Vehicle Door Frame Projection Structure for Precise Sealing
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Solution Overview
Problem
Traditional vehicle door frames face challenges in accurately forming the projection that supports the upper frame from below, due to the complexity of bending plate materials, which can lead to difficulties in achieving precise alignment and sealing between the upper and lower frame components.
Innovation Solution
A vehicle door frame design featuring a lower member with a projection that extends from its end face, where the direction normal to the fourth end face changes from parallel to the external face to an upward direction, allowing for accurate formation and improved welding and sealing between the upper and lower frames, including a cutout to prevent damage during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the projection is formed by bending plate material, then the lower member can be manufactured, but it is difficult to accurately form the part facing the lower face of the upper frame
Solution Approach 1:
The lower member is divided into multiple parts: the main body and the projection are formed as separate components that are subsequently joined together. This segmentation allows each part to be manufactured independently with optimal precision, avoiding the difficulty of forming complex bent surfaces from a single plate material.
Solution Approach 2:
The projection and the lower member body, which were previously formed as a single bent plate, are now combined through a joining process after separate manufacturing. This merging approach enables accurate formation of the projection surface while maintaining manufacturing feasibility.
2Reliability
If the projection is formed by bending plate material, then the lower member structure is simple, but alignment and sealing between upper and lower frames are difficult to achieve
Solution Approach 1:
By segmenting the lower member into a body and a separately formed projection, the design achieves reliable sealing through precise projection geometry while managing complexity through modular construction and joining processes.
3Manufacturing precision
If the projection is formed by bending plate material, then material usage is efficient, but the part facing the lower face of the upper frame cannot be accurately formed
Solution Approach 1:
The segmentation of the lower member allows the projection to be manufactured with high precision using optimal processes for each component, reducing material waste from rework and ensuring accurate fitment that minimizes material loss.
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
This design enables the accurate formation and precise alignment of the projection, enhancing the structural integrity and sealing performance between the upper and lower frames, while simplifying the manufacturing process and reducing the risk of damage during machining.
Implementation Method 1
the external face and the third end face are welded together
Data Source
AI summary
A vehicle door frame includes an upper frame having a first end face at a longitudinal end, and a lower external face; and a lower member of a plate form bonded to the upper frame. The lower member includes a second end face facing the first end face, a projection projecting from the second end face in a longitudinal direction below the upper frame, and a third end face located at an upper end of the projection, extending in the longitudinal direction, and facing a lower side of the external face of the upper frame.