Extruded Vehicle Door Sash With Thickened Enclosed Section

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Solution Overview

Problem

Existing vehicle door sashes formed by extrusion molding face challenges in maintaining strength while achieving reduced thickness and weight, particularly during bending processes, as they are prone to buckling due to insufficient material thickness.

Innovation Solution

A vehicle door sash with an enclosed or U-shaped section, featuring thicker inner and outer walls compared to the body-side and window-opening-side walls, and an outer extending wall with a crank shape, which provides enhanced strength and resistance to buckling during bending, allowing for a balanced strength and reduced thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the material thickness of the extruded door sash is reduced to achieve weight reduction, then the weight decreases, but the strength and resistance to buckling during bending processes deteriorate

Engineering Contradiction:

Improveweight of door sashVSAvoidstrength and buckling resistance

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies local quality by varying the wall thickness at different locations of the extruded door sash. Specifically, the enclosed section features thicker inner and outer walls compared to the body-side and window-opening-side walls. This localized thickening provides enhanced strength and buckling resistance at critical areas while maintaining overall weight reduction through thinner walls in non-critical areas.

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If the material thickness is reduced to achieve reduced thickness, then the thickness decreases, but the strength required to prevent buckling during subsequent bending processes deteriorates

Engineering Contradiction:

Improvethickness of door sashVSAvoidbuckling resistance during bending

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The enclosed section with selectively varied wall thicknesses enables the door sash to achieve reduced overall thickness while maintaining sufficient strength during bending. The thicker inner and outer walls in the enclosed section provide the necessary structural integrity to prevent buckling during vertical-pillar sash bending and upper sash bending processes.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The door sash is segmented into distinct wall sections (inner wall, outer wall, body-side wall, window-opening-side wall) with different thickness characteristics. This segmentation allows each wall to be optimized independently - with the inner and outer walls of the enclosed section being thicker for strength, while other walls can be thinner for weight reduction.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS8839565B2Extruded vehicle door sash

Publication Date: 2014.09.23 AISIN CORP

AI summary

A vehicle door sash having a uniform cross-sectional shape is provided, including an enclosed section on a vehicle inner side, and an outer extending wall which extends from the enclosed section toward the vehicle outer side, the enclosed section provided with inner and outer walls, with respect to a vehicle width direction, a body-side wall, and a window-opening-side wall that is adjacent to a window glass of the vehicle door. A weather strip is abutted against the body-side of the outer extending wall, and a glass runner is abutted against the window side of the outer extending wall. The body-side wall of the enclosed section is straight in cross section. A thickness of at least one of the inner and outer walls of the enclosed section is greater than a thickness of each of the body-side wall and the window-opening-side wall.