Door Inner Panel Impact Beam Integration
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Solution Overview
Problem
Existing car door inner panels require separate reinforcement members to ensure impact characteristics, leading to low production efficiency and high costs due to their complexity and need for additional components.
Innovation Solution
A car door inner panel design featuring a metal sheet with integrated standing wall portions, a flat sheet portion acting as a door impact beam, and a manufacturing method using press working that integrates the flat sheet portion with the standing walls, eliminating the need for a separate impact beam and enhancing impact characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate belt line reinforcement is attached to the door inner panel, then the impact characteristics and strength are improved, but the device complexity and production cost increase
Solution Approach 1:
The patent integrates the belt line reinforcement function directly into the door inner panel by forming a reinforcement component as an integral part of the panel structure through press working. The reinforcement component includes a reinforcement sheet portion and a standing wall portion that are continuously formed from the same metal sheet, eliminating the need for separate attachment operations and reducing structural complexity while maintaining impact resistance
2Strength
If a separate door impact beam is attached to the door inner panel, then the impact energy absorption is improved, but the productivity decreases and cost increases
Solution Approach 1:
The patent combines the door impact beam function with the door inner panel structure by forming an integral reinforcement component through a single press working process. The reinforcement component's standing wall portion extends in the vehicle width direction and integrates with the panel's standing wall, allowing impact energy absorption without requiring separate assembly operations, thereby improving productivity and reducing costs
3Ease of manufacture
If a metal sheet with high workability is used for the door inner panel, then the ease of manufacture is improved, but the strength and stiffness decrease
Solution Approach 1:
The patent applies local quality by creating a reinforcement component with different structural characteristics in specific regions of the metal sheet. The reinforcement component includes a reinforcement sheet portion with increased thickness or density in areas requiring higher strength, while maintaining the overall workability of the base metal sheet. This localized enhancement provides necessary strength without compromising the ease of manufacture of the entire panel
Data Source
AI summary
This door inner panel is a door inner panel formed of a metal sheet and includes a first panel portion having a first top sheet portion and a first standing wall portion connected to the first top sheet portion, a second panel portion having a second top sheet portion disposed with a gap with the first top sheet portion of the first panel portion and a second standing wall portion connected to the second top sheet portion, a flange portion connected to the first standing wall portion and the second standing wall portion, and a flat sheet portion disposed between the first panel portion and the second panel portion, the first standing wall portion and the second standing wall portion respectively have a level difference portion, and both ends of the flat sheet portion are integrated with the flange portion or the level difference portions.