Vehicle Sash Coupling Structure with Segmented Bonding
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Solution Overview
Problem
The existing sash coupling structure for vehicle windows, where a column and an upper sash are composed of two members, faces issues with rust prevention due to plating vapor generation during welding, necessitating a process to chip off the plated layer at the welded junction.
Innovation Solution
A sash coupling structure where the channel member and inner member, which form a bag portion, have bonded portions with both adhering and non-adhering surfaces, allowing the non-adhering surfaces to form the coupling portion, eliminating the need for chipping off the plated layer by welding the butted parts directly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the two members (channel member and inner member) are plated for antirust and then welded, then rust prevention is improved, but plating vapor is generated causing explosion and safety deteriorates
Solution Approach 1:
The bonded portion is divided into two functional segments: an adhering portion for bonding the members together and a non-adhering portion for welding. This segmentation allows the plated surface to be preserved in the welding area without generating harmful vapor, while still maintaining rust prevention capabilities in the adhering portion.
Solution Approach 2:
The plated layer is selectively applied only to the adhering portion where rust prevention is needed, while the non-adhering portion (welding area) remains unplated or has a different surface treatment. This local differentiation eliminates plating vapor explosion risk at the welding location while maintaining corrosion protection where required.
2Ease of manufacture
If the plated layer is chipped off before welding, then welding safety is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The non-adhering portion is designed from the beginning to not require plating removal, eliminating the need for chipping operations. The plated surface is intentionally left intact in the welding area, so no preliminary or post-plating removal steps are needed, simplifying the manufacturing process.
3Strength
If the channel member and inner member are bonded along the longitudinal direction, then structural strength is improved, but the coupling surface for welding becomes difficult to access
Solution Approach 1:
The bonded portion is segmented into adhering and non-adhering portions, with the non-adhering portion specifically positioned to provide accessible welding surfaces. This segmentation allows the bonding function to occur along the longitudinal direction while the welding function occurs at accessible transverse surfaces.
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 solution eliminates the need for the process that chips off the plated layer, preventing rust and simplifying the coupling process while ensuring a secure weld between the column and upper sash.
Implementation Method 1
The bonded portions of the channel member and the inner member each include: an adhering portion that adheres to the other member
Implementation Method 2
the butted parts are welded
Data Source
AI summary
An object is to provide a sash coupling structure and a method for sash coupling that ensures omission of the process. The sash coupling structure is made such that on a door frame constituted of a column and an upper sash, a coupling cross-sectional surface of the column and a coupling cross-sectional surface of the upper sash are butted together. The column is constituted of a channel member and an inner member. The channel member and the inner member include adhering portions coupled one another along a longitudinal direction. The inner member is plated. A non-adhering portion, which faces a non-not-yet-adhering portion of the inner member, is formed on the channel member at a butted coupling portion.