Vehicle Door Frame Abutting Face Angles for Smooth Fold Continuity
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Solution Overview
Problem
Conventional vehicle door frames with sash doors have aesthetic issues due to discontinuous folds at the joined portions of the pillar and main frame, requiring additional processing steps and cumbersome welding to maintain a smooth appearance.
Innovation Solution
A vehicle door frame design featuring first and second frames with abutting faces forming predetermined angles, allowing for smooth continuation of folds and easy assembly through roll forming and welding, while maintaining a channel-like cross-sectional configuration for window glass guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the pillar is joined with the main frame using conventional methods with protrusions, then the design portions can be joined, but the folds are not continued smoothly causing poor appearance and requiring additional processing steps
Solution Approach 1:
The invention applies preliminary action by pre-forming complementary abutting faces on the pillar and main frame before assembly. The first abutting face on the pillar and the second abutting face on the main frame are designed with specific angles and geometries that ensure smooth fold continuity upon joining, eliminating the need for post-assembly protrusion formation and additional processing steps.
Solution Approach 2:
The invention applies local quality by designing specific abutting face geometries at the joining location. The first abutting face includes a first planar portion and a second planar portion with specific angle relationships, while the second abutting face has corresponding portions that complement the first. This localized geometric design ensures smooth fold continuity only at the critical joining portion without affecting the overall structure.
2Shape
If welding is performed at the joined portion to make folds continue smoothly, then appearance is improved, but the process becomes cumbersome and complex
Solution Approach 1:
The invention eliminates cumbersome welding by applying preliminary action - the abutting faces are pre-designed with specific geometric configurations that naturally align and continue the folds smoothly upon assembly. The first abutting face with its planar portions and the complementary second abutting face are formed during manufacturing, ensuring fold continuity is achieved through design rather than post-assembly welding operations.
3Shape
If additional pressing steps are performed to form protrusions, then the design portions can be joined, but the number of manufacturing steps increases
Solution Approach 1:
The invention improves manufacturing efficiency by applying preliminary action - the abutting faces are pre-formed during the roll forming process with specific angle configurations. The first abutting face includes first and second planar portions with defined angle relationships, and the second abutting face has complementary portions. This preliminary geometric configuration ensures proper design portion alignment upon assembly without requiring additional pressing steps to form protrusions, thereby increasing productivity.
4Shape
If the abutting faces are designed with specific angle relationships, then fold continuity is achieved, but the design complexity increases
Solution Approach 1:
The invention manages design complexity by applying segmentation - the abutting faces are divided into distinct planar portions with specific functions. The first abutting face is segmented into a first planar portion and a second planar portion, each forming specific angles with reference planes. The second abutting face is similarly segmented into corresponding portions. This segmentation allows each portion to be designed and manufactured independently with precise geometric controls, achieving fold smoothness while managing overall design complexity through modular geometric decomposition.
Data Source
Figure 1~2(b)
Figure 3(a)~3(b)
Figure 4~5
AI summary
A vehicle door frame includes a first frame 4 and a second frame 5 abutted against each other at abutting faces 4a and 5b thereof at a predetermined angle. The abutting faces 4a and 5b include first abutting faces 44 and 54 provided in design portions 43 and 53 and second abutting faces 45 and 55 provided in hollow portions 41 and 51, respectively. The first abutting faces 44 and 54 form a first angle θ1 with respect to the second abutting faces 45 and 55 viewed from a direction perpendicular to the design faces 43a and 53a, respectively. The first abutting faces 44 and 54 also form a second angle θ2 with respect to the second abutting faces 45 and 55 when viewed from a direction perpendicular to the longitudinal direction of the frames 4 and 5 and the extending direction of flange portions 42 and 52, respectively.