Vehicle Door Frame Molding with Insertion Protrusion
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Solution Overview
Problem
Existing vehicle door structures face challenges in balancing appearance quality, assembly ease, and stiffness, with frame doors compromising on appearance and invisible panel doors complicating assembly, while also increasing production costs.
Innovation Solution
A combination door structure featuring a bent metal upper rail, an inner panel with an insertion hole, a frame molding with an exposure plate and protrusion, and sealing members to enhance appearance and assembly ease, using stainless steel for durability and corrosion resistance without adhesive tapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a frame door structure is used, then the assembly structure is simple, but the appearance quality deteriorates due to exposed frame and roll forming
Solution Approach 1:
The door structure is divided into distinct functional segments: the inner panel for structural support, the upper rail for glass mounting, and the frame molding for appearance. This segmentation allows each component to be optimized independently - the inner panel and upper rail can be simple metal structures for ease of assembly, while the frame molding provides the aesthetic finish without complicating the overall assembly process.
Solution Approach 2:
The frame molding acts as an intermediary element between the functional components (inner panel and upper rail) and the external environment. It conceals the structural elements while maintaining their functional integrity, thereby improving appearance quality without requiring complex assembly structures underneath.
2Shape
If an invisible panel door structure is used, then the appearance quality is high with hidden panel, but the assembly structure becomes complicated requiring molding and sealing member additions
Solution Approach 1:
The frame molding integrates multiple functions into a single component: it provides the aesthetic finish, incorporates the sealing member attachment, and serves as the mounting structure for the glass. By merging these functions into one piece rather than using separate components, the assembly structure remains simple while achieving high appearance quality similar to invisible panel doors.
3Productivity
If traditional door structures are used, then the manufacturing process is established, but the production cost increases and assembly easiness deteriorates
Solution Approach 1:
The frame molding is pre-assembled with the sealing member attached during the molding process itself, rather than requiring separate assembly steps afterward. The insertion portions are also pre-formed on the frame molding, allowing for quick and easy installation onto the inner panel and upper rail. This preliminary preparation reduces both production time and assembly complexity.
4Ease of manufacture
If frame door with exposed roll forming is used, then the manufacturing process is simple, but the stiffness may be insufficient for overall vehicle stability
Solution Approach 1:
The door structure employs composite construction combining the inner panel (metal plate for structural strength), the upper rail (bent metal plate for rigidity), and the frame molding (providing additional structural support). This composite structure achieves high stiffness for vehicle stability while maintaining manufacturing simplicity through the use of standard metal forming processes for each component.
Data Source
AI summary
A combination structure of a door that is equipped on a vehicle may include an upper rail formed by bending a metal plate and disposed to correspond to an edge of a door glass, an inner panel disposed by a distance from the upper rail to form an insertion hole and one side of the inner panel is fixed to the upper rail, a frame molding in which a protrusion portion is formed on at least one side thereof and the protrusion portion is inserted into the insertion hole formed between the upper rail and the inner panel, a vehicle body disposed by a distance from the inner panel, and a first sealing member and a second sealing member.