Door Channel Corner Punching for Interference Control
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Solution Overview
Problem
The existing method of manufacturing door channels requires two punching operations to form cut portions in the corner portions, increasing the manufacturing process and cost.
Innovation Solution
A method that forms both the first and second cut portions in the corner portions of the outside and connection walls simultaneously using a single punching operation with a punch, creating parallel cut surfaces to minimize interference with other members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If punching is performed twice to form cut portions in the corner portion of the door channel, then the cut portions can be formed to suppress interference with other members, but the manufacturing process and manufacturing cost increase
Solution Approach 1:
The patent combines two separate punching operations into a single punching operation by designing a punch with multiple cutting edges. The punch simultaneously forms both the first cut portion (reaching from the outside wall to part of the connection wall) and the second cut portion (reaching from the outside wall to part of the inside wall) in one action, thereby reducing the number of manufacturing steps while maintaining the required precision for suppressing interference with other members
Solution Approach 2:
The punch is segmented into multiple functional cutting edges, where each cutting edge is responsible for forming a specific cut portion. This segmentation allows the single punch to perform multiple cutting functions that previously required separate punching operations, thus improving productivity without compromising the precision of cut portion formation
2Manufacturing precision
If punching is performed twice to form cut portions in the corner portion of the door channel, then the cut portions can be formed to suppress interference with other members, but the manufacturing cost increases
Solution Approach 1:
The patent merges two punching operations into one by using a multi-edged punch, which directly reduces the number of manufacturing steps. This consolidation lowers manufacturing cost by reducing machine setup time, operation time, and associated labor costs, while still achieving the precise cut portions needed to suppress interference with other members
3Object-affected harmful factors
If the corner portion of the door channel is punched to form cut portions, then interference with other members is suppressed, but the manufacturing process becomes more complex
Solution Approach 1:
The patent simplifies the manufacturing process by combining multiple punching operations into a single operation using a punch with multiple cutting edges. This reduces process complexity while still forming the necessary cut portions that suppress interference with other members such as the resin member and door glass
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This simplifies the manufacturing process, reduces costs, and effectively suppresses interference between the door channel and other components by forming cut portions in a single step.
Implementation Method 1
forming a cut portion in a corner portion of the door channel by punching the corner portion by a punch
Implementation Method 2
By the first cut portion, a first cut surface and a second cut surface facing each other are formed on the outside wall
Data Source
AI summary
A method of manufacturing a door channel is provided. The door channel is provided in a space defined between an inner panel and an outer panel of a vehicle door and has an outside wall and a connection wall connected to the outside wall. The method includes: (a) disposing the door channel in a die; and (b) forming a cut portion in a comer portion of the door channel by punching the comer portion by a punch. The cut portion includes: a first cut portion formed in a comer portion of the outside wall; and a second cut portion formed in a corner portion of the connection wall and communicating with the first cut portion. By the first cut portion, a first cut surface and a second cut surface facing each other are formed on the outside wall. In the step (b), the first cut portion and the second cut portion are formed by a single punching.