Multi-Thickness Motor Vehicle Door Sheet for Uniform Appearance
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Solution Overview
Problem
Multi-thickness metal sheets in motor vehicle doors exhibit a discontinuous appearance due to visible thickness transitions in the frame area, particularly in tailored welded blanks, leading to an unattractive and non-uniform appearance.
Innovation Solution
A motor-vehicle door structure utilizing a multi-thickness metal sheet with area-wise differentiated thickness, where the thickness varies in multiple directions to ensure the boundary between different stress areas is positioned to be hidden during upholstery, eliminating visible transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-thickness metal sheet with band-wise differentiated thickness is used to concentrate material in high-stress areas, then the structural strength is improved, but the appearance uniformity deteriorates due to visible thickness transitions in the frame area
Solution Approach 1:
The patent applies local quality by differentiating the metal sheet thickness in three specific areas: the hinge area receives the greatest thickness for maximum structural strength, the frame area receives intermediate thickness for adequate support while maintaining aesthetics, and the panel area receives the least thickness to reduce weight. This localized thickness differentiation resolves the contradiction by optimizing strength where needed while preserving appearance uniformity in visible areas.
Solution Approach 2:
The patent transitions from band-wise differentiated thickness (one-dimensional variation) to area-wise differentiated thickness (two-dimensional variation). By defining three distinct thickness areas rather than two bands, the solution creates a more sophisticated thickness distribution that can accommodate both structural requirements and aesthetic considerations simultaneously, eliminating the visible transition lines that plagued the band-wise approach.
2Ease of manufacture
If the boundary between different thickness areas is positioned in the frame area, then the manufacturing process is simplified, but the visual appearance deteriorates due to discontinuous and unattractive transitions
Solution Approach 1:
The patent strategically positions the boundaries between different thickness areas to align with functional zones rather than arbitrary manufacturing divisions. The first boundary separates the hinge area from the frame area, and the second boundary separates the frame area from the panel area. This positioning ensures that thickness transitions occur at functional interfaces where they are less visually prominent, resolving the contradiction between manufacturing ease and visual appearance.
3Weight of moving object
If the metal sheet thickness is reduced in low-stress areas to prevent excessive weight, then the weight is reduced, but the structural integrity may be compromised in high-stress areas
Solution Approach 1:
The patent implements local quality by assigning different thickness values to different functional areas: the hinge area (highest stress) receives the greatest thickness for maximum structural integrity, the frame area (intermediate stress) receives moderate thickness, and the panel area (lowest stress) receives the least thickness to minimize weight. This localized optimization resolves the contradiction by ensuring structural integrity where needed while reducing weight in non-critical areas.
Data Source
AI summary
Described herein is a structure of a motor-vehicle door including a multi-thickness metal sheet pressed and shaped to define: a hinge area configured for fastening one or more hinges for connection to the body of a motor vehicle; a panel area configured for receiving an upholstery-trim element for the door; and a frame area configured for receiving a window of the door. The above multi-thickness metal sheet has a first thickness in said hinge area, a second thickness in said panel area, and a third thickness in said frame area.