Vehicle door assembly, vehicle and method of assembling a vehicle door assembly

Abstract

This invention relates to the field of vehicle technology, specifically to a door assembly, a vehicle, and a method for assembling the door assembly. The door assembly includes a door sheet metal part and a door interior panel mounted and connected to the inner side of the door sheet metal part. The door interior panel includes a main body portion and an edge mating portion connected to the edge of the main body portion. The edge mating portion is adapted to fit against the inner surface of the door sheet metal part. When the door interior panel is mounted and connected to the door sheet metal part, the distance between the main body portion and the edge mating portion along the thickness direction of the main body portion is a first distance. When the door interior panel is in a free state, the distance between the main body portion and the edge mating portion along the thickness direction of the main body portion is a second distance. The second distance is greater than the first distance.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and more specifically to door components, vehicles, and assembly methods of door components. Background Technology

[0002] Door components are one of the most important exterior parts of a vehicle, typically assembled from door trim panels and door sheet metal. During vehicle development, the fit between the door trim panels and the door sheet metal is a key control factor affecting the overall appearance and perceived quality of the vehicle.

[0003] Currently, there is a common problem in the industry of excessive gaps between the interior trim panels and the sheet metal of the doors, with actual measured gaps ranging from 0.5mm to 1.2mm.

[0004] Traditional development methods rely heavily on post-production vehicle testing, mold repair, and tooling adjustments to reduce gaps. This approach requires modifications after manufacturing, which can lead to long development cycles and high development costs. Summary of the Invention

[0005] One of the objectives of this invention is to provide a door assembly, a vehicle, and a method for assembling the door assembly, in order to solve the problem of excessive matching gaps in the existing door assembly.

[0006] In a first aspect, this application provides a vehicle door assembly, including a vehicle door sheet metal part and a vehicle door interior panel mounted and connected to the inner side of the vehicle door sheet metal part. The vehicle door interior panel includes a main body portion and an edge mating portion connected to the edge of the main body portion. The edge mating portion is adapted to fit against the inner surface of the vehicle door sheet metal part. When the vehicle door interior panel is mounted and connected to the vehicle door sheet metal part, the distance between the main body portion and the edge mating portion along the thickness direction of the main body portion is a first distance. When the vehicle door interior panel is in a free state, the distance between the main body portion and the edge mating portion along the thickness direction of the main body portion is a second distance. The second distance is greater than the first distance.

[0007] According to the above technical features, the difference between the second distance and the first distance can compensate for the deformation of the door interior panel and the door sheet metal. When the door interior panel and the door sheet metal are assembled and connected, the difference between the second distance and the first distance can offset the deformation caused by the assembly, thereby reducing the gap between the edge mating part and the inner surface of the door sheet metal, and improving the appearance quality and perceived quality of the door assembly.

[0008] In some embodiments, when the door interior panel is assembled and connected to the door sheet metal part, the included angle between the main body and the edge mating part on the inner side of the door interior panel is a first included angle; when the door interior panel is in a free state, the included angle between the main body and the edge mating part on the inner side of the door interior panel is a second included angle; the second included angle is greater than the first included angle.

[0009] According to the above technical features, when the door interior panel is in a free state, the edge mating part is deflected relative to the main body towards the door sheet metal part. In this way, when the door interior panel is assembled and connected to the door sheet metal part, the deflection of the edge mating part can offset the deformation generated during assembly, so that the edge mating part returns to a state parallel to the main body, so that the edge mating part fits more tightly with the inner surface of the door sheet metal part, thereby further reducing the gap between the door interior panel and the door sheet metal part after assembly.

[0010] In some embodiments, along the thickness direction of the main body, the edge mating portion is closer to the door sheet metal than the main body; the door interior panel also includes a transition portion connecting the main body and the edge mating portion, extending from the main body to the edge mating portion and toward the door sheet metal.

[0011] Based on the aforementioned technical features, a transition section connects the main body and the edge mating section, buffering the dimensional difference between the main body and the edge mating section along the thickness direction of the main body. This results in a smoother and more streamlined appearance for the door interior panel. Furthermore, because the edge mating section is equipped with compensation amount and compensation angle, during assembly of the door interior panel and the door sheet metal, deformation occurs through the transition section, causing the edge mating section to move with compensation amount and compensation angle. This compensation amount and angle cancel out the deformation during assembly, reducing gaps. In this way, the edge mating section is less prone to deformation, ensuring a close fit between the edge mating section and the inner surface of the door sheet metal, guaranteeing assembly accuracy.

[0012] In some embodiments, the transition portion is an arc-shaped structure that arches toward the door sheet metal.

[0013] Based on the aforementioned technical features, the arc-shaped structure allows for a smoother and more seamless connection between the edge mating parts and the main body. Furthermore, the arc-shaped structure arches towards the door sheet metal. When the door interior panel is assembled with the door sheet metal, causing the edge mating parts to deflect away from the door sheet metal, the arc-shaped structure only needs to increase its bending degree to cause the edge mating parts to deflect, making it easier to compensate for deformation and thus quickly reducing the gap between the door components.

[0014] In some embodiments, a plurality of connecting structures are provided between the edge of the main body facing the edge mating portion and the door sheet metal part, and the plurality of connecting structures are arranged along the length direction of the edge mating portion; the distance between two adjacent connecting structures is less than or equal to 170mm.

[0015] Based on the aforementioned technical features, the connecting structure is used to achieve a fixed connection between the door interior panel and the door sheet metal. Multiple connecting structures are arranged along the length of the edge mating portion, which improves the stability of the fixed connection between the door interior panel and the door sheet metal, preventing increased gaps due to vibration, deformation, or other factors. The distance between two adjacent connecting structures is less than or equal to 170mm, which reduces the span of the unsupported free area of ​​the door interior panel between adjacent connection points, improving local rigidity and bending resistance, and reducing assembly deformation and gap fluctuations.

[0016] In some embodiments, the edge mating portion includes a mating portion body and a contact portion disposed on the outer edge of the mating portion body. The contact portion protrudes toward the door sheet metal relative to the surface of the mating portion body facing the door sheet metal. The door sheet metal includes an outer sheet metal and an inner sheet metal, with the inner sheet metal located between the outer sheet metal and the door interior panel. A weld point connects the outer sheet metal and the inner sheet metal, and the distance between the weld point and the contact portion along a second direction is greater than or equal to 2.5 mm. The second direction is perpendicular to the length direction of the edge mating portion and parallel to the main body.

[0017] Based on the aforementioned technical features, during the welding of the outer and inner sheet metal parts of a car door, welding protrusions or pits may form at the weld points. If the interior trim panel is assembled with the welded area, the weld point can easily lift the interior trim panel, increasing the gap between the interior trim panel and the car door sheet metal. In this embodiment, the contact portion protrudes towards the car door sheet metal relative to the surface of the mating part body facing the car door sheet metal. Therefore, when the edge mating part is fitted against the inner surface of the car door sheet metal, the contact portion can contact the inner surface of the car door sheet metal, creating a gap between the mating part body and the inner surface of the car door sheet metal. A distance greater than or equal to 2.5mm between the weld point and the contact portion allows the weld point to avoid contact with the contact portion, thereby preventing welding thermal deformation and thermal stress from affecting gap stability.

[0018] In some embodiments, the surface flatness of the area on the door sheet metal suitable for connecting the edge mating portion is less than or equal to 1 mm.

[0019] Based on the above technical features, the surface flatness of the assembly area between the door sheet metal parts and the edge mating parts can be improved, thereby making the assembly gap between the door sheet metal parts and the edge mating parts more uniform and reducing the impact of the door sheet metal parts on the assembly gap.

[0020] In some embodiments, the gap width between the door sheet metal part and the edge mating part along the thickness direction of the main body is less than or equal to 0.25 mm.

[0021] Based on the above technical features, the gap between the door sheet metal parts and the edge mating parts can be minimized, solving the problem of excessive gap in the existing technology, improving the appearance quality and perceived quality of the finished product, reducing the steps of actual vehicle debugging, mold modification, tooling adjustment, etc., saving production costs and improving production efficiency.

[0022] In some embodiments, the door panel metal part includes opposing first edge portions and second edge portions, the first edge portions being adapted to hinge with the vehicle body, and edge mating portions engaging with the second edge portions.

[0023] Based on the aforementioned technical features, the first edge portion and the second edge portion are opposite each other. The first edge portion of the door sheet metal is hinged to the vehicle body, thus the first edge portion is a non-exterior surface, while the second edge portion is an exterior surface. The edge mating portion mates with the second edge portion. Through the aforementioned technical features, the gap between the edge mating portion and the door sheet metal is less than or equal to 0.25mm, which allows for precise control of the exterior surface of the door sheet metal and improves its appearance quality.

[0024] Secondly, this application provides a vehicle including the door assembly provided in the first aspect of this application.

[0025] Thirdly, this application provides a method for assembling a door assembly for assembling the door assembly provided in the first aspect of this application. The assembly method includes assembling a door interior panel to the inside of a door sheet metal part, and bending the edge mating portion relative to the main body portion in a direction away from the door interior panel so that the edge mating portion fits against the inner surface of the door sheet metal part.

[0026] The beneficial effects of this invention are: The door assembly provided in this application, by setting a second distance greater than a first distance, can compensate for the deformation of the door interior panel and the door sheet metal parts by the difference between the second distance and the first distance. When the door interior panel and the door sheet metal parts are assembled and connected, the difference between the second distance and the first distance can offset the deformation caused by assembly, thereby reducing the gap between the edge mating part and the inner surface of the door sheet metal parts, and improving the appearance quality and perceived quality of the door assembly. Attached Figure Description

[0027] Figure 1 A structural schematic diagram of a vehicle provided in this application; Figure 2 An assembly diagram of a door assembly provided in this application; Figure 3 A partial cross-sectional view of a door assembly provided in this application; Figure 4 This application provides a structural schematic diagram of a vehicle door interior panel; Figure 5 This is a structural schematic diagram of a car door sheet metal provided in this application.

[0028] Reference numerals: 1000, vehicle; 100, body; 200, wheel; 300, door assembly; 1. Door interior trim panel; 11. Main body; 12. Edge mating part; 121. Mating part body; 122. Contact part; 13. Transition part; 14. Connecting structure; 2. Door sheet metal parts; 21. First edge; 22. Second edge; 23. Welding points. Detailed implementation methods; The terms "first," "second," etc., are used for descriptive purposes only and have no sequential or technical meaning, nor should they be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Directional terms used in this application, such as "upper," "lower," "front," "rear," "left," "right," "inner," and "outer," are merely for reference to the orientation shown in the accompanying drawings. The use of directional terms is for better and clearer explanation and understanding of this application, and does not indicate the orientation of the referred device or component in an actual application scenario.

[0030] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. "Fixed connection" refers to a connection where the relative positional relationship remains unchanged after connection. "Rotary connection" refers to a connection where the two parts can rotate relative to each other after connection. "Sliding connection" refers to a connection where the two parts can slide relative to each other after connection.

[0031] In the embodiments of this application, "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0032] The terms "parallel" and "perpendicular" are relative to the current technological level, not absolute mathematical definitions. Slight deviations are permissible; approximations of parallelism or perpendicularity are acceptable. For example, "A and B are parallel" means that A and B are parallel or approximately parallel, with the angle between them ranging from 0 to 5 degrees. Similarly, "A and B are perpendicular" means that A and B are perpendicular or approximately perpendicular, with the angle between them ranging from 85 to 95 degrees.

[0033] The embodiments of this application are described below with reference to the accompanying drawings.

[0034] Please refer to Figure 1 , Figure 1 This application provides a structural schematic diagram of a vehicle 1000. The vehicle 1000 can be a passenger vehicle or a freight vehicle. The vehicle 1000 can also be an electric vehicle or a hybrid vehicle. This application does not limit the specific purpose or power type of the vehicle 1000, and the choice can be made according to actual needs.

[0035] Vehicle 1000 may include a body 100 and wheels 200. The body 100 is used for passengers and for carrying goods, and the wheels 200 are mounted under the body 100 to support the body 100 and to roll on the road surface so that vehicle 1000 can move. The body 100 may include a passenger compartment for accommodating passengers.

[0036] In some embodiments, the vehicle 1000 includes a door assembly 300, which is used to open or close the passenger compartment and is an important exterior component of the vehicle 1000.

[0037] Please refer to Figure 2 and Figure 3 , Figure 2 This is an assembly diagram of a door assembly 300 provided in this application. Figure 3 A partial cross-sectional view of a door assembly 300 provided for this application. In some embodiments, the door assembly 300 includes a door sheet metal part 2 and a door interior panel 1 assembled and connected to the inner side of the door sheet metal part 2.

[0038] The door interior panel 1 includes a main body 11 and an edge mating part 12 connected to the edge of the main body 11. The edge mating part 12 is adapted to fit against the inner surface of the door sheet metal 2.

[0039] During the production of the door sheet metal part 2 and the door interior panel 1, and during their assembly, deformation may occur, resulting in the actual matching gap between the edge mating part 12 and the inner surface of the door sheet metal part 2 being larger than the expected matching gap after assembly, causing a decline in appearance quality and perceived quality.

[0040] For example, the reasons for the excessive gap between the door sheet metal part 2 and the door interior panel 1 may include: the door sheet metal part 2 may deform during stamping or welding; the heat-affected zone of the door sheet metal part 2 may interfere with the dimensional stability of the matching area between the door sheet metal part 2 and the door interior panel 1; the door interior panel 1 may deform during injection molding; or the insufficient rigidity of the mounting point between the door sheet metal part 2 and the door interior panel 1 may cause deformation of both during assembly.

[0041] Based on this, in the door assembly 300 provided in this application embodiment, when the door interior panel 1 is assembled and connected to the door sheet metal part 2, the distance between the main body 11 and the edge mating part 12 along the thickness direction of the main body 11 is a first distance; when the door interior panel 1 is in a free state, the distance between the main body 11 and the edge mating part 12 along the thickness direction of the main body 11 is a second distance; the second distance is greater than the first distance.

[0042] If the door interior panel 1 and the door sheet metal part 2 are in a free state, and the structural form of the door sheet metal part 2 and the door interior panel 1 is set to the expected structural form after assembly, then when the door interior panel 1 and the door sheet metal part 2 are assembled and connected, due to the injection molding of the door interior panel 1 and the deformation of the door interior panel 1 and the door sheet metal part 2 during the assembly process, a gap will be formed between the edge mating part 12 and the inner surface of the door sheet metal part 2, resulting in poor assembly effect.

[0043] The door assembly 300 provided in this application, by setting a second distance greater than a first distance, can compensate for the deformation of the door interior panel 1 and the door sheet metal 2 by the difference between the second distance and the first distance. When the door interior panel 1 and the door sheet metal 2 are assembled and connected, the difference between the second distance and the first distance can offset the deformation caused by assembly, thereby reducing the gap between the edge mating part 12 and the inner surface of the door sheet metal 2, and improving the appearance quality and perceived quality of the door assembly 300.

[0044] In some possible examples, the deformation of the door trim panel 1 during injection molding includes the deformation of the edge mating portion 12. Due to uneven edge stress, the edge mating portion 12 will deform relative to the predetermined structure during the injection molding process.

[0045] In some possible examples, the door trim panel 1 may include a connecting mounting portion disposed on the side of the edge mating portion 12 away from the edge of the door trim panel 1, for engaging with the door sheet metal 2 to fix the door trim panel 1 to the door sheet metal 2, and to allow the edge mating portion 12 to fit against the inner surface of the door sheet metal 2. The connecting mounting portion may also deform due to uneven stress.

[0046] In some embodiments, injection molding flow analysis and assembly simulation can be performed on the interior panel of the door during the design phase to predict and quantify the deformation of the interior panel 1 in advance, providing data support for the compensation of the interior panel 1.

[0047] In some embodiments, through mold flow analysis and assembly simulation, the deformation of the edge mating portion 12 can be greater than or equal to 1.7 mm and less than or equal to 3.7 mm. For example, the deformation of the edge mating portion 12 can be 1.7 mm, 2.1 mm, 2.5 mm, 3.2 mm, 3.6 mm, or 3.7 mm, etc. The deformation of the connecting mounting portion can be greater than or equal to 1.8 mm and less than or equal to 3 mm. For example, the deformation of the connecting mounting portion can be 1.8 mm, 1.9 mm, 2.6 mm, 2.8 mm, or 3.0 mm, etc.

[0048] For example, the deformation of one point of the edge mating part 12 can be equal to 2.5 mm, and the deformation of the connecting mounting part at the corresponding point can be equal to 1.9 mm. Then, the deformation that can be generated when the door interior panel 1 is injection molded at this point can be 0.6 mm.

[0049] It is understood that the deformation of the door interior panel 1 during injection molding is 0.6mm only as an example. Depending on the material of the door interior panel 1 and the location of the deformation, the deformation of the door interior panel 1 during injection molding will also be different. For example, the deformation of the door interior panel 1 during injection molding can be greater than or equal to 0.3mm and less than or equal to 1mm.

[0050] In some embodiments, the historical project deformation database can also provide data support for the compensation amount of the door interior panel 1. This compensation amount, when added to the compensation amount obtained from the mold flow analysis, can yield the tolerance compensation amount required for the assembly of the door interior panel 1. In this way, deformations generated during manufacturing and assembly can be offset.

[0051] In some embodiments, the assembly gap between the door interior panel 1 and the door sheet metal part 2 in historical projects can be greater than or equal to 0 mm and less than or equal to 1 mm. The average gap value between the door interior panel 1 and the door sheet metal part 2 in multiple historical projects can be used as the tolerance compensation amount provided by the historical project database. For example, this tolerance compensation amount is 0.62 mm.

[0052] In some embodiments, the total compensation amount is the sum of the deformation amount of 0.6 mm that can be generated when the door interior panel 1 is injection molded at that location and the tolerance compensation amount of 0.62 mm, which is 1.22 mm. In this way, the difference between the second distance and the first distance can be equal to 1.22 mm.

[0053] It is understood that the difference between the second distance and the first distance being 1.22mm is merely an illustrative example. Depending on the material of the door interior panel 1 and the location of the deformation, the difference between the second distance and the first distance may be less than or equal to 1.5mm.

[0054] Based on the above technical features, the compensation value set for the door interior panel 1 can be made more accurate, so that after the door interior panel 1 and the door sheet metal 2 are assembled, the gap between the edge mating part 12 and the inner surface of the door sheet metal 2 is minimized as much as possible, and the assembly interference caused by excessive compensation is prevented from altering the appearance of the door assembly 300, thus further improving the appearance quality of the door assembly 300.

[0055] In some embodiments, the material of the door interior panel 1 can be polypropylene plastic, EPDM rubber, or polypropylene plastic containing 10% talc, etc. The material of the door interior panel 1 can also be injection molded from a material composed of polypropylene plastic, EPDM rubber, and polypropylene plastic containing 10% talc.

[0056] In some embodiments, when the door interior panel 1 is assembled and connected to the door sheet metal part 2, the included angle between the main body part 11 and the edge mating part 12 on the inner side of the door interior panel 1 is a first included angle; when the door interior panel 1 is in a free state, the included angle between the main body part 11 and the edge mating part 12 on the inner side of the door interior panel 1 is a second included angle; the second included angle is greater than the first included angle.

[0057] For example, the first included angle is 180°, that is, when the interior door panel 1 is assembled and connected to the door sheet metal part 2, the main body part 11 and the edge mating part 12 are arranged in parallel, so that the edge mating part 12 can fit with the inner surface of the door sheet metal part 2.

[0058] The second included angle is greater than the first included angle. That is, when the door interior panel 1 is in a free state, the edge mating part 12 is deflected relative to the main body part 11 toward the door sheet metal part 2. In this way, when the door interior panel 1 is assembled and connected to the door sheet metal part 2, the deflection of the edge mating part 12 can offset the deformation generated during assembly, so that the edge mating part 12 returns to a state parallel to the main body part 11, so that the edge mating part 12 fits more tightly with the inner surface of the door sheet metal part 2, thereby further reducing the gap between the door interior panel 1 and the door sheet metal part 2 after assembly.

[0059] In some embodiments, the difference between the second included angle and the first included angle is less than or equal to 3°.

[0060] According to the above technical features, the difference between the second included angle and the first included angle is used to offset the deformation of the door interior panel 1 during assembly, so as to reduce the assembly gap between the door interior panel 1 and the door sheet metal part 2. The difference between the second included angle and the first included angle is less than or equal to 3°, which can offset the deformation and reduce the gap while avoiding substantial changes in the shape of the door interior panel 1 due to an excessively large difference between the second included angle and the first included angle.

[0061] In some embodiments, along the thickness direction of the main body 11, the edge mating portion 12 is closer to the door sheet metal part 2 than the main body 11.

[0062] Along the thickness direction of the main body 11, the edge mating portion 12 is close to the door sheet metal part 2, which facilitates fitting the inner surface of the door sheet metal part 2, thereby minimizing the external gap at the edge of the door assembly 300 and improving the appearance quality. The main body 11 is farther from the door sheet metal part 2 than the edge mating portion 12, allowing other structures, such as window tracks or anti-collision beams, to be provided between the main body 11 and the door sheet metal part 2, which helps improve the space utilization of the door assembly 300.

[0063] The door interior panel 1 also includes a transition portion 13 connecting the main body portion 11 and the edge mating portion 12, extending from the main body portion 11 to the edge mating portion 12, and the transition portion 13 extends toward the door sheet metal part 2.

[0064] The transition portion 13 connects the main body portion 11 and the edge mating portion 12, which can be used to buffer the dimensional difference between the main body portion 11 and the edge mating portion 12 along the thickness direction of the main body portion 11, thereby making the appearance of the door interior panel 1 smoother and more fluid.

[0065] Furthermore, since the edge mating part 12 is provided with compensation amount and compensation angle, when the door interior panel 1 and the door sheet metal part 2 are assembled, deformation can occur through the transition part 13 to drive the edge mating part 12 to move. The compensation amount and compensation angle cancel each other out with the deformation during assembly, thereby reducing the gap. In this way, the edge mating part 12 is not easily deformed, which can ensure that the edge mating part 12 fits the inner surface of the door sheet metal part 2 and ensure assembly accuracy.

[0066] In some embodiments, the transition portion 13 is an arc-shaped structure that arches toward the door sheet metal 2.

[0067] The arc-shaped structure makes the connection between the edge mating part 12 and the main body part 11 smoother and more fluid. Furthermore, the arc-shaped structure arches towards the door sheet metal part 2. When the door interior panel 1 is assembled with the door sheet metal part 2, causing the edge mating part 12 to bend away from the door sheet metal part 2, the arc-shaped structure only needs to increase the degree of bending to drive the edge mating part 12 to bend, making it easier to compensate for the amount of deformation, thereby quickly reducing the gap of the door assembly 300.

[0068] In some other embodiments, the transition portion 13 may also be configured as a planar structure, or the transition portion 13 may be configured as an arc-shaped structure that arches in the direction opposite to the door sheet metal 2. This application does not further limit this.

[0069] Please refer to Figures 2-4 , Figure 4This application provides a structural schematic diagram of a car door interior panel 1. In some embodiments, a plurality of connecting structures 14 are provided between the edge of the main body 11 facing the edge mating part 12 and the car door sheet metal part 2. The plurality of connecting structures 14 are arranged along the length direction of the edge mating part 12; the distance between two adjacent connecting structures 14 is less than or equal to 170mm.

[0070] The connecting structure 14 is used to achieve a fixed connection between the door interior panel 1 and the door sheet metal. For example, the connecting structure 14 may include bolts, clips, rivets, etc. Arranging multiple connecting structures 14 along the length direction of the edge mating part 12 can improve the stability of the fixed connection between the door interior panel 1 and the door sheet metal part 2, and avoid the increase of gaps caused by vibration, deformation, and other factors.

[0071] The distance between two adjacent connecting structures 14 is less than or equal to 170mm, which can reduce the span length of the unsupported free area of ​​the door interior panel 1 between two adjacent connecting points, improve local rigidity and bending resistance, and reduce assembly deformation and gap fluctuation.

[0072] For example, the distance between two adjacent connecting structures 14 can be 136mm, 156mm, 168mm or 170mm, etc.

[0073] In some embodiments, the edge mating portion 12 includes a mating portion body 121 and a contact portion 122 disposed on the outer edge of the mating portion body 121. The contact portion 122 protrudes toward the door sheet metal 2 relative to the surface of the mating portion body 121 facing the door sheet metal 2. The door sheet metal 2 includes an outer sheet metal part and an inner sheet metal part. The inner sheet metal part is located between the outer sheet metal part and the door interior panel 1. A welding point 23 is connected between the outer sheet metal part and the inner sheet metal part. Along the second direction, the distance between the welding point 23 and the contact portion 122 is greater than or equal to 2.5 mm. The second direction is perpendicular to the length direction of the edge mating portion 12 and parallel to the main body portion 11.

[0074] When the outer sheet metal part and the inner sheet metal part of the door sheet metal part 2 are welded, a welding protrusion or a welding pit may be formed at the weld point 23. If the door interior panel 1 is assembled and connected to the welded position, the weld point 23 may easily push up the door interior panel 1, causing an increase in the gap between the door interior panel 1 and the door sheet metal part 2. In the embodiment of this application, the contact part 122 protrudes towards the door sheet metal part 2 relative to the surface of the mating part body 121 facing the door sheet metal part 2. When the edge mating part 12 is attached to the inner surface of the door sheet metal part 2, the contact part 122 can contact the inner surface of the door sheet metal part 2, and there is a gap between the mating part body 121 and the inner surface of the door sheet metal part 2. The distance between the weld point 23 and the contact part 122 is greater than or equal to 2.5mm, which can make the weld point 23 and the contact part 122 avoid each other, thereby preventing the weld point 23 from protruding or welding pit from affecting the assembly quality between the door interior panel 1 and the door sheet metal part 2, and preventing welding thermal deformation and thermal stress from affecting the gap stability.

[0075] In some embodiments, along a direction perpendicular to the main body 11, the projection of the weld point 23 on the door interior panel 1 is located within the edge mating portion 12 or the transition portion 13. In this way, the weld point 23 can cover the connection point between the door interior panel 1 and the door sheet metal part 2, which can make the appearance surface of the door assembly 300 smoother and improve the appearance quality of the door assembly 300.

[0076] In some embodiments, the surface flatness of the area on the door sheet metal 2 suitable for connecting the edge mating portion 12 is less than or equal to 1 mm.

[0077] This design improves the surface flatness of the assembly area between the door sheet metal part 2 and the edge mating part 12, resulting in a more uniform assembly gap between the door sheet metal part 2 and the edge mating part 12, and reducing the impact of the door sheet metal part 2 on the assembly gap.

[0078] It should be noted that the surface flatness of the area of ​​the door sheet metal part 2 suitable for connecting the edge mating part 12 is less than or equal to 1mm. This means that, taking the average surface height of the area of ​​the door sheet metal part 2 suitable for connecting the edge mating part 12 as the reference value, the difference between the lowest surface height of the area of ​​the door sheet metal part 2 suitable for connecting the edge mating part 12 and the reference value, and the difference between the highest surface height of the area of ​​the door sheet metal part 2 suitable for connecting the edge mating part 12 and the reference value, are both less than or equal to 0.5mm.

[0079] In some embodiments, the stamping and welding precision of the door sheet metal part 2 can be controlled to achieve a surface flatness of less than or equal to 1 mm in the area of ​​the door sheet metal part 2 suitable for connecting the edge mating part 12.

[0080] For example, in the stamping process, the error value of the material wall thickness is controlled within ±0.05mm, the die precision of the punch and concave dies is controlled within ±0.002mm, the structure is optimized with flange face reinforcement ribs and pressure ribs to prevent warping, the blank holder force in the stamping process parameters is stabilized within ±5%, the speed is low-speed and stable flow, the punching burr is ≤0.05mm, the stamping equipment adopts rigid guide rails with small clearance, and online detection uses pressure / displacement sensors for real-time monitoring. The machine automatically stops if the tolerance is exceeded, and the inspection method of first piece full inspection, process sampling inspection, and last piece comparison is adopted.

[0081] In the welding process, welding fixtures are used for strong positioning, and welding process parameters are optimized to control deformation and stabilize the weld nugget.

[0082] In some embodiments, the gap width between the door sheet metal part 2 and the edge mating part 12 along the thickness direction of the main body part 11 is less than or equal to 0.25 mm.

[0083] By making the gap width between the door sheet metal part 2 and the edge mating part 12 along the thickness direction of the main body part 11 less than or equal to 0.25mm, the gap between the door sheet metal part 2 and the edge mating part 12 can be reduced as much as possible, solving the problem of gap deviation in the prior art, improving the overall appearance quality and perceived quality of the vehicle, reducing steps such as actual vehicle debugging, mold modification, and tooling adjustment, saving production costs and improving production efficiency.

[0084] Through the above embodiments, dimensional accuracy control can be achieved from the entire process of design, simulation, manufacturing and process, thereby improving the tolerance of the door assembly 300, achieving one-time design compliance, and stably controlling the assembly gap of the door assembly 300.

[0085] Please refer to Figures 2-5 , Figure 5 This application provides a structural schematic diagram of a car door sheet metal. In some embodiments, the car door sheet metal includes a first edge portion 21 and a second edge portion 22, the first edge portion 21 being adapted to be hinged to the car body 100, and the edge mating portion 12 mating with the second edge portion 22.

[0086] Since the door assembly 300 is hinged to the body 100, the door can be opened and closed by rotating the door assembly 300 around the hinge axis. The first edge portion 21 and the second edge portion 22 are opposite each other. Since the first edge portion 21 of the door sheet metal part 2 is hinged to the body 100, the first edge portion 21 is a non-exterior surface, while the second edge portion 22 is an exterior surface. The edge mating portion 12 mates with the second edge portion 22. Through the aforementioned technical features, the gap between the edge mating portion 12 and the door sheet metal part 2 is less than or equal to 0.25mm, which allows for precise control of the exterior surface of the door sheet metal part 2 and improves its appearance quality.

[0087] This application embodiment also provides a method for improving the tolerance capability of a door assembly 300. This method may include step S1, optimizing the mounting point spacing between the door interior panel 1 and the door sheet metal part 2. Specifically, a connecting structure 14 is provided between the door interior panel 1 and the door sheet metal part 2, and the center-to-center distance between adjacent connecting structures 14 between the door interior panel 1 and the door sheet metal part 2 is controlled within 170mm. This step can reduce the cantilever length of the door assembly 300, improve local rigidity, and reduce assembly deformation and gap fluctuations.

[0088] The method for improving the tolerance of the door assembly 300 may also include step S2: performing injection molding flow analysis on the door interior panel 1 body during the design phase, simultaneously conducting assembly process simulation, and predicting and quantifying the deformation of the interior panel body body in the molding and assembly states in advance.

[0089] This step may specifically include: Step S21, establishing a mass production process database for the door interior panel 1; Step S22, organizing the data in the database, handling any abnormal situations, and then organizing the range of key process parameters; Step S23, selecting the injection molding process based on the project's styling and product structure; Step S24, inputting the selected process parameters into the mold flow software for mold flow analysis; Step S25, reading the mold flow analysis results; Step S26, performing mold flow deformation conversion based on the product design matching relationship to obtain the converted deformation value.

[0090] The method for improving the tolerance capability of the door assembly 300 may also include step S3, setting a reasonable tolerance compensation amount based on mold flow analysis, assembly simulation results and historical project deformation database.

[0091] The historical project deformation database is derived from statistical data on the gap values ​​between multiple door interior panels 1 and door sheet metal parts 2 in historical projects. By organizing the values ​​in the database, the average of multiple sets of data is calculated. The average value, plus the deformation value obtained in step S2, is the tolerance compensation amount for the door interior panel 1.

[0092] This step allows the tolerance compensation of the door interior panel 1 to offset the deformation that occurs during manufacturing and assembly.

[0093] It should be noted that step S3 needs to be performed after step S2, while step S1 can be performed before or after steps S2 and S3. This application does not impose any restrictions.

[0094] In some embodiments, the method for improving the tolerance of the door assembly 300 may further include step S4, sheet metal manufacturing precision control, controlling the surface flatness of the area on the door sheet metal part 2 suitable for connecting the edge mating part 12 to be less than or equal to 1 mm.

[0095] This step can improve the surface flatness of the assembly area between the door sheet metal part 2 and the edge mating part 12, thereby making the assembly gap between the door sheet metal part 2 and the edge mating part 12 more uniform and reducing the impact of the door sheet metal part 2 on the assembly gap.

[0096] In some embodiments, the method for improving the tolerance of the door assembly 300 may further include step S5: under the premise of meeting the performance requirements of the whole vehicle such as strength, rigidity, and collision, optimize the welding position of the door sheet metal part 2, use computer-aided engineering (CAE) analysis methods to perform performance analysis, and under the premise of meeting the performance requirements, make the welding area avoid the matching area between the door interior panel 1 and the door sheet metal part 2, and keep a safe distance of not less than 2.5mm between the matching area and the welding area to avoid the impact of welding thermal deformation and thermal stress on the gap stability.

[0097] Through the above steps, the assembly gap between the interior door panel 1 and the door sheet metal part 2 can be stably controlled within 0.25mm, achieving the design standard in one go without the need for extensive subsequent modifications.

[0098] The door assembly 300 produced by the above-mentioned method for improving the tolerance capability of the door assembly 300, after testing, has a gap between the door interior panel 1 and the door sheet metal part 2 that is less than or equal to 0.2mm, which meets the tolerance specification design target of less than or equal to 0.25mm, and achieves a first-time design qualification.

[0099] This application provides an assembly method for a car door assembly 300. The assembly method includes assembling the car door interior panel 1 to the inner side of the car door sheet metal part 2, and bending the edge mating part 12 relative to the main body part 11 in a direction away from the car door interior panel 1, so that the edge mating part 12 fits against the inner surface of the car door sheet metal part 2.

[0100] Because the second distance between the main body 11 and the edge mating part 12 along the thickness direction of the main body 11 is greater than the first distance, when the door interior panel 1 is assembled with the door sheet metal part 2, the edge mating part 12 can be bent relative to the main body 11, so that the distance between the main body 11 and the edge mating part 12 along the thickness direction of the main body 11 changes from the second distance to the first distance. The difference between the second distance and the first distance can be used to compensate for possible tolerances, thereby reducing the gap between the edge mating part 12 and the inner surface of the door sheet metal part 2, and improving the appearance quality and perceived quality of the door assembly 300.

[0101] The door assembly 300 provided in this application controls deformation from the design stage, achieving high assembly precision. It can stably control the matching gap within 0.25mm, ensuring first-time design compliance and significantly reducing mold modifications, on-site debugging, and rectification costs. Furthermore, it improves the consistency of dimensions in mass production and reduces the defect rate. In addition, the method for improving the tolerance capability of the door assembly 300 provided in this application is highly versatile and can be directly applied to the development of interior door panels for various passenger vehicle models, demonstrating high engineering application value.

[0102] The above embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention.

Claims

1. A door assembly, characterized in that, include: The door sheet metal part (2) and the door interior panel (1) assembled and connected to the inner side of the door sheet metal part (2), the door interior panel (1) includes a main body part (11) and an edge mating part (12) connected to the edge of the main body part (11), the edge mating part (12) being adapted to fit against the inner surface of the door sheet metal part (2); When the interior door panel (1) is assembled and connected to the door sheet metal part (2), the distance between the main body part (11) and the edge mating part (12) along the thickness direction of the main body part (11) is the first distance; When the door interior panel (1) is in a free state, the distance between the main body (11) and the edge mating part (12) along the thickness direction of the main body (11) is the second distance; The second distance is greater than the first distance.

2. The door assembly according to claim 1, characterized in that, When the interior door panel (1) is assembled and connected to the door sheet metal part (2), the included angle between the main body part (11) and the edge mating part (12) on the inner side of the interior door panel (1) is the first included angle; When the door interior panel (1) is in a free state, the included angle between the main body (11) and the edge mating part (12) on the inner side of the door interior panel (1) is the second included angle; The second included angle is greater than the first included angle.

3. The door assembly according to claim 1, characterized in that, Along the thickness direction of the main body (11), the edge mating part (12) is closer to the door sheet metal part (2) than the main body (11). The interior door panel (1) also includes a transition portion (13) connecting the main body (11) and the edge mating portion (12), extending from the main body (11) to the edge mating portion (12), and the transition portion (13) extends toward the door sheet metal part (2).

4. The door assembly according to claim 5, characterized in that, The transition part (13) is an arc-shaped structure, which arches toward the door sheet metal part (2).

5. The door assembly according to claim 1, characterized in that, The edge of the main body (11) facing the edge mating part (12) and the door sheet metal part (2) are provided with a plurality of connecting structures (14), and the plurality of connecting structures (14) are arranged along the length direction of the edge mating part (12); The distance between two adjacent connecting structures (14) is less than or equal to 170 mm.

6. The door assembly according to claim 1, characterized in that, The edge mating part (12) includes a mating part body (121) and a contact part (122) provided on the outer edge of the mating part body (121). The contact part (122) protrudes toward the door sheet metal part (2) relative to the surface of the mating part body (121) facing the door sheet metal part (2). The door sheet metal part (2) includes an outer sheet metal part and an inner sheet metal part, wherein the inner sheet metal part is located between the outer sheet metal part and the door interior panel (1); The outer sheet metal part and the inner sheet metal part are connected by a weld point (23), and along the second direction, the distance between the weld point (23) and the contact part (122) is greater than or equal to 2.5mm; The second direction is perpendicular to the length direction of the edge mating part (12) and parallel to the main body part (11).

7. The door assembly according to any one of claims 1-6, characterized in that, The surface flatness of the area on the door sheet metal part (2) suitable for connecting the edge mating part (12) is less than or equal to 1 mm; and / or, The gap width between the door sheet metal part (2) and the edge mating part (12) along the thickness direction of the main body part (11) is less than or equal to 0.25mm.

8. The door assembly according to any one of claims 1-6, characterized in that, The door panel metal part includes a first edge portion (21) and a second edge portion (22) opposite to each other. The first edge portion (21) is adapted to be hinged to the body (100), and the edge mating portion (12) mates with the second edge portion (22).

9. A vehicle, characterized in that, Includes the door assembly (300) as described in any one of claims 1-8.

10. A method for assembling a vehicle door assembly, characterized in that, The assembly method for assembling the door assembly according to any one of claims 1-8 includes: The interior door panel (1) is assembled and connected to the inside of the door sheet metal part (2), and the edge mating part (12) is bent away from the interior door panel (1) relative to the main body part (11) so that the edge mating part (12) fits against the inner surface of the door sheet metal part (2).

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