Door Channel Notch Design for Wrinkle Suppression
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Solution Overview
Problem
Existing door channels experience wrinkles during bending, leading to compromised airtightness and performance due to plastic deformation in the bent portions between the vertical and horizontal frame portions.
Innovation Solution
A door channel design with a notch that extends beyond the boundary between the curved and linear parts of the bent portion, allowing excess thickness to be released and absorbed, thereby preventing wrinkles and maintaining dimensional accuracy and sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bending is performed on a single metal member to form the door channel, then manufacturing efficiency is improved, but wrinkle occurs in the bent portion due to plastic deformation
Solution Approach 1:
A notch is formed in advance in the metal member at the position corresponding to the bent portion before bending. This preliminary action creates a stress relief zone that prevents wrinkle formation during the subsequent bending process, while still allowing the door channel to be formed from a single metal member for maintaining manufacturing efficiency
2Manufacturing precision
If the notch extends to exceed the boundary between curved and linear parts, then wrinkle is suppressed during bending, but the structure becomes more complex
Solution Approach 1:
The notch is designed with specific dimensional characteristics - extending to exceed the boundary between the curved and linear parts of the bent portion - to create a localized stress relief zone. This local modification prevents wrinkle formation without requiring complex changes to the overall door channel structure
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
The notch design effectively suppresses wrinkles and distortions during bending, ensuring the door channel maintains airtightness and dimensional accuracy while allowing for uniform stress distribution and easy integration with existing glass runs.
Implementation Method 1
wrinkle occurs due to plastic deformation in a bent portion formed between the vertical frame portion and the horizontal frame portion
Data Source
AI summary
A door channel, which is provided in a space formed between an inner panel and an outer panel of a vehicle door, the door channel includes: a frame monolithically that has: a vertical frame portion, which extends in a vertical direction of a vehicle; a horizontal frame portion, which extends in a front-and-rear direction of the vehicle; and a curved bent portion, which connects the horizontal frame portion and the vertical frame portion, wherein a curved part and a linear part in the bent portion are present in an outer edge of the outer circumferential wall part, a notch which is open to an inner corner part of the bent portion is provided in the side wall part, and both ends of the notch extend to a position that exceeds a boundary between the curved part and the linear part in the bent portion.