Vehicle Door Division Channel Roll Forming
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Solution Overview
Problem
The existing vehicle door division channel assembly is complex and costly due to the use of different materials for the skin and core, leading to increased manufacturing costs and noise/vibration issues from gaps between components.
Innovation Solution
A vehicle door assembly with a division channel made of a single metal material through roll forming, featuring a joint portion with an embedded insert and a mounting bracket that connects to the glass run, reducing assembly complexity and costs by using a unified material for all components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the division channel is made of different materials (plastic core and TPV skin) through insert molding, then the structural strength and material compatibility are improved, but the manufacturing cost increases
Solution Approach 1:
The patent applies homogeneity by making the division channel entirely from metal material (steel or aluminum alloy) through roll forming, eliminating the need for multi-material insert molding. This single-material approach reduces manufacturing complexity and cost while maintaining structural strength through the inherent properties of metal materials.
Solution Approach 2:
The patent changes the material parameter from composite (plastic + TPV) to single metal material, and changes the manufacturing process parameter from insert molding to roll forming. This parameter change simplifies the manufacturing process and reduces costs while achieving the required structural strength.
2Strength
If the division channel is connected to the window frame in the lateral direction using multiple fasteners, then the connection strength is improved, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the division channel with the glass run into a single integrated component, both made of metal material. This integration eliminates the need for separate fasteners and multiple connection points, reducing assembly complexity while maintaining connection strength through the unified structure.
Solution Approach 2:
The metal division channel serves multiple functions: it divides the window glass from the fixed glass, guides window glass movement, and connects to the window frame structure. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly.
3Ease of manufacture
If the division channel and lower channel are spaced apart, then the manufacturing and assembly of individual components is simplified, but noise and vibration increase severely
Solution Approach 1:
The patent merges the division channel and lower channel into a continuous, integrated metal structure. This eliminates gaps and spacing between the channels, preventing noise and vibration generation while maintaining ease of manufacture through the roll forming process that creates the continuous structure in one piece.
Data Source
AI summary
A vehicle door assembly includes: a door panel; a window frame connected to the door panel; a glass run disposed on the window frame; and a division channel extending from the glass run in a height direction of the vehicle, wherein the glass run has a joint portion to which a top end of the division channel is connected and an extension portion extending from the joint portion toward the door panel, the division channel has a mounting bracket connected to the top end of the divisional channel, and the mounting bracket is connected to the joint portion.