Vehicle Door Window Frame with Integrated Waist Reinforcement
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Solution Overview
Problem
The current method of manufacturing automobile vehicle doors with separate window frame and waist reinforcements, which are then welded together before being attached to the main reinforcement, is laborious and expensive due to the complexity of requirements and material constraints.
Innovation Solution
A method for manufacturing a window frame with integrated waist reinforcement, where the upper and lower parts are independent pieces joined by a weld joint, with the waist reinforcement formed in a horizontal sector of the lower part, allowing for different materials and thicknesses, and using advanced welding systems like TWB, FSW, or brazing to combine initial formats into a single multi-thickness/multimaterial format.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If window frame reinforcement and waist reinforcement are manufactured separately and then welded together, then each piece can be optimized for its specific function, but the manufacturing process becomes laborious and expensive
Solution Approach 1:
The patent merges the window frame reinforcement and waist reinforcement into a single integrated piece called a 'reinforcement frame'. This eliminates the need to manufacture and weld separate components, directly resolving the contradiction by combining two functions into one manufacturable unit while reducing assembly complexity
Solution Approach 2:
The integrated reinforcement frame serves multiple functions simultaneously: it provides the window frame reinforcement function and the waist reinforcement function. This multi-functionality allows a single component to replace what previously required two separate pieces, simplifying the manufacturing process while maintaining all necessary structural functions
2Ease of manufacture
If window frame reinforcement is made from easily pressed materials, then it can be easily formed, but it may not provide sufficient strength for the upper area
Solution Approach 1:
The reinforcement frame is constructed from two initial formats of different materials welded together: a first initial format (easily pressed material) forming the upper part, and a second initial format (high resistance material) forming the lower part with waist reinforcement. This composite structure allows each section to be made from the most suitable material for its specific functional requirements
3Strength
If waist reinforcement uses high resistance materials, then collision resistance is improved, but the material and processing become more complex
Solution Approach 1:
The patent applies different material qualities to different locations: the lower part containing the waist reinforcement uses high resistance materials for collision resistance, while the upper part uses easily pressed materials for formability. This localized material selection optimizes each region's properties without requiring the entire structure to use complex high-strength materials
4Reliability
If separate reinforcements are welded together, then functional requirements are met, but manufacturing time and cost increase
Solution Approach 1:
By combining the window frame reinforcement and waist reinforcement into a single integrated reinforcement frame manufactured from two welded initial formats, the patent eliminates the need for additional welding operations that would be required if separate pieces were assembled. This improves productivity while maintaining all necessary functional performance through the integrated design
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 approach simplifies the architecture, reduces material duplication, optimizes assembly costs, and enhances collision resistance by integrating the waist reinforcement, thereby improving the structural integrity and stability of the door.
Implementation Method 1
using advanced welding systems like TWB, FSW, or brazing to combine initial formats into a single multi-thickness/multimaterial format
Implementation Method 2
subjecting the combined format to forming, for example by means of pressing or stamping, forming the upper part of the reinforcement frame from the first initial format and forming the lower part with the waist reinforcement of the reinforcement frame from the second initial format
Data Source
Figure 1~2
Figure 3
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AI summary
The invention relates to a window frame reinforcement (2) to be combined with the main reinforcement of a door of an automobile comprising an upper part (2a) which comprises at least one upper horizontal sector and two side sectors demarcating a hole (2c) for a window top-wise and side-wise; a horizontal lower part (2b); and a waist reinforcement (3) arranged in correspondence with the lower part (2b), in which the upper part (2a) and the lower part (2b) are independent pieces joined to one another by means of weld joint (4,4a,4b,4c) and the waist reinforcement (3) is formed in a horizontal sector of the lower part (2b). The frame can be manufactured by means of a method which comprises welding a first initial format (2a') and a second format (2b') to one another to obtain a combined format (2') and forming the upper part (2a) from the first initial format (2a') and the lower part (2b) with the waist reinforcement (3) from the second initial format (2b'). When the initial formats (2a',2b') are of different materials, TBW welding, FSW welding, brazing welding, CMT welding can be used depending on the materials of the initial formats (2a',2b').