OEM & Lieferant - Ausgabe 1/2021

76 Lightweight and safe Dr. Marcus Klopp, Director Advanced Development Door Modules Brose, Michael Thienel, Expert Door Concepts Advanced Development Door Modules Brose and Eike Ritthaler, Project Engineer Advanced Development Door Modules Brose Door moduleswith innovative carrier materials help tomeet stricter crash test guidelineswhile savingweight and costs. As of 2023, the Insurance Institute for High- way Safety (IIHS) is raising the criteria for its side impact tests. Vehicle flanks will then have to withstand over 80 percent more en- ergy than before. Against this background, car manufacturers are not only examining the design of their bodies but also their door struc- tures. Although the interior of the door plays only a minor role in the crash, door modules used there enable new approaches to the test procedure. Pre-tested systems for uncomplicated assembly processes The door module principle is well estab- lished in the automotive industry: The most impor tant functional components of the vehicle door are combined into one system on a carrier plate. In the conventional con- struction of side doors, many individual com- ponents must first be assembled on a door assembly line. With the modular construc- tion method, however, the manufacturer re- ceives the system as a pre-tested unit from the supplier. It can be inserted into the door frame with just a few hand movements. The more functions of the door are integrated on the module, the less additional work has to be carried out until the side door is attached to the body. Various equipment variants are already implemented at the supplier and, if required, are made available just-in-se- quence, which means in line with the cus- tomer’s production cycle. Door modules in a side crash Even with the adapted IIHS system, the criteria for lateral barrier impact remain unchanged – intrusion depth and occupant exposure. The key factor for the test re- sult is the structural integrity of the body. Inside the door, only the hinges, the lock as well as the sill cover and the side impact beam are relevant. The interior area of the door, in which the module is located, only plays a minor role. Therefore, the decision for or against the modular design has only minimal effects on the test result of the vehi- cle. In the future, however, vehicles will have to be able to withstand crash loads at a higher level in the event of a side impact. According to the announcements of the IIHS, mass and impact velocity of the barrier will increase. The energy input will change from 145 kJ to 265 kJ. Vehicle manufacturers have to react to the increased requirements with adjust- ments to the vehicle body. Door modules can support OEMs in this task. The possibilities are particularly promising when using carrier plates made of continuous glass reinforced thermoplastics, so-called organo sheets. Weight reduction with functional advantages Organo sheet is an innovative lightweight con- struction material. It consists of continuous glass fibers embedded in a thermoplastic ma- trix. When the material is heated, it acquires a soft consistency and can be pressed into the desired shape. At the same time, reinforce- ments and functional elements made of plastic Established structure of a modular door. The door system with all components is attached to the door frame and covered by the interior paneling. Images: © Brose Innovations S H A R E