Manufacturers are striving to improve automotive door design by developing lighter materials that meet emissions targets, improving noise reduction, and integrating more advanced electronics. Door suppliers face the challenge of advancing all areas of door design while combining the best technologies. Noise reduction remains important as it impacts brand image and satisfaction. Door modules increasingly contain technologies like power windows and keyless entry to meet consumer demands. Kuster Holding supplies technologically advanced door modules to automakers like Audi.

1. Introducing New Concepts into Automotive Door Design
By Colin Pawsey
There are several trends of development within door design which manufacturers
are constantly striving to improve upon. The development of lightweight parts and
components in the automotive industry is an important part of the future of car-
making, as manufacturers move towards meeting EU targets on reduced carbon
emissions. The development of materials which offer weight savings along with
equal or enhanced crash performance over steel is also playing a big part in new
designs and innovations. Car makers are looking towards materials and
technologies which can improve noise reduction, and are asking for the integration
of a wide range of advanced electronic controls into door modules.
The challenge for complete door suppliers and component suppliers is to continue
the development of all areas of the automotive door, while integrating the best
technologies in each area into an overall design.
Noise Reduction
Noise, vibration and harshness (NVH) is a complex issue within the automotive
industry, with many different contributors to noise, and several ways to improve a
vehicle’s noise reduction. NVH is important nonetheless, as it can impact on the
luxury level of the car, the warranty costs, the image of the manufacturer’s brand,
and the level of customer satisfaction. The door manufacturing sector is constantly
improving the noise reduction characteristics of their products, and innovation can
be seen in the development of materials with better acoustic properties, and the use
of expandable foams, and anti-vibration pads to lessen noise through the door.
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2. Integrating Technology into Door Modules
Complete door modules are supplied by several manufacturers to the auto industry,
and the development and integration of newer more advanced technology into door
modules is being demanded by car makers and consumers alike. Cars are packed
with electronics, and new cars are expected to have options such as remote control
functions, power electric windows, and key-less operation. The module itself is
typically a steel or plastic carrier with a rubber seal; the various components of the
door are fitted to the carrier, including locking systems, window mechanisms, wiring
and speakers etc. The module is then attached to the outer door once it has been
full tested.
Kuster Holding GmbH is a leading supplier of door modules to the automotive
sector, and produce complete modules with a variety of technology built in (1). The
door module pictured below, manufactured for the Audi TT is an example of the
products they supply and the technology they have integrated. It was the first
structure supporting door module ever used in a passenger car, integrating an
aluminium support system shown in the transparent view. Included in the module
are the side window, the window regulator with the drive and the electronics, the
quarter light, the window bar and seal, along with several adjusting components.
Other door modules made by the company incorporate a support plate of steel,
aluminium or plastic; and include the window regulator, the wiring and speakers,
the lock, the interior door latch cable link and handle, the window regulator driver
motor with the door control unit, and can also include the side airbag and crash
pads. The integral door control unit provides the operation of the window and all its
functions, the central locking, the side mirror adjustment, the illumination of the
door zone, and the LED lights which indicate whether the door is opened or closed.
These door modules are supplied tested and adjusted to car manufacturers, to
reduce the adjustment and time required when fitting on the assembly line.
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IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany
t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de
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3. Source: Kuster Holding GmbH
Colin Pawsey
Colin Pawsey’s background and experience is in the water heating industry, with a focus on
technical data analysis and energy efficient products for both commercial and residential
sectors. He also works as a freelance journalist focussing on renewable and sustainable
resources, energy efficiency, and consumer information.
References:
(1) http://www.kuester.net/en/produkte/tuersysteme/tuermodule.shtml
(2) http://www.magnaclosures.com/en/innovation/comfort-
convenience/innovation/non-contact-anti-pinch
(3) http://www.conti-
online.com/generator/www/de/en/continental/automotive/themes/passenger
_cars/interior/simplify_your_drive/simplify_your_drive_en,tabNr=4.html
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