This paper presents a proprietary side impact protective door system within the space between the outer skin of a car door and the occupant, which will be as efficient as those already standard in frontal impact. The main objective for introducing the side impact structural system is to maximise energy absorption and minimise injury to the occupant. The developed structural side impact door system acts as a Primary Structure, to be assembled as a truly modular entity. This primary structure is also packaging modular in the sense that it acts as a carrier for the door latch, window regulator and hinges. A variation in safety and structural performance of the developed door system can be achieved by integrating the structural modular door with the vehicle body, using a patented integration system known as Door And Chassis-frame Integration Technology (DACIT). Unlike the traditional doors, that are just suspended weights, the modular door is truly structural and therefore adds strength to the vehicle body. When DACIT is used with the door system, the vehicle door becomes part of the overall vehicle structure. The design and development of the side impact modular door system for different size vehicles with and without DACIT is discussed. In addition, the five stars rating achieved during several side impact crash tests simulating Sport Utility Vehicles hitting mid-size vehicles, equipped with the developed modular door system, is presented.
Abstract