Automotive Door Frame Segmentation for Assembly and Safety
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Solution Overview
Problem
Existing door structures for automotive vehicles face challenges in achieving design property, productivity, and collision safety, particularly with light-weight door frames made from light-metal casting and hollow extrusion molding, as they struggle with attaching internal modules smoothly and ensuring superior design and safety features.
Innovation Solution
A door structure comprising vertical frame portions made of light-metal casting and connecting members made of hollow extrusion molding, with inward and outward connecting members that engage through protrusions and ribs, allowing for improved assemblability and design integration, while enhancing collision safety through strategic attachment points and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a door frame is composed only by frame members made by extrusion molding process extending straightly in longitudinal direction, then manufacturing cost and productivity are improved, but it is difficult to attach another member having curved front view, which deteriorates precision and reliability of attachment
Solution Approach 1:
The door frame is divided into multiple members (first frame member, second frame member, third frame member) with different functions. The first and second frame members are made by extrusion molding with straight configurations for cost efficiency, while the third frame member is made by casting to achieve curved front view for precise attachment. This segmentation allows each component to be optimized for its specific function.
Solution Approach 2:
The patent combines extrusion molding and casting processes to create a hybrid door frame structure. The extrusion-molded frame members provide structural support and cost efficiency, while the cast frame member provides curved geometry and precise attachment capability. This merging of manufacturing processes resolves the contradiction between manufacturing simplicity and attachment precision.
2Adaptability or versatility
If a door structure uses only casting process to form complex members with attachment portions, then design flexibility and attachment capability are improved, but large-sized mold is required which increases costs reversely
Solution Approach 1:
The door frame is segmented into multiple members with different manufacturing processes. Complex curved members requiring high design flexibility are made by casting, while simpler straight members are made by extrusion molding. This segmentation allows design flexibility to be applied only where necessary, reducing overall manufacturing costs.
Solution Approach 2:
Different manufacturing processes are applied to different parts of the door frame based on local requirements. The third frame member with curved front view is made by casting to provide local design flexibility, while the first and second frame members are made by extrusion molding for cost efficiency. This local application of manufacturing processes optimizes both design flexibility and cost.
3Adaptability or versatility
If a door structure uses only casting process with complex shape, then attachment capability is improved, but the strength of the member may vary improperly
Solution Approach 1:
The door frame is divided into members with different manufacturing processes optimized for their specific functions. The extrusion-molded frame members provide consistent strength due to their controlled manufacturing process, while the cast frame member provides attachment capability. This segmentation ensures that strength requirements are met through the extrusion process while attachment requirements are met through the casting process.
Solution Approach 2:
The door frame uses a composite structure combining members made by different processes (extrusion molding and casting). This composite approach allows each material to contribute its strengths: extrusion-molded members provide consistent structural strength, while cast members provide attachment capability with curved geometries.
4Productivity
If internal module is attached from vehicle inward side through opening at center of door, then assembly process is simplified, but it is difficult to arrange internal module at gap between door frames and smoothly attach to frames
Solution Approach 1:
The door frame members are pre-configured with specific geometries (straight members for structural support, curved member for attachment) before assembly. This preliminary design of the frame structure creates optimal attachment points and pathways for the internal module, facilitating smooth attachment from the inward side through the center opening.
Solution Approach 2:
The third frame member is designed with curved front view and specific attachment portions at locations optimized for module attachment. This local optimization of the frame structure at the attachment region enables smooth module installation while maintaining overall assembly simplicity through the inward side access.
Data Source
AI summary
Vertical frame portions provided at both side portions of a door frame are a light-metal casting, plural connecting frames, which are a light-meal hollow extrusion molding, connect the vertical frame portions, the vertical frame portions are provided with protrusion portions which engage with inward connecting frames in a longitudinal direction, plural attachment portions which attach the outward connecting frames and the vertical frame portion are provided at different points in the longitudinal direction, and an outward connecting frame is provided with an upper rib which engages with an engagement recess portion provided at an upper portion of a door outer panel formed in a non-planar shape.