Vehicle Side Outer Structure with Changeable Quarter Garnish
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Solution Overview
Problem
The existing vehicle side outer panel manufacturing process is inefficient in responding to partial design changes across various body types and vehicle models, requiring new molds and excessive investment costs.
Innovation Solution
A vehicle side outer structure comprising a master side outer panel and a changeable quarter garnish panel made of synthetic resin, coupled to a quarter outer panel using fasteners, allowing for flexible design adjustments without the need for new molds, with both panels made of the same metal material for enhanced sealability and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If new molds are manufactured for each body type and design change, then design adaptability is improved, but manufacturing cost increases excessively
Solution Approach 1:
The side outer panel is divided into a master side outer panel (fixed mold) and a quarter garnish panel (changeable component). The quarter garnish panel is further segmented into upper and lower panels that can be independently replaced. This segmentation allows design changes to be made by swapping only the quarter garnish panel rather than manufacturing entirely new molds, resolving the contradiction between design adaptability and manufacturing cost.
Solution Approach 2:
The master side outer panel is designed as a universal base component that can be used across multiple body types and vehicle models. The quarter garnish panel serves as a multi-functional element that can be customized for different designs while maintaining compatibility with the same master panel. This universality reduces the need for new mold investments while maintaining design flexibility.
2Productivity
If a one-piece side outer panel is manufactured, then productivity is improved, but flexibility to respond to design changes deteriorates
Solution Approach 1:
While maintaining the master side outer panel as a one-piece manufactured component for high productivity, the quarter garnish panel is segmented into separable upper and lower portions that can be independently produced and assembled. This allows the majority of the panel to be efficiently produced as one piece while retaining flexibility to modify the quarter garnish portions for different designs.
Solution Approach 2:
The side outer panel structure transitions from a completely fixed one-piece design to a dynamic assembly where the quarter garnish panel can be easily attached and detached. This dynamic configuration enables rapid response to design changes by simply replacing the quarter garnish panel while keeping the master panel production efficient.
3Adaptability or versatility
If multiple individually manufactured pieces are assembled by welding, then design flexibility is improved, but manufacturing complexity and time increase
Solution Approach 1:
The side outer panel is segmented into a master side outer panel and a quarter garnish panel that are joined through a standardized coupling mechanism rather than complex welding operations. The quarter garnish panel itself is segmented into upper and lower portions that can be pre-assembled and then attached to the master panel, reducing on-site assembly complexity while maintaining design flexibility.
Solution Approach 2:
A coupling structure serves as an intermediary element between the master side outer panel and the quarter garnish panel, replacing complex welding operations with a simpler mechanical connection system. This intermediary coupling mechanism maintains design flexibility while significantly reducing assembly complexity and manufacturing time.
Data Source
AI summary
A vehicle side outer structure includes a master side outer panel having a front door opening and a rear door opening, and a quarter garnish panel joined to a rear edge of the master side outer panel, wherein the quarter garnish panel is configured to be changeable in response to a partial design change of a vehicle.