Doors Form Factor Concepting

Most likely designing our own custom latch+handle assembly

Some videos on latches

1. https://www.youtube.com/watch?v=v3iUZ-UmbOQ

2. https://www.youtube.com/watch?v=U4CWCrjODPE

3. https://www.youtube.com/watch?v=bGk6xT80VgM

Rotary Latch

Cars typically use two-stage latch, as it provides safety to “false” latching, meaning that it prevents the event of accidentally opening or not completely closing a door.

The double rotor provides more tolerance to misalignment and can withstand greater loading than the single rotor.

Handle

Functional Requirements:

• Allow the opening of the door

• Flushed with the surface for aero efficiency

Non-functional requirements:

• Aesthetically pleasing

• Easy to access and use

• Easy to manufacture

• Good durability

Constraints:

• Dimensions already defined

Some handle ideas (exterior)

Some Videos on Exterior Handle Mechanism

1. https://www.youtube.com/watch?v=9LBbjwAmvBc&list=WL&index=14&t=376s

2. https://www.youtube.com/watch?v=rGkd_hB-nKQ&list=WL&index=12

Concept Design:

1. Handle Design

2. Handle Cover

Spring Mechanism:

Functional Requirements:

• Allow for easy access to and operation of the interior handle / latch

• Should not touch seats or other components of the car

• Should not interfere with opening/closing of door

• Lightweight: should not be too heavy for hinges to handle

Non-functional requirements:

• Aesthetically pleasing

• Easy to manufacture

• Should not cause injury if bumped against (want rounded edges, soft material)

How To (general idea)

There’s a surprising amount of youtube video of people diy-ing their own door panels

https://www.youtube.com/watch?v=qr9CGT3BQGo

https://www.hotrodders.com/forum/door-panel-tutorial-145092.html → nice written tutorial w pics

https://www.youtube.com/playlist?list=PLDUPNrOKk-RF5x4L6ft7bPJao3loGOYf4 → a whole playlist!

• this guy uses ABS, so will need to figure out how PVC foam board is worked

Materials

• PVC foamboard and ABS plastic sheets seem to be the most common materials

https://www.hotrodders.com/forum/interior-door-panel-material-393769.html

https://www.hotrodders.com/forum/abs-vs-pvc-66825.html

List of benefits of PVC foamboard

1. is completely waterproof.

2. is easily cut, shaped, drilled, and sanded with regular wood working tools, and there are no splinters.

3. is easily stapled, accepts contact adhesive with no problems, can be heat formed, sewed, and glued together.

4. will never warp, rot, or absorb liquids.

5. is completely smooth, and tough enough to allow you to install and remove your panels numerous times with no problems.

6. is lightweight (1/2 the weight of solid PVC and 2/3 the weight of ABS)

7. is less expensive than solid PVC and ABS. One $30 sheet of PVC foamboard should do your door panels and kick panels, which also makes it less expensive than waterproof panel board and about the same price as good quality luan plywood.

Things to look out for

• Excess heat can warp the plastic: as in leaving the car out in the sun can cause issues.

  • The package tray (horizontal surface right under the window) is especially prone to overheating: might be best to use plywood on those surfaces

Procurement/Cost

• “None of this stuff is a building product, and it will never be available at a home center, it is used in the upholstery trade and in the sign making trade.”

• https://waterfalldecor.com/products/pvc-foam-board-embossed-wood-grain-4x8-sheets

  • About $90 for PVC Foam Boards - Celuka - 12mm - 0.55 to 0.9 density - 48" x 96"

Manufacture

• PVC can be glued together

• It can also be sewed together with a regular sewing machine