Improvement Technology of Hinge Reinforcing Plate Structure for Increasing Vertical Rigidity of Auto

The vertical stiffness of a car's side door is an important factor in its overall performance. To ensure that the door system meets the necessary requirements, the design must adhere to certain performance indexes. One such index is the LSR (Load-Sharing Ratio), which is calculated by dividing the front door hinge distribution law (HS) by the door length (DL). For passenger cars, the LSR value should be less than or equal to 2.5, while commercial vehicles generally require an LSR value less than or equal to 2.7. The LSR value directly affects the vertical stiffness of the door, and the design of the hinge reinforcement plate plays a crucial role in increasing this stiffness.

However, if the door system has layout defects during the early stage of design, such as a hinge distribution that is too large and a stopper installation surface without proper reinforcement, it is necessary to find a solution to compensate for these defects. This can be achieved through the design of the hinge reinforcement plate, which aims to increase the overall stiffness of the door system. Furthermore, this design must also ensure the waterproof, dustproof, and rustproof performance of the hinge and stopper installation area.

The existing traditional front door hinge reinforcement plate structure consists of a hinge nut plate welded with nuts, which overlaps with the door inner panel using two welding spots. However, this structure has some disadvantages. When the hinge distribution law is relatively small compared to the length of the door, the overlapping surface between the inner panel and the hinge reinforcement plate is small, leading to stress concentration and potential damage to the inner panel. This can result in insufficient vertical stiffness of the front door, causing sagging and misalignment of the entire door system.

Another issue arises when the installation space for the sheet metal on the hinge side of the front door is insufficient. In order to reinforce the installation surface of the limiter, a reinforcement plate is necessary. However, a single hinge reinforcement plate is not enough to solve the problem of insufficient vertical rigidity and door deformation. In such cases, the hinge reinforcement plate and limiter reinforcement plate need to be added separately, which increases the cost and requires additional molds.

To address these structural defects, a new hinge reinforcement plate structure has been proposed. In this design, the front door hinge reinforcement plate and stopper reinforcement plate are combined into one plate, increasing the overlapping area with the inner panel. This helps prevent stress concentration and strengthen the hinge mounting surface, leading to improved vertical stiffness of the door. Additionally, this new structure solves the problem of deformation and cracking of the inner panel due to stress on the limiter installation surface. Furthermore, by integrating the reinforcement plates into one design, the number of parts and molds needed for the limiter reinforcement plate is reduced, thereby reducing costs.

The improved structure of the new hinge reinforcement plate also considers other factors such as rust prevention, waterproofing, and dustproofing. The installation surface of the reinforcement plate limiter is designed to fit the limiter completely, while also preventing rust and leakage. A space is reserved between the reinforcement plate and inner panel to allow the passage of electrophoretic fluid, preventing rust between the two surfaces.

An application example of this new structure is provided, where the front door LSR value exceeds the required limit. Through the use of the new hinge reinforcement plate, the vertical stiffness of the door meets the set standards, indicating the effectiveness of the new structure.

In terms of economic benefits, the integration of the hinge and limiter reinforcement plates into one design eliminates stress concentration and improves the vertical stiffness of the side door. It also enhances the waterproof, dustproof, and rustproof performance of the door system. Additionally, the reduction in the number of parts and molds for the limiter reinforcement plate helps reduce costs associated with mold development, packaging, transportation, and labor.

In conclusion, when the hinge distribution law of the front door is too large relative to the door length, resulting in insufficient vertical rigidity and installation surface defects, the structural design of the hinge reinforcement plate can effectively compensate for these deficiencies. The design not only improves the overall performance of the door system but also addresses cost and labor considerations. The experience gained from this design can serve as a reference for future structural designs in the development of new models. The outstanding quality and professionalism displayed by Tallsen's products and staff have been widely recognized by customers. Their products are known for their high quality and competitive prices.