Vehicle Door Handle Cam Assembly for Compact Mechanical Switching
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Solution Overview
Problem
Existing automated door latches in vehicles require complex and costly electrical switches, occupying significant space and complicating the door assembly, while mechanical switches are space-efficient but increase manufacturing costs.
Innovation Solution
A vehicle door handle assembly with a rotatable flap and cam holder system that activates a mechanical actuation switch using a minimal stroke, allowing for a compact design by leveraging a cam holder's rotation to amplify the flap's movement and activate the switch with minimal space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If an electrical switch is used to activate the door latch, then the door assembly space is reduced, but the manufacturing cost and electronic system complexity increase
Solution Approach 1:
The patent replaces the electrical switch with a mechanical switch activated by a cam mechanism. The cam is rotated by the door handle lever to directly actuate the mechanical switch, eliminating the need for electrical switching components while maintaining compact space requirements. This substitution reduces manufacturing cost and electronic system complexity while preserving the space efficiency of electrical actuation.
2Ease of manufacture
If a mechanical switch is used to activate the door latch, then the manufacturing cost is reduced, but the door assembly space and activation space increase
Solution Approach 1:
The patent employs a cam mechanism that converts the rotational movement of the door handle lever into precise linear movement to actuate the mechanical switch. The cam's geometric profile allows activation of the switch with minimal lever rotation, effectively utilizing spatial transformation to minimize the space required for mechanical actuation while maintaining the cost advantages of mechanical switches.
3Ease of operation
If a large stroke is provided for the door handle lever, then the mechanical switch can be easily activated, but the air drag increases and the visual aspect is compromised
Solution Approach 1:
The patent utilizes a cam mechanism with a curved profile that efficiently converts small rotational movements of the door handle lever into the linear motion needed to activate the mechanical switch. The cam's geometric shape allows for minimal lever stroke while ensuring reliable switch actuation, thereby reducing the protrusion of the handle assembly and minimizing air drag without compromising the ease of operation.
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
The system reduces manufacturing costs and space requirements by efficiently activating the door latch with a small flap movement, maintaining a streamlined vehicle design and providing a backup mechanical release mechanism.
Implementation Method 1
rotation of the cam holder causes the cam to activate said mechanical actuation switch
Data Source
AI summary
A vehicle door handle assembly includes a housing that sits flush against an outer panel of the vehicle, a rotatable flap housed within the housing, the flap extending along and configured to rotate about a rotation axis between a rest position and a door opening position, a mechanical actuation switch generating an electrical signal to be sent to a vehicle door controller to release the vehicle door. The door assembly includes a cam holder and a cam supported by the cam holder. The cam holder being connected to the flap such that the cam holder is rotatable about the rotation axis and that rotation of the flap causes rotation of the cam holder, rotation of the cam holder causing the cam to activate the switch.