inner panel and outer panel have different shapes or structures, then the panels can be optimized for their respective functions, but differential deformation occurs during collision causing the outer panel edge to contact the door handle
Solution Approach 1:
The cover with its projection serves as an intermediary that accommodates the different shapes and structures of the inner and outer panels. The projection extends into the space between these differently configured panels to prevent their differential deformation from causing contact between the outer panel opening edge and door handle.
3Ease of operation
If no cover is provided, then the door handle is fully exposed through the opening of the outer panel for easy access, but the door handle is vulnerable to contact with the outer panel edge during collision
Solution Approach 1:
The opening of the outer panel is segmented into two functional zones: an exposed region that allows easy access to the door handle, and a protected region where the projection blocks the path of the outer panel opening edge. This segmentation maintains accessibility while preventing harmful contact during collision.
Solution Approach 2:
The projection on the cover acts as an intermediary barrier that does not completely block access to the door handle but prevents the harmful contact between the outer panel opening edge and door handle, thus protecting against collision-induced harmful factors while maintaining ease of operation.
Data Source
AI summary
A side door disclosed herein is a side door for a vehicle, and includes an inner panel, a door handle attached to the inner panel and operable by a user, an outer panel covering the inner panel from an outer side of the vehicle and having an opening that exposes the door handle, and a cover attached to the inner panel and at least partially closing the opening of the outer panel. A projection is provided in the cover to project into a space between the door handle and the outer panel at least in a vehicle front-rear direction across the door handle.