Vehicular Door Inner Panel Structure With Fewer Overlapping Parts
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Solution Overview
Problem
Existing vehicular doors with a metal outer panel and resin trim configuration require multiple overlapping panels, increasing production steps and costs due to the need for high-rigidity mount members fixed via welding, leading to a complex production process.
Innovation Solution
A vehicular door design featuring an outer panel and inner panel with non-overlapping portions, utilizing a double-structure configuration where the inner panel comprises multiple resin panel members, including a first panel member made of aluminum alloy for enhanced rigidity and a second panel member for additional support, fixed to the vehicle body via a hinge mechanism, reducing the number of components and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal outer panel with resin trim configuration is used, then mounting functionality is achieved, but the number of components and production complexity increase
Solution Approach 1:
The patent combines the outer panel and inner panel into a unitary structure where the inner panel is formed by joining multiple resin panel members together to create a single integrated component that performs both structural and trim functions, reducing the total number of separate parts while maintaining mounting capabilities
2Strength
If a mount member with high rigidity is used, then structural stability is improved, but the thickness and welding requirements increase production cost
Solution Approach 1:
The patent uses composite resin panel members that combine multiple materials or structures within the inner panel to achieve the required rigidity and strength without needing thick metal mount members, thereby reducing production cost while maintaining structural stability
3Stability of the object's composition
If three plate members are overlapped for door configuration, then structural integrity is maintained, but production steps and cost increase
Solution Approach 1:
The patent merges the functions of multiple plate members into a integrated inner panel structure formed by joining resin panel members, maintaining the necessary structural integrity through the composite design while reducing the number of separate assembly steps required in production
Data Source
AI summary
A vehicular door includes an outer panel having an external side surface that is configured as an outer wall surface of a vehicle and an inner panel disposed on a vehicular interior side with respect to the outer panel and having an interior side surface that faces a compartment space of the vehicle. The inner panel includes at least a first panel member and a second panel member. Each of the first panel member and the second panel member includes a non-overlapping portion that has the interior side surface facing the compartment space and an exterior side surface directly facing the outer panel without having any panels between the non-overlapping portion and the outer panel.