Aluminum Vehicle Door Inner Panel Segmented Extension Wall
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Solution Overview
Problem
Aluminum alloy vehicle door panels face challenges in formability during draw-forming, resulting in larger obtuse angles that reduce door opening size, and existing segmented configurations complicate the structure and increase noise and vibration.
Innovation Solution
A vehicle door structure where the door inner panel is made from an aluminum alloy, with a single cabin-interior upright wall and a segmented extension wall, allowing for a bend angle comparable to steel by using two separate panel members joined in a specific configuration, which also enhances noise and vibration suppression and collision resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single aluminum alloy sheet is drawn to form an inner panel, then the material can be kept simple and manufacturing can be easier, but the bend angle between the cabin-interior upright wall and extension wall becomes large, reducing the door opening size
Solution Approach 1:
The extension wall is segmented into multiple sections: a first extension portion formed from the first panel member, and a second extension portion formed from a second panel member. This segmentation allows each portion to be independently formed with optimal bend angles, preventing the door opening from being reduced while maintaining manufacturing feasibility.
Solution Approach 2:
The first extension portion and second extension portion are joined together through overlap joining to form the complete extension wall. This merging combines the advantages of both segments: the first portion maintains the single-member simplicity while the second portion enables the proper bend angle, achieving both ease of manufacture and adequate door opening size.
2Ease of manufacture
If the angle of the obtuse-angled bend between the cabin-interior upright wall and extension wall is made large, then the door opening is reduced, but the formability of aluminum alloy is improved
Solution Approach 1:
By segmenting the extension wall into multiple portions, each portion can be formed with an optimal bend angle that balances formability requirements with door opening size requirements. The first extension portion can use a larger bend angle for better formability, while the second extension portion compensates to maintain adequate door opening.
3Device complexity
If the cabin-interior upright wall is configured from a single member, then the structure is simpler and noise/vibration is reduced, but the bend angle control becomes more difficult
Solution Approach 1:
The extension wall is divided into segments that can be independently formed and controlled. This segmentation makes bend angle control more manageable by allowing each segment to be formed separately with precise angle control, while the overall structure remains relatively simple.
Solution Approach 2:
The segmented extension portions are merged through overlap joining to create the complete extension wall. This merging maintains structural simplicity while enabling precise bend angle control in each segment, as each portion can be formed independently before assembly.
4Manufacturing precision
If the extension wall is segmented into multiple members, then the bend angle can be controlled properly, but the structural complexity and noise/vibration increase
Solution Approach 1:
The extension wall is segmented into a first extension portion and second extension portion, allowing proper bend angle control. The segmentation is minimal and targeted only where needed for angle control, rather than dividing the entire structure into many pieces.
Solution Approach 2:
The segmented portions are merged through overlap joining to form an integrated extension wall structure. This merging reduces the overall structural complexity compared to fully segmented designs, while still achieving the necessary bend angle control through the localized segmentation.
Data Source
AI summary
A cabin-interior upright wall of a door inner panel is configured by a first panel member alone. An extension wall extends toward a door outer panel from an end of the cabin-interior upright wall. A lower portion of a front upright wall, which is part of the extension wall, is segmented in a door thickness direction. The extension wall is configured such that a first extension portion of a first panel member is joined to a second extension portion of a second panel member in a state overlapped with the second extension portion.