Vehicle Door Frame Multi-Surface Welding Strength
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Solution Overview
Problem
The existing vehicle door frame design limits the weld strength between the inner and outer members, as the inner member is only welded to the outer member at the apical surface of the edge of the extension part, restricting the enhancement of this weld strength.
Innovation Solution
The door frame design includes multiple welding portions along the longitudinal direction where the inner and outer joint parts are welded, with an inner notch creating a weld path that is filled with a weld bead on multiple surfaces, and an outer folded part with a notch that allows easy exposure of the weld path for improved weld strength, and the weld bead is applied to the inner and outer surfaces, including the folded parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the inner member is welded to the outer member only at the apical surface of the edge of the extension part, then the welding process is simple, but the weld strength is insufficient
Solution Approach 1:
The welding structure transitions from single-surface (apical surface only) to multi-surface welding by creating a folded part with an opening that exposes multiple surfaces (apical surface, side surface, and inner surface) for comprehensive weld bead attachment, thereby significantly improving weld strength through three-dimensional welding geometry
Solution Approach 2:
The edge of the extension part is divided into multiple surfaces (apical surface, side surface, inner surface) through the folded part structure, allowing weld beads to be attached to each segmented surface independently, which collectively enhances the overall weld strength while maintaining manageable welding complexity
2Ease of operation
If an inner notch is provided at the outer edge of the inner joint part to form a weld path, then the weld path is exposed to the outside for easier welding operation, but the structure becomes more complex
Solution Approach 1:
The inner notch is pre-formed at the outer edge of the inner joint part to create an exposed weld path opening before the welding operation begins, allowing the weld bead to be easily applied from the outside without requiring complex positioning or access maneuvers during the welding process itself
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 configuration significantly enhances the weld strength between the inner and outer members by ensuring a strong bond across multiple surfaces, improving the structural integrity of the door frame while facilitating easier welding operations.
Implementation Method 1
an inner joint part of the inner member and an outer joint part of the outer member are welded at a plurality of welding portions along a longitudinal direction in which the glass run storage part extends
Data Source
AI summary
A door frame includes: an outer joint part of an outer member and an inner joint part of an inner member are welded at a plurality of welding portion; wherein, in a cross-section orthogonal to an longitudinal direction, the inner joint part includes an inner inside surface an inner outside surface and an inner side surface, and the outer joint part includes an outer inside surface and an outer side surface; wherein, in at least one of the welding portions, an inner notch is provided at an outer edge of the inner joint part and a weld path is formed between the inner side surface and the outer side surface; and wherein a weld bead, which is formed to fill the weld path, is attached to the inner outside surface, the inner side surface, the inner inside surface, the outer side surface, and the outer inside surface.