Automotive Door Sash Manufacturing via Laser Welding
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Solution Overview
Problem
The existing door sash for automobile windows experiences rust due to water stagnation in gaps between overlapping plate materials and has issues with close contact with weather strips, requiring complex sealing and cutting processes.
Innovation Solution
A door sash manufacturing method involving a roll-forming process to create a stepped section with a tubular extension and flange sections, followed by press working to ensure the end portions do not protrude beyond the weather strip's fitting surface, and continuous laser-welding along the longitudinal direction to prevent rust and enhance contact with the weather strip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plate materials are overlapped and welded to form a door sash, then the structural integrity is improved, but gaps form between overlapping sections allowing water penetration and rust
Solution Approach 1:
The patent extracts and eliminates the harmful gap between overlapping plate materials by extending one plate material to cover the gap area, effectively removing the source of water penetration and rust prevention problems
Solution Approach 2:
The door sash is divided into functional sections: overlapping section for structural strength, stepped section for gap coverage, and holder section for weather strip mounting, with each section optimized for its specific function
2Object-affected harmful factors
If seal material is applied to seal gaps between plate materials, then rust prevention is improved, but manufacturing complexity and labor requirements increase
Solution Approach 1:
The patent removes the need for separate seal material by integrating the gap-sealing function directly into the plate material structure through extension and overlapping, eliminating the sealing step entirely
Solution Approach 2:
The plate material itself serves the dual function of providing structural strength and sealing against water penetration, without requiring additional sealing materials or processes
3Adaptability or versatility
If the holder is cut to fit certain weather strip shapes, then adaptability to different weather strips is improved, but the cut end may protrude and interfere with weather strip fitting
Solution Approach 1:
The plate material is extended in advance to cover the potential protrusion area of the holder cut end, preventing interference with weather strip fitting before the weather strip is even installed
Solution Approach 2:
The extended plate material serves multiple functions: maintaining structural integrity, covering gap areas for sealing, and preventing holder end protrusion interference, making the design universally compatible with various weather strip configurations
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 method prevents rust and improves the close contact between the door sash and weather strip, while also enhancing bending resistance properties by welding near the cross-sectional center of gravity.
Implementation Method 1
continuous laser-welding along the longitudinal direction
Implementation Method 2
water penetrates between the plate materials configuring the overlapping section 2 due to capillarity
Data Source
AI summary
A method for manufacturing a door sash formed from a single plate material includes: a roll-forming step of providing a gap portion between the plate materials forming a stepped section and roll-forming a periphery of an end portion of a plate material extending from a tubular section, so as to come into contact along the plate material forming the stepped section; a press working step of pressing the end portion of the plate material to a position where the end portion does not protrude further toward the side on which a weather strip is fitted than a surface of an overlapping section and a surface of the tubular section on the side on which the weather strip is fitted, while crushing the gap portion; and a welding step of continuously laser-welding the overlapping section along a longitudinal direction of the door sash.