Vehicle Door Handle Assembly With Blocking Lever Load Protection
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Solution Overview
Problem
Existing vehicle door handle assemblies are prone to damage from excessive pressure or shock when the handle grip is in the deployed position, which can cause damage to the actuator gearbox and deploying mechanism.
Innovation Solution
A vehicle door handle assembly with a deploying mechanism that includes a bracket, levers, a blocking lever, and a locking rod, which stabilize the handle grip in the deployed position by preventing rotation back to the flush position under pressure or shock, using pivot connections and a blocking lever mechanism to absorb loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the handle grip is left protruding in the deployed position for easy grasping, then user accessibility is improved, but the handle grip becomes vulnerable to damage from excessive pressure or shock
Solution Approach 1:
The blocking lever is pre-positioned to engage with the recess in the bracket before any external force is applied to the handle grip. This preliminary positioning ensures that when pressure or shock is applied, the blocking lever is already in place to prevent the levers from rotating and transmitting damaging forces to the actuator gearbox, thus protecting the system while maintaining the handle in the deployed position
Solution Approach 2:
The blocking lever mechanism acts as a protective cushion by absorbing and dissipating the energy from external pressure or shock before it can reach the actuator gearbox. When force is applied to the deployed handle grip, the blocking lever engages to stop the lever rotation, effectively cushioning the impact and preventing severe damage to the actuator gearbox and deploying mechanism
2Device complexity
If friction in the actuator gearbox is used to maintain handle grip stability in the deployed position, then the structure remains simple, but severe damage occurs when pressure exceeds the friction threshold
Solution Approach 1:
The blocking lever serves as an intermediary protective element between the handle grip levers and the actuator gearbox. Instead of relying solely on the friction within the actuator gearbox to prevent lever rotation, the blocking lever intercepts the rotational motion before it can transmit damaging forces to the gearbox, thereby protecting the system while maintaining structural simplicity
Solution Approach 2:
The blocking lever applies a preliminary counter-action to prevent the levers from rotating under external pressure. By engaging with the recess in the bracket before excessive force can damage the actuator gearbox, the blocking lever neutralizes the harmful rotational motion in advance, preventing the transmission of damaging loads to the gearbox
Data Source
AI summary
A vehicle door handle assembly includes a bracket and a deploying mechanism configured to move a handle grip between a flushing and a deployed position. The deploying mechanism includes at least one lever having a front lever, a rear lever, a recess on the bracket, a contact surface on the at least one lever, and a blocking lever placed between the recess and the contact surface. The blocking lever configured to move from a first position, when the handle grip is flush, to a second position, when the handle grip is deployed, in its second position, the blocking lever is pressed against the recess on the bracket and against the contact surface, thereby blocking the rotation of the at least one lever in its first position.