Car Door Types and Study

Door Design
DOOR TYPES & CONVENTIONAL DOOR STUDY (IN BRIEF)
BY Nelson jasper W
2014 RLE INTERNATIONAL Group
1 I www.rle.international
Automotive Door Development process in conceptual phase

STYLING
DOOR TYPE
PROJECT MODULES
ERGONOMICS & COMFORT
SHUT LINE STUDY
DOOR OPENING STUDY
WINDOW KINEMATICS
SEALING CONCEPTS
CONCEPT GEOMENTRY
PACKAGE
STRUCTURAL OPTIMIZATION
PROJECT DURATION
STYLING
The way in which something is made, designed, or performed is styling.
DOOR TYPES
CONVENTIONAL DOOR
SCISSOR DOOR
BUTTERFLY DOOR
DOOR TYPES
SUICIDE DOOR
GULL-WING DOOR
SLIDING DOOR
CANOPY DOOR
DOOR TYPES
CONVENTIONAL DOOR
A conventional door, also known as a regular door is a type of door that is hinged
at the front-facing edge of the door, and so allows the door to swing outward from the body of the car.
These doors are relatively safe, in that if they are opened during forward motion of the vehicle, the wind
resistance will work against the opening door, and will effectively force its closure
Panel Door
Sash Door
SCISSOR DOOR
Scissor doors (also beetle-wing doors, turtles, switchblade doors, Lamborghini doors,
and Lambo doors) are automobile doors that rotate vertically at a fixed hinge at the front of the door,
rather than outwardly as with a conventional door.
BUTTERFLY DOOR
Butterfly doors or vertical doors are a type of door sometimes seen on high-performance automobiles.
They are similar to scissor doors. While scissor doors move straight up via hinge points at the bottom of
the A-pillar, butterfly doors move up and out via hinges along the A-pillar. This makes for easier entry/exit
at the expense of requiring more opening space than needed for scissor doors.
SUICIDE DOOR
A "suicide door" is the slang term for a door hinged at its rear rather than the front.
Such doors were originally used on horse-drawn carriages, but are rarely found on modern vehicles
due primarily to safety concerns.
Popularized in the custom car trade, the term is avoided by major automobile manufacturers in favor
of alternatives such as "coach doors" (Rolls-Royce),"Flex Doors" (Opel), "freestyle doors" (Mazda),
"rear access doors" (Saturn), and "rear-hinged doors.
DOOR TYPES
SLIDING DOOR
A sliding door is a type of door is mounted on or suspended from a track for the door to slide, usually
horizontally. It is a feature predominately relegated to minibuses and buses to provide a large entrance
or exit for passengers without obstructing the adjacent pathway between the vehicle and any adjoining
object or the side(s) of passenger and commercial vans so as to allow a larger unobstructed access to
the interior for loading and unloading.
Sliding doors are often used in mini MPVs
CANOPY DOOR
A vehicle canopy is a rarely used type of door for cars. It has no official name so it is also known as an
articulated canopy, bubble canopy, cockpit canopy, canopy door, or simply a canopy.
A canopy is a type of door which sits on top of a car and lifts up in some way, to provide access
for passengers. It is similar to an aircraft canopy. There are no set rules to canopies, so they can be
hinged at the front, side, or back, although hinging at the front is most common.
Canopy doors are rarely used on production cars, and are sometimes used on concept cars.
GULL-WING DOOR
Gull-wing door is an automotive industry term describing car doors that are hinged at the roof rather
than the side, as pioneered by the 1952 Mercedes-Benz 300SL race car (W194) and
its road-legal version (W198) introduced in 1954.
ERGONOMICS & COMFORT

Ergonomics is the science of refining the design of products to optimize them for human use. Human characteristics, such as height, weight,
and proportions are considered, as well as information about human hearing, sight, temperature preferences, and so on.
Ergonomics is sometimes known as human factors engineering.
CONVENTIONAL DOOR DESIGN

ROOF
B PILLAR
C PILLAR
A PILLAR
ORVM
BSO
FENDER
SILL AREA
CLOSURES
DOOR STUDY
SHUT LINE STUDY

HINGE AXIS STUDY
LATCH STUDY
DOOR OPEN STUDY
CHECK LINK STUDY
GLASS DROP STUDY
DOOR SEAL STUDY
TAIL GATE
HOOD
FRONT DOOR
REAR DOOR
SHUT LINE STUDY or DOOR GAP
What is shut line?
Shut lines are the small spaces where sections of the vehicle body meet, i.e. between front wing and front door
Or
The line between a closed door and the bodywork.
Shut line Design Consideration
Shut line gap will be minimum 3.5- 5mm gap
Shut line depends on the Hinge axis study and door opening study
Shut line study will be engineered by the technical team from the given
styling shut line.
Shut line can be seen in all closure part.
HINGE AXIS STUDY
What is Hinge axis ?

Hinge axis is the connecting line between two hinge centre
Hinge axis Design Consideration
Hinge axis is inboard 86.5-88 deg in front view
Hinge axis is 90-92 deg at side view
Hinge axis inboard at front view and side view will vary as per door mass and weight
HINGE AXIS 90 - 92 Deg - SIDE VIEW
FRONT VIEW
SIDE VIEW
HINGE AXIS INBOARD
FRONT VIEW
86.5 - 88 deg
90 92 deg
NOTE: THE ABOVE SHOWN HINGE AXIS ANGLE ARE NOT MANDATORY,IT DEPENDS ON THE OEM AND DOOR MASS.
LATCH STUDY & STRIKER POSITION

UPR HINGE
LATCH STUDY DEPENDS ON THE HINGE POSITION
LATCH POSITION
UPR HINGE
CENTER POINT
LWR HINGE
LWR HINGE
LATCH POSITION
AND
STRIKER POSITION
A - DISTANCE BETWEEN SILL AREA AND LOWER HINGE

B - DISTANCE BETWEEN UPR AND LWR HINGE
A & B DISTANCE WILL BE VARY AS PER DOOR MASS
HINGE POSITION AND LATCH POSITION DEPENDS ON THE DOOR MASS
LATCH POSITION CAN BE POSITIONED WITH RESPECT TO CENTER POINT BETWEEN THE UPR AND LWR HINGE
DOOR OPEN ANGLE
72 deg + 10 deg tolerance
Door closed condition
Hinge axis
Door Open condition
Front & Rear Door Opening angle 72 deg + 10 deg tolerance

Conditions Front Door should not clash with fender, A pillar, proper clearance should be maintain
between BSO
CAR SIDE WINDOW
FRONT DOOR SIDE WINDOW GLASS
Glass A surface is always proposed by stylist
Olden days car windows are Planar windows

Present car windows are Curved windows (circular &Spherical)
d - Day light curve

b - Boundary curve towards the B Pillar
c - Roof curve
S car side window
Advantages of curved windows

Strength
Aesthetic
Aerodynamic Enhancement
GLASS DROP STUDY
GLASS RUN PATH WILL BE DERIVED FROM THE BELOW SHOWN BOUNDRYS B-PILLAR BOUNDRY & ORVM BOUNDRY
B-PILLAR AND ORVM BOUNDRYS ARE FROM STYLING
ORVM BOUNDRY LINE
B PILLAR BOUNDRY LINE

GLASS RUN PATHS
Thickness 3.8 to 4.1 mm
Material - LAMINATED GLASS
GLASS DROPPED CONDITION
At the 80% glass dropped condition, proper clearance should be maintain with environment part
NOTE: THE ABOVE SHOWN GLASS DROP STUDY IS NOT THE COMPLETE STUDY , BUT IT IS THE BASIC IDEA TO UNDERSTAND THE STUDY.
DOOR SEALS
SEAL TYPES
DOOR PRIMARY SEAL

WAIST BELT INR & OTR
GLASS RUN
ENCAPSULATED GLASS SEAL
SUNROOF SEAL
HOOD SEAL
BACK WINDOW / LIFT GATE SEAL
13 mm
seal
Door
Sec A-A
CAD -DEVELOPMENT STAGE

STAGE 1
STAGE 2
HINGE AXIS STUDY
SHUT LINE STUDY
1st SHUT LINE BY STYLING
SHUT LINE GAP

W R T FRT DOOR
LATCH STUDY
A - SURFACE EXTRACTED FROM STYLING
REAR DOOR
VEHICLE CENTER
4 mm
STAGE 1
1. FROM THE GIVEN STYLING THE DOOR OTR SURFACE WILL BE EXTRACTED
2. EXTRACTED DOOR OTR SURFACE WILL BE TRIMMED WITH THE GIVEN STYLING SHUT LINE
STAGE 2
1.HINGE AXIS STUDY
2.SHUT LINE STUDY
3.LATCH STUDY
FRONT DOOR
SHUT LINE
REAR DOOR SHUT LINE
Detail A
Detail A

TOOLING DIRECTION
STAGE 3
ENGINEERED
SEAL SURFACE
SEAL SURFACE WILL BE SHARED WITH BSO
DOOR SEAL AREA

STAGE 3
1.SEAL SURFACE ENGINEERED AND DESIGNED BY ENGINEERING DEPT
2.MAINTAIN PROPER DRAFT ANGLE AND FLOW WITH TOOLING DIRECTION
3.LATCH MOUNTING AREA SHOULD BE FLAT
LATCH AREA

STAGE 5
STAGE 4
AB FLANGE
SECTION DEVELOPMENT WITH RESPECT TO INPUTS

SEAL SURFACE
NO OF SECTIONS
INPUT FOR DEVELOPING THE INR PANEL ARE

1.STYLING A SURFACE
2.SEAL SURFACE
3.AB FLANGE
A PILLAR SECTION
B PILLAR SECTION
ROOF SECTION
UPR AND LWR HINGE SECTION
CHECK LINK SECTION
LATCH SECTION
SILL SECTION
OTR HANDLE SECION
DEVELOPED SECTION FROM THE INPUTS
STAGE 5
EXAMPLE FOR ROOF SECTION
A
STYLING A SURFACE
OTR PANEL
SEAL SURFACE
AB FLANGE
OF BSO
SEC A-A
STAGE 6
STAGE 7
STAGE 8
PACKAGE
STRUCTURAL OPTIMIZATION
DEVELOPED (CONSEPT GEOMENTRY) INNER PANEL FROM THE SECTIONS
DIFFERENTS BETWEEN PANEL AND SASH DOOR

PANEL DOOR
SASH DOOR
Panel Door- Both the inr and otr panel will be stamped completely with
multiple stage operation
Sash Door- Both the inr and otr panel will be stamped up to the waist level with
Multiple stage operation, sash will be manufactured
separately
INR AND OTR PANEL

WAIST AREA
A OUTER PANEL
B INNER PANEL
A OUTER PANEL
B INNER PANEL
F OTR BELT REINFO
C GLASS CHANNEL
G INTRUSION BAR
C1 FRAME ASSEMBLY MODULAR DOOR
D - HINGE REINFO
H HINGES
C2 WINDOW FRAME SASH
E INR BELT REINFO
Examples of Door saftey beam positioning
Safety beam are other wise called Door Guard Beam

Door Guard beam is designed to absorb the impact energy
Door safety beam Cross Sections
Door Guard Beam
ABOVE FIGURE SHOWS THE DOOR GUARD BEAM PLACED IN DIRERENT POSITION
HINGE TYPES AND ITS PARTS
Forged steel hinges
CHECK LINK
Regarding automobile doors, a door is held at intermediate holding positions and fully-opened holding position by a
check link device in order to prevent the door from being closed due to externally applied load such as wind, etc.
In addition, during parking on a sloping road or on a curbstone, a door is opened and should be held in this intermediate
open position, and therefore the following device has been known: the door can be held in an intermediate open position
in addition to the fully-opened angle position, and the door can be moved from such holding positions upon application
of a certain level or more of opening/closing force.
Lift gate single joint 3 screw hinge
1.Movable Half Hinge

2.Fixed Half Hinge
3.Pin retaining screw
4.End stop tooth
DOOR PARTS
DOOR PARTS
OTR PANEL
SHEET METAL PARTS

LATCH MECH
MECHANISM PARTS
WINDOW WINDING MECH
INR PANEL
HINGE REIFO UPR & LWR
LATCH REIFO
INSIDE HANDLE MECH

DOOR GUARD BEAM
OUTSIDE HANDLE MECH
WAIST REINFO INR & OTR

CHECK LINK MECH
SASH REIFO
DOOR TRIM
DOOR PARTS
TRIM PARTS
LOCK REIFO
INR HANDLE
WINDOW WINDER HANDLE
OUTSIDE HANDLE MECH
PRIMARY SEAL
SEAL PARTS
GLASS RUNS
WAIST BELT INR / OTR
GLASS
To be continue with some more details

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Door Design

DOOR TYPES & CONVENTIONAL DOOR STUDY (IN BRIEF)

Automotive Door Development process in conceptual phase

ERGONOMICS & COMFORT

SHUT LINE STUDY

DOOR OPENING STUDY

The way in which something is made, designed, or performed is styling.

2014 RLE INTERNATIONAL Group

2014 RLE INTERNATIONAL Group

2014 RLE INTERNATIONAL Group

2014 RLE INTERNATIONAL Group

ERGONOMICS & COMFORT

2014 RLE INTERNATIONAL Group

CONVENTIONAL DOOR DESIGN

SHUT LINE STUDY

2014 RLE INTERNATIONAL Group

SHUT LINE STUDY or DOOR GAP

What is shut line?

Shut line Design Consideration

Shut line gap will be minimum 3.5- 5mm gap

Shut line can be seen in all closure part.

2014 RLE INTERNATIONAL Group

HINGE AXIS STUDY

What is Hinge axis ?

2014 RLE INTERNATIONAL Group

LATCH STUDY & STRIKER POSITION

LATCH STUDY DEPENDS ON THE HINGE POSITION

A - DISTANCE BETWEEN SILL AREA AND LOWER HINGE

2014 RLE INTERNATIONAL Group

DOOR OPEN ANGLE

72 deg + 10 deg tolerance

Door closed condition

Door Open condition

Front & Rear Door Opening angle 72 deg + 10 deg tolerance

CAR SIDE WINDOW

FRONT DOOR SIDE WINDOW GLASS

Glass A surface is always proposed by stylist

Olden days car windows are Planar windows

d - Day light curve

Advantages of curved windows

2014 RLE INTERNATIONAL Group

GLASS DROP STUDY

ORVM BOUNDRY LINE

B PILLAR BOUNDRY LINE

Thickness 3.8 to 4.1 mm

Material - LAMINATED GLASS

GLASS DROPPED CONDITION

2014 RLE INTERNATIONAL Group

DOOR PRIMARY SEAL

CAD -DEVELOPMENT STAGE

1st SHUT LINE BY STYLING

SHUT LINE GAP

A - SURFACE EXTRACTED FROM STYLING

REAR DOOR SHUT LINE

2014 RLE INTERNATIONAL Group

CAD -DEVELOPMENT STAGE

SEAL SURFACE WILL BE SHARED WITH BSO

DOOR SEAL AREA

2014 RLE INTERNATIONAL Group

CAD -DEVELOPMENT STAGE

SECTION DEVELOPMENT WITH RESPECT TO INPUTS

INPUT FOR DEVELOPING THE INR PANEL ARE

2014 RLE INTERNATIONAL Group

DEVELOPED SECTION FROM THE INPUTS