Vehicle Door Handle Actuator with Torque-Limiting Coupling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Designing actuating mechanisms for flush door handles that can reliably and repeatedly move into a closed position, especially in the presence of dirt or ice, while allowing for both electrical and manual actuation, is challenging due to the need for continuous torque increase and prevention of damage from hindrances.

Innovation Solution

A coupling mechanism with a spring biasing system that transfers torque continuously until a threshold is reached, allowing for manual operation and automatic adjustment to overcome resistance, featuring a dual function spring that increases torque when necessary and limits it to prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a purely mechanical door handle is used, then the door can be opened reliably, but the handle must extend beyond the vehicle exterior requiring more space

Engineering Contradiction:

Improveflush position of door handleVSAvoidgripability of door handle

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The door handle cover is designed to be movable between a flush resting position and an exposed operating position. When actuated, the cover pivots outward to provide a gripable handle, and returns to flush position when released. This dynamic transformation allows the handle to provide both aesthetic flush mounting and functional gripability.

Inventive Principle:

Principle #15Dynamics

2Shape

If an electric door handle is used, then the door handle can be made flush with the vehicle exterior, but manual actuation capability is reduced

Engineering Contradiction:

Improveflush position of door handleVSAvoidmanual and electrical actuation capability

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The door handle assembly is designed with dual actuation capability: an electric actuator provides automated operation, while a mechanical Bowden cable system provides manual emergency operation. This multi-functionality ensures the door can be opened regardless of whether the electrical system is functional, enhancing versatility and reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the door handle cover is pushed into the recess automatically, then the cover can be closed reliably, but dirt and ice can impede the movement

Engineering Contradiction:

Improvereliable closure of door handle coverVSAvoiddirt and ice accumulation in recess

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The actuating mechanism is designed to apply sufficient force to overcome resistance from dirt or ice before the cover reaches its final closed position. The mechanism includes a travel stop that allows the cover to be forced into the recess with adequate force to clear obstructions, ensuring reliable closure even in adverse conditions.

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If the door handle recess is designed to accept the cover, then the cover can be engaged, but dirt and water can accumulate in the recess

Engineering Contradiction:

Improveengagement of door handle recessVSAvoiddirt and water accumulation in recess

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The door handle cover is designed to be completely removable from the recess. The cover can be detached from its mounting position and removed entirely, allowing the recess to be cleaned of accumulated dirt and water. This extraction capability eliminates the trapping of contaminants that would otherwise remain in the recess.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Ensures secure and reliable closure of flush door handles even in dirty or icy conditions, preventing damage by gradually increasing torque and allowing manual operation when necessary, while maintaining easy actuation under normal conditions.

Implementation Method 1

A coupling mechanism with a spring biasing system that transfers torque continuously until a threshold is reached

Methodology Applied

Scientific EffectSpring: Spring

Implementation Method 2

a kinematics associated with the drive, which kinematics is configured so as to tap a rotational movement from the drive shaft when the drive is actuated and convert it into a movement, in particular a pivoting, of the cover

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Data Source

PatentUS20230340810A1Actuating Mechanism for Actuating Covers for Vehicles

Publication Date: 2023.10.26 ILLINOIS TOOL WORKS INC

AI summary

The present disclosure relates to an actuating mechanism (100) for actuating covers (102) for vehicles, in particular covers for flush door handles, wherein the cover (102) is reversibly movable, and in particular pivotable, between a closed position and an opened position, wherein the actuating mechanism (100) comprises the following: a drive (108), in particular in the form of an electric motor, having a drive shaft; and a kinematics associated with the drive, which kinematics is configured so as to tap a rotational movement from the drive shaft (160) when the drive is actuated and convert it into a movement, in particular a pivoting, of the cover (102), wherein the kinematics is associated with a coupling (110). The coupling (110) has a normal state, in which a torque of the drive shaft (160) is transferred to the cover continuously increasing up to a first torque threshold, and an emphatic state, in which the torque of the drive shaft (160) is transferred to the cover abruptly up to a second torque threshold, wherein the second torque threshold is higher than the first torque threshold.