Vehicular Door Sash Hook Member Welding Design

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Solution Overview

Problem

The existing techniques for attaching hook members to vehicular door sashes, particularly roll-formed sashes, face challenges such as the difficulty in processing closed cross-sections and the formation of protuberant weld beads, which can be aesthetically unsatisfactory and require additional processing steps to correct.

Innovation Solution

A hook member design featuring a circumferential wall surface with projecting portions that allow for welding to the door sash without forming mounting holes, preventing the grinder from tilting and ensuring a flush weld bead, and incorporating an extending portion and hook portion to enhance attachment and reduce the risk of separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If screw holes are formed in the roller sash to attach hook members, then the hook members can be firmly fastened to the door sash, but the roller sash becomes difficult to process and requires additional processing steps

Engineering Contradiction:

Improveattachment strengthVSAvoidprocessing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical screw-fastening system with a welding system. The hook member includes a welded face that is weldable to the door sash surface, eliminating the need to form screw holes in the closed cross-section roller sash. This substitution of attachment mechanism resolves the contradiction by providing firm attachment through welding while avoiding the difficult hole-forming process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If MIG welding is performed to attach hook members to the roller sash, then the hook members can be attached without forming holes, but protuberant weld beads are formed that require additional scraping processing

Engineering Contradiction:

Improveattachment process easeVSAvoidweld bead flatness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-forming projecting portions on the circumferential wall surface before welding. These projecting portions serve as stop surfaces that prevent the grinder from tilting during the scraping process, ensuring that the weld bead is scraped to the correct height without damaging the door sash. This preliminary structural feature resolves the contradiction by enabling easy welding while ensuring precise weld bead flatness through the projecting portion's protective function.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If the grinder is used to scrape the weld bead, then the appearance can be improved, but the grinder may tilt and contact the door sash causing contact marks

Engineering Contradiction:

Improveweld bead height controlVSAvoidgrinder contact damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an intermediary structure - the projecting portion on the circumferential wall surface - that acts as a mediator between the grinder and the door sash. The projecting portion's upper surface serves as a physical stop that prevents the grinder from tilting and contacting the door sash. This intermediary feature resolves the contradiction by enabling weld bead scraping while preventing grinder contact damage to the door sash.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 easy attachment to both roll-formed and press-formed door sashes, reduces production costs, maintains a clean appearance by preventing grinder contact marks, and enhances the structural integrity of the weld bead.

Implementation Method 1

At least a part of the circumferential wall surface is a welded face weldable to the surface of the door sash with a welding material

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS8978309B2Hook member for vehicular door sash and vehicular door sash including the same

Publication Date: 2015.03.17 HONDA MOTOR CO LTD

AI summary

A door-sash hook member is attached to a surface of a door sash of a vehicular door. The door-sash hook member includes a superposed surface superposed on the surface of the door sash, and a circumferential wall surface standing from the superposed surface to form a circumferential edge of the superposed surface. At least a part of the circumferential wall surface is a welded face weldable to the surface of the door sash with a welding material. The circumferential wall surface includes a projecting portion adjacent to the welded face, and the projecting portion protrudes outwardly compared to the welded face along a plane of the superposed surface.