Door Sash Stepped Connection for Flush Welding
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Solution Overview
Problem
Conventional door sashes face challenges in attaching to the inner panel of a door body due to step differences between overlapping parts, requiring additional processing time and cost to achieve flush surfaces, which complicates the joining process.
Innovation Solution
A door sash configuration with a tubular part and connection parts, where the second connection part is positioned closer to the inner side than the first, allowing the overlapping parts to be flush or aligned, facilitating easy attachment by eliminating the step difference obstacle and enhancing rigidity through strategic overlapping and projection designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the plate material is overlapped to form a closed cross section, then the structural integrity of the door sash is improved, but a step difference is created that prevents close contact with the inner panel during welding
Solution Approach 1:
The patent introduces a stepped part that creates a multi-level structure in the connection part. The first connection part extends to a first position while the second connection part extends to a second position closer to the inner side, creating a step difference that allows the overlapping part to form a closed cross section while the first connection part remains accessible for welding against the inner panel.
2Manufacturing precision
If stamp processing is performed to make surfaces flush, then the welding contact is improved, but additional time and cost are required
Solution Approach 1:
The stepped part structure is formed during the roll forming process itself, without requiring additional stamping operations. The first connection part and second connection part are created with different extension lengths as an integral part of the door sash manufacturing, allowing the overlapping part to self-align properly for welding without external intervention.
3Ease of manufacture
If the overlapping part is pressed onto the inner panel, then the attachment is achieved, but the step difference creates a gap that prevents proper welding contact
Solution Approach 1:
The connection part is divided into two distinct segments: the first connection part that extends to the first position for welding contact with the inner panel, and the second connection part that extends to the second position closer to the inner side to support the overlapping part. This segmentation allows each part to fulfill its specific function without interfering with the other.
Data Source
AI summary
A door sash joined to a door body in a simple manner is provided. A door sash includes a design part, a tubular part, and a connection part. The connection part includes a first connection part continuous to the design part, a second connection part continuous to the tubular part, and a stepped part between the first connection part and the second connection part. The second connection part is closer to the inner side of the door opening than the first connection part. A vicinity of one end of the plate material in a cross section view includes an overlapping part forming a closed cross section by overlapping on the second connection part from the outside. The surface of the overlapping part is closer to the inner side of the door opening than the surface of the first connection part or flush with the surface of the first connection part.