Vehicle Door Reinforcement Profile Mechanical Connection
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Solution Overview
Problem
Conventional welding processes for manufacturing closed-section vehicle door reinforcements are complex, time-consuming, and prone to defects, leading to increased costs and reduced production efficiency.
Innovation Solution
A reinforcement system using a metal sheet with a high elastic limit, featuring a closed profile with windows and flanges that are mechanically connected by deformation, eliminating the need for welding and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding processes are used to connect closed-section reinforcements, then the mechanical strength and reliability are improved, but the production time increases and productivity decreases
Solution Approach 1:
The patent extracts the welding operation from the manufacturing process and replaces it with a mechanical deformation connection. The flange is deformed to engage with the window, creating a secure connection without requiring welding, thus eliminating the productivity bottleneck while maintaining structural integrity.
Solution Approach 2:
The patent replaces the welding mechanical system with a mechanical deformation system. Instead of using heat and pressure to fuse metal surfaces, the invention uses controlled deformation of the flange to create a interference fit connection, substituting a faster, defect-free mechanical process for the slower welding process.
2Reliability
If continuous welding processes are used to ensure optimal connection quality, then the reliability is improved, but the process complexity and preparation requirements increase
Solution Approach 1:
The patent removes the complex continuous welding process entirely and replaces it with a simple mechanical deformation operation. The flange is deformed to engage with the window in a single step, eliminating the need for continuous welding equipment, metal surface preparation, and quality control systems.
Solution Approach 2:
The patent substitutes the complex welding mechanical system with a simpler mechanical deformation system. The deformation process inherently creates a reliable connection through interference fit without requiring the complex equipment and procedures associated with continuous welding.
3Productivity
If spot welding processes are used to connect reinforcements, then the manufacturing speed is improved, but the weight and cost increase due to double overlap requirements
Solution Approach 1:
The patent extracts the double overlap requirement from the design and replaces it with a single flange-deformation connection. The mechanical deformation creates sufficient connection strength without requiring additional overlapping material, thereby reducing weight while maintaining manufacturing efficiency.
Solution Approach 2:
The patent replaces the spot welding mechanical system with a mechanical deformation system that achieves comparable or superior connection strength without requiring double overlap. The deformation creates an interference fit that is both lighter and potentially faster to manufacture than spot welding with double overlap.
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
The mechanical connection provides effective reinforcement comparable to welding without defects, reducing production time and costs while maintaining mechanical properties.
Implementation Method 1
at least one flange in an edge opposite of the mentioned metal sheet. This flange is housed in the window such that an end projects with respect to the window and is deformed to allow the retention of said flange with respect to the window
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The invention relates to a reinforcement formed by a one-piece bent profile (1) having next to a longitudinal edge a row of consecutive windows (2) and in the opposite edge a plurality of projections (3) corresponding with said windows (2) for the closed forming of the section of the profile (1) by means of the lateral deformation of the end of the mentioned projections (3) passing through the windows (2). The invention also relates to a process for manufacturing a lateral reinforcement for vehicle doors from planar metal plates of material with a high elastic limit, and comprising the phases of: - forming the windows (2) and the projections (3); profiling the metal sheet for the configuration of the section of the profile (1); - passing the projections (3) through the windows (2); - deforming the projections (3) to close the section of the profile (1) of the reinforcement.