Motor Vehicle Door Die-Cast Frame Merging
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Solution Overview
Problem
The production of motor vehicle doors with multi-part load-bearing frames is complex and expensive, resulting in a heavy product with high rigidity, which is not easily manufacturable and weighs significantly.
Innovation Solution
The use of large, frame-shaped die-cast parts made of light metal alloys for the inner frame and upper window frame, along with a non-positive connection and a special mounting support plate, reduces the number of components and weight while maintaining rigidity, allowing for integration of door components like locks and hinges within the die-cast parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-part load-bearing door frame made of extruded profiles is used, then the door has high rigidity, but the production is complicated and expensive and the weight is considerable
Solution Approach 1:
The patent merges multiple separate extruded profile components into a single integrated die-cast door frame. The die-cast frame combines the functions of the upper window frame, side frames, and reinforcement elements that were previously separate welded extruded profiles, thereby simplifying production while maintaining structural rigidity
Solution Approach 2:
The patent changes the manufacturing parameter from extrusion and welding processes to die-casting. This parameter change enables the production of a complex three-dimensional frame structure in a single casting operation, reducing production complexity and cost while achieving the required rigidity through the die-cast structure's inherent strength
2Strength
If a multi-part load-bearing door frame made of extruded profiles is used, then the door has high rigidity, but the weight is considerable
Solution Approach 1:
The patent employs a composite construction by combining the die-cast aluminum frame with a plastic door panel and interior trim components. The plastic materials used have lower density than metal, and when combined with the optimized die-cast frame structure, achieve the required rigidity with reduced overall weight compared to traditional all-metal extruded profile constructions
3Strength
If multiple separate components are used for the door frame, then the door has high rigidity, but the number of components is high and manufacturing is complex
Solution Approach 1:
The patent combines multiple separate door frame components (upper window frame, side frames, reinforcement elements) into a single integrated die-cast frame structure. This merging reduces the component count from multiple separate extruded profiles that required welding assembly to one monolithic die-cast component, simplifying manufacturing while preserving the rigid structural framework
Solution Approach 2:
The die-cast frame is designed with integrated segmentation features including recesses, protrusions, and mounting points that allow the single frame component to functionally replace multiple separate components. The frame includes integrated mounting structures for windows, mirrors, and door handles, eliminating the need for separate reinforcement brackets and mounting elements
Data Source
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AI summary
A motor vehicle door has an outer module (A) and an inner module (J), the outer module (A) and the inner module (J) being connectable to each other by screwing, riveting, gluing, or the like. The outer module (A) consists of an outer panel (2) and an inner frame part (3) to which an impact beam (11) and hinges (10) can be attached. The inner module (J) has mounting points for door components. The inner frame part (3) of the outer module (A) is formed by a one-piece die-cast part (4) made of a light metal alloy. The inner module (J) consists of an upper surrounding window frame (19) and a lower mounting bracket (20) connected to it. The upper window frame (19) is also formed as a one-piece die-cast part (21) made of a light metal alloy.A lower frame part (22) of the upper window frame (19) is connected to the upper edge area of the cake tray-like mounting support plate (20) by forming a longitudinal hollow beam (24) and the upper window frame (19) is locally connected to the inner frame part (3) via detachable connecting elements (54).