Completed Projects

Low Cost Door

• Unique, foam core, plastic shell construction results in an extremely low cost ($30.00 USF), light weight door.
• Simple construction allows fabrication/assembly in low skill environments.
• Although simple, structure meets or exceeds all applicable global side impact protection legislation.
• Low tooling costs and flexible configuration facilitates multiple styling themes using common hardware and sub-structure.

Although not patented, this totally unique low cost door concept was originated by Multimatic and has been manifest in a number of paper and advanced studies for various OEMs.

The basis of the concept is a plastic shell (either two pieces bonded together or single continuous shell) completely filled with a structural foam. This creates a very light, rigid and low cost door structure that incorporates the inner trim detail (arm rest, door pull, surface texture), outer panel "A" class surface and a carrier for all other sub-systems (sealing, latching, hinging etc.).

A simple triangulated steel sub-structure is "foamed in place" and incorporates the hinge and latch mounting reinforcements, intrusion protection beam and inner belt reinforcement. The hinges mount directly to the reinforcement through the plastic skin as is the latch which is directly actuated without rods or cables. A simple glass module that includes the frame, guidance/sealing and two pieces of sliding glass is mounted to the top of the shell (fastened through to the steel sub-structure).

Comprehensive analytical investigations have been completed that prove the structural concept including its conformance to side impact requirements. Additionally, a number of prototypes have been constructed which confirm that the functionality, weight and structural performance are as predicted. Finally, a number of independent costing studies have confirmed that this door configuration can be built at a fully accounted cost of some 15% of a conventional assembly.