Integrated Upper Rail Structure for Sliding Door NVH and Sealing
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Solution Overview
Problem
The existing slide-type occupant compartment opening/closing door systems in vehicles experience issues with noise, vibration, harshness (NVH), and abrasion due to friction and misalignment between multiple components, leading to deteriorated watertightness and operational performance.
Innovation Solution
A vehicle-body-integrated upper rail structure is designed as a single component using an aluminum casting process, featuring a rail portion with a sliding route, pillar connections, and a roof rail connection, which eliminates assembly tolerance issues and prevents gaps between components, thereby enhancing the connection between the vehicle body and the door bearing, reducing noise and abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple components are assembled to form the upper rail structure, then the structure can be manufactured using conventional processes, but friction and misalignment occur between components leading to noise and abrasion
Solution Approach 1:
The patent merges multiple separate components (side roof rail, upper rail, stoppers, roof rail panel, bearing) into a single integrated upper rail structure. This integration eliminates the interfaces between components where friction and misalignment occurred, thereby preventing noise and abrasion while maintaining manufacturability through aluminum casting processes.
2Ease of operation
If multiple components are coupled together, then the upper rail structure can be assembled, but gaps or voids form between components deteriorating watertightness and NVH performance
Solution Approach 1:
By integrating the upper rail structure as a single component with built-in features for door support and sealing, the patent eliminates gaps and voids that would form between separately coupled components. The integrated design ensures continuous watertight sealing and improved NVH performance while maintaining ease of installation as a single unit.
3Object-affected harmful factors
If a single integrated component is used for the upper rail structure, then noise and abrasion are prevented, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functional elements (side roof rail, upper rail, stoppers, roof rail panel, bearing) into one integrated component manufactured via aluminum casting. This approach eliminates noise and abrasion from component interfaces while managing manufacturing complexity through established casting processes and precise post-casting treatments.
4Ease of manufacture
If conventional multi-component assembly is used, then manufacturing is simpler, but alignment precision deteriorates leading to trajectory dimension issues
Solution Approach 1:
By integrating the upper rail structure as a single precision-cast component, the patent eliminates alignment errors that accumulate in multi-component assemblies. The integrated design ensures precise trajectory dimensions for door movement while managing manufacturing complexity through controlled casting processes and post-processing.
Data Source
AI summary
A vehicle-body-integrated upper rail structure is provided at an upper side of a door opening portion formed in a vehicle body and includes: a rail portion including a rail opening that provides a sliding route for a door and is formed in a longitudinal direction of the vehicle body; a pillar connection portion extending from the rail portion toward a lower side of the vehicle body and connected to a pillar, and a roof rail connection portion extending from an upper end portion of the rail portion toward a center portion of the vehicle body and connected to a roof rail of the vehicle body.