Rail Vehicle Door Leaf Frame Assembly Using Modular Profiles
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Solution Overview
Problem
The manufacturing costs of rail vehicle door leaves are high due to complex welding and adhesive bonding requirements, leading to expensive corner connecting parts and high quality control demands, which increases the overall cost of rail vehicle production.
Innovation Solution
A rail vehicle door leaf frame composed of four frame hollow profiles, produced from two different original profiles, which are plugged, fitted, and riveted or screwed together in corner regions, eliminating the need for complex welding and reducing the number of components, with integrated radii and seal edges providing a pressure-tight seal without an exterior panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding and adhesive bonding are used to assemble frame profiles and corner connecting parts, then the structural strength and pressure-tightness are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The door frame is divided into modular frame hollow profiles that can be assembled from pre-fabricated sections. Each profile segment is designed with standardized connection interfaces that simplify assembly while maintaining structural integrity and pressure-tightness without requiring complex welding or adhesive bonding processes.
2Strength
If welding and adhesive bonding processes are implemented, then the structural integrity is improved, but the quality control demands and manufacturing cost increase
Solution Approach 1:
The invention replaces welding and adhesive bonding processes with mechanical connection systems such as rivets, screws, or snap-fit connectors. This substitution eliminates the need for complex quality control procedures associated with welding and adhesive bonding while maintaining structural integrity through proven mechanical fastening methods.
3Stability of the object's composition
If corner connecting parts are used to join frame profiles, then the structural stability is improved, but the component quantity and manufacturing cost increase
Solution Approach 1:
The invention merges the corner connecting parts into integrated corner sections that are either pre-formed as single pieces with built-in connection features or directly formed as part of the frame hollow profiles themselves. This integration reduces the total component count by eliminating separate corner connectors while maintaining structural stability through the unified design.
Solution Approach 2:
The frame hollow profiles are designed with universal connection interfaces that can accommodate various joining methods and configurations. These multi-functional profiles serve both structural and connection purposes, eliminating the need for dedicated corner connecting parts and reducing overall component quantity while maintaining structural stability.
Data Source
AI summary
A vehicle door leaf frame, in particular a rail vehicle door leaf frame, preferably for an inwardly opening vehicle door leaf for an entry door. The vehicle door leaf frame has a plurality of, in particular precisely four, hollow frame profiles constituting the actual vehicle door leaf frame. The hollow frame profiles are produced from a plurality of, in particular precisely two, different hollow profiles. In an alternative embodiment, a vehicle door leaf, in particular a rail vehicle door leaf, preferably an inwardly opening vehicle door leaf for an entry door, has a vehicle door leaf frame and is itself pressure-tight and/or water-tight.