Door Overbend - Design Synthesis & Analysis 2004-01-0875

This paper describes the analytical methodology for calculating the overbend needed in the door design to counteract the non-linear seal forces acting on the door header. Overbend in the door design will allow the Original Equipment Manufacturer to achieve competitive above belt flushness and gap dimensional targets at static equilibrium of the door header and weatherstrip. This method combines two analytical models of the weatherstrip and the Door-In-White (DIW) to forecast the design overbend necessary to achieve good fit and finish. These models are: 1) Seal compression-load deflection (CLD) models for each angle of attack of the weatherstrip to the door 2) A nonlinear Finite Element Analysis (FEA) model of the trimmed DIW. Bringing these two elements together to model the static equilibrium deflection, this is developed, into overbend requirements. The design synthesis process to meet the overbend design criteria is demonstrated. This method improves product quality and reduces door fit warranty by producing a product design that comprehends the inherent deflection of seal loads on the door structure.