Rail-Integrated Flush Door Frame for Easier Glass Assembly
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Solution Overview
Problem
Existing vehicle door designs with separate rails for guiding the upward and downward movements of the door glass face challenges in assembly complexity and lack of rigidity due to the need for vertical manipulation of the rail during assembly, which complicates the integration of reinforcing components.
Innovation Solution
A flush door design with a rail integrated door frame that guides the upward and downward movements of the door glass directly through the door frame, incorporating an inner and outer guide system to restrict slider movement, and a tension mechanism to support the slider, allowing for easier assembly and increased rigidity by eliminating the need for a separate rail structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate rail structure is used to guide the door glass, then the door glass can move upward and downward, but the assembly complexity increases and rigidity is reduced
Solution Approach 1:
The patent merges the separate rail structure with the door frame by integrating the guiding function directly into the door frame's inner panel. The inner panel includes a guiding surface that directly guides the door glass, eliminating the need for a separate rail structure. This integration reduces the number of components and simplifies the overall assembly while maintaining the door glass movement function.
2Reliability
If a separate rail structure is used to guide the door glass, then the door glass can move upward and downward, but the rigidity of the door is reduced
Solution Approach 1:
The guiding function is merged into the door frame's inner panel, which is a rigid structural component. The inner panel includes a guiding surface that directly guides the door glass, and the garnish plate is fastened to this rigid structure. This integration allows the rigid door frame to provide both structural support and guiding function, enhancing overall rigidity while eliminating the need for a separate, potentially weaker rail structure.
3Device complexity
If the rail is formed integrally with the door frame, then the structure is simplified, but the assembly becomes difficult due to vertical manipulation requirements
Solution Approach 1:
The patent segments the guiding function from the vertical rail manipulation by providing a guiding surface on the inner panel that allows horizontal insertion of the door glass assembly. The inner panel includes a guiding surface that guides the door glass in the width direction, allowing the assembly to be installed horizontally rather than requiring vertical manipulation of a rail structure.
4Productivity
If a separate rail structure is used, then the door glass can be guided, but the manufacturing cost and assembly time increase
Solution Approach 1:
The patent combines the guiding function with the existing door frame structure, specifically the inner panel and garnish plate. The inner panel includes a guiding surface that guides the door glass, and the garnish plate is fastened to the door frame to provide additional guiding support. This merger eliminates the separate rail component, reducing the total number of parts and simplifying the assembly process, thereby improving productivity and reducing manufacturing costs.
Data Source
AI summary
An embodiment flush door for a vehicle with a rail integrated door frame includes a door frame of the vehicle, a door glass whose upward and downward movements are guided by the door frame, a garnish plate fastened to the door frame and configured to guide the upward and downward movements of the door glass together with the door frame, and a slider fixed to an end portion of the door glass and configured to move up and down between the door frame and the garnish plate.