Vehicle Frame Joint Structure for Smooth TWB Thickness Transitions
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Solution Overview
Problem
The existing vehicle frame manufacturing processes result in quality issues such as poor gap steps, wind noise, road noise, and reduced water-tightness due to thickness and material distribution discrepancies between metal plates, leading to increased weight and reduced rigidity.
Innovation Solution
A frame structure featuring a first member with a thicker metal plate and a second member with a thinner plate, connected via an inclined surface, welded using tailor welded blank (TWB) technology, which minimizes step formation and enhances rigidity while optimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple metal plates with different thicknesses and materials are individually processed and bonded by welding, then the rigidity of each section can be optimized, but distribution discrepancies occur leading to poor gap steps, wind noise, road noise, and reduced water-tightness
Solution Approach 1:
The patent applies local quality by using metal plates with different thicknesses and materials at different sections of the frame. The first member uses a thicker metal plate for high rigidity requirements, while the second member uses a thinner metal plate where less rigidity is needed. This localized optimization allows each section to have the optimal material properties for its specific functional requirements, resolving the contradiction between achieving section-specific rigidity and maintaining uniform gap steps through proper design and welding control.
Solution Approach 2:
The patent applies preliminary action by pre-forming the metal plates with different thicknesses and materials before assembly, and by designing the connection portions with inclined surfaces that facilitate proper alignment. The plates are individually processed with predetermined characteristics, and the welding process is planned in advance to account for the thickness differences, preventing distribution discrepancies and gap step issues before they occur during assembly.
2Strength
If the thickness of the door frame is increased to improve rigidity, then the rigidity is enhanced, but the weight is excessively increased
Solution Approach 1:
The patent resolves the contradiction between rigidity and weight by applying local quality - using a thicker first member (quadrant reinforce frame or B pillar frame) where high rigidity is critical for structural integrity, and a thinner second member (roof frame or inner belt rail) where less rigidity is required. This localized thickness optimization ensures that material is only used where structurally necessary, achieving sufficient overall rigidity while minimizing frame weight through strategic material distribution.
Solution Approach 2:
The patent applies segmentation by dividing the frame into multiple members with different thicknesses and materials - the first member with thicker plate for high-stress areas and the second member with thinner plate for lower-stress areas. This segmentation allows the frame to achieve the required rigidity through strategic reinforcement at critical locations rather than uniformly increasing the thickness of the entire frame, thereby reducing overall weight while maintaining structural performance.
3Strength
If reinforcement members are welded to the door frame to enhance rigidity, then the rigidity is improved, but the matching is not complete and reinforcement cannot be applied to all sections requiring it
Solution Approach 1:
The patent resolves the contradiction between rigidity improvement and reinforcement coverage by integrating the reinforcement function directly into the frame members themselves rather than adding separate reinforcement members. The first member is designed with optimal thickness and material properties to provide reinforcement where needed, and the connection portions are designed with inclined surfaces that enable complete coverage. This integrated approach ensures that reinforcement is applied precisely where required without the matching and accessibility issues of separate reinforcement members.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration achieves lightweight and sufficient rigidity, reduces noise and water-tightness issues, and minimizes material waste, improving overall vehicle frame quality and reducing scrap.
Implementation Method 1
a second member composed of a metal plate having a thickness thinner than that of the first member, the second member integrally connected to the first member by welding
Data Source
AI summary
A frame structure of a vehicle includes: a first member composed of a metal plate, and a second member composed of a metal plate having a thickness thinner than that of the first member, the second member integrally connected to the first member by welding. The connection portion between the first member and the second member has an inclined surface configured to obliquely connect an upper surface of the first member and an upper surface of the second member such that the upper surface of the second member is positioned to be lowered than the upper surface of the first member in a gradual manner.