Framed Vehicle Door Bodyshell With Hidden Window Seal
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Solution Overview
Problem
Conventional framed doors in motor vehicles face challenges in achieving a non-visible seal between the window pane and the door bodyshell, particularly due to the frame structure, which limits the ability to form a horizontal or inclined flange or weld seam without colliding with the frame, resulting in a widened window well and compromised design aesthetics.
Innovation Solution
A two-part construction of the door bodyshell, comprising an inner door panel and an outer door skin, allows for the formation of a horizontal or inclined flange or weld seam along the complete length of the outer door skin, enabling a seal to be placed below the flange or weld seam, thus avoiding the need for an external cover element and maintaining design integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a frame structure is used in a framed door, then structural strength and support are improved, but the ability to form a hidden seal is worsened due to tool collision with the frame
Solution Approach 1:
The door bodyshell is segmented into an inner door panel and an outer door skin that are joined together. The outer door skin is formed separately and then attached to the inner door panel, allowing the sealing flange to be created on the outer door skin without interference from the frame structure on the inner door panel.
Solution Approach 2:
The sealing function is moved to a different dimensional plane by forming the sealing flange on the outer door skin surface, which is exterior to the frame structure. This allows the sealing operation to occur in a spatial dimension where the frame does not interfere with tool access.
2Ease of manufacture
If the window well is widened to accommodate sealing, then sealing capability is improved, but design aesthetics are worsened due to visible cover elements
Solution Approach 1:
The sealing flange is extracted from the traditional window well location and repositioned to the outer door skin surface. This extraction allows the seal to be formed externally without requiring a widened window well, thereby maintaining the original aesthetic design while achieving effective sealing.
Solution Approach 2:
The outer door skin acts as an intermediary element between the inner door panel and the external environment. The sealing flange is formed on this intermediary surface, allowing the seal to be created without directly modifying the window well structure or requiring visible cover elements.
3Strength
If the outer door skin is shaped and assembled traditionally, then structural integrity is maintained, but compression or pressing is required which complicates the assembly process
Solution Approach 1:
The outer door skin is pre-formed with the sealing flange integrated into its structure before assembly. The reinforcing structure is also prepared in advance with appropriate attachment features. This preliminary preparation eliminates the need for compression or pressing during final assembly, simplifying the manufacturing process while maintaining structural integrity.
Data Source
AI summary
A door bodyshell of a framed door of a motor vehicle is provided. The door bodyshell includes a door inside panel and an assembly fastened to the door inside panel. The door inside panel has an inner sill region and a peripheral frame structure, which is connected to the inner sill region, for a motor vehicle side window. The assembly fastened to the door inside panel has a reinforcing structure, which is arranged level with the inner sill region, and a door outside skin, which is connected to the reinforcing structure level with the inner sill region by way of a flange or a welded joint. In a state in which the door body shell is installed on the motor vehicle, the reinforcing structure level with the inner sill region is inclined in the direction of a motor vehicle interior such that the flange or the welded joint and a horizontal plane enclose an angle of less than 90°. In the state in which the door body shell is installed on the motor vehicle, the flange or the welded joint is formed as far as at least an outer comer, in the longitudinal direction of the motor vehicle, of an outer sill region of the door body shell.