Door Handle Assembly Counterweight Design
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Solution Overview
Problem
Conventional vehicle inside door handles are prone to swinging open during impacts due to their weight and design, and existing manufacturing methods are inefficient and costly, requiring separate tools for different handle styles and lacking strong, decorative, and easily manufacturable solutions.
Innovation Solution
A door handle assembly with a handle pivot housing, main handle, bumper, and interchangeable caps, featuring a counterweight positioned to move the center of gravity closer to the pivot axis, and a system allowing universal use with various door handles, including in-mold decorating for decorative caps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the door handle is made heavier to increase robustness, then the strength and robustness are improved, but the center of gravity moves further from the pivot axis making it easier to swing open during impact
Solution Approach 1:
The patent introduces a counterweight component that is positioned to offset the handle's weight distribution. This counterweight acts as an anti-weight mechanism to balance the center of gravity, allowing the handle to maintain robustness while preventing it from swinging open during impact by counteracting the rotational force generated by the handle's weight.
Solution Approach 2:
The patent changes the physical parameters of the door handle system by adjusting the center of gravity position through strategic placement of counterweights and internal components. This parameter change allows the handle to maintain strength while improving its resistance to unintended movement during impact by optimizing the distribution of mass relative to the pivot axis.
2Manufacturing precision
If different door handle styles are separately manufactured with different molds or dies, then each handle style can be precisely produced, but manufacturing time and costs increase
Solution Approach 1:
The patent segments the door handle into modular components that can be produced using standardized manufacturing processes. By dividing the handle into separate modules that can be assembled in different configurations, the system maintains manufacturing precision for various handle styles while improving productivity through standardized production of common components.
Solution Approach 2:
The patent creates a universal base structure and component set that can serve multiple handle style requirements. This universal platform allows different handle styles to be produced using the same core molds and dies, significantly improving manufacturing efficiency while maintaining the precision needed for different aesthetic and functional requirements through configurable components.
3Shape
If in-mold decorating is used with resins for bonding inlays, then decorative capability is improved, but the bond strength is insufficient for vehicle door handle specifications
Solution Approach 1:
The patent employs composite material construction where decorative inlays are integrated with structurally superior base materials. The composite structure combines the aesthetic properties of decorative materials with the high bond strength of engineered materials, allowing the handle to achieve both decorative capability and sufficient bond strength to meet vehicle door handle specifications.
Solution Approach 2:
The patent applies different material properties to different regions of the door handle. The decorative surfaces use materials optimized for appearance through in-mold decorating, while the structural portions and bonding interfaces use materials specifically selected for high bond strength. This local differentiation of material quality allows simultaneous achievement of decorative capability and structural integrity.
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 door handle assembly remains closed during impacts and is easier to manufacture, with universal components and decorative options, reducing manufacturing time and costs while ensuring robustness and safety.
Implementation Method 1
The pivot joint rotatably secures to the boss, and the counterweight and the arm are positioned on opposite sides of the pivot axis in order to move the center of gravity closer to the pivot axis.
Data Source
AI summary
A door handle assembly includes a handle pivot housing and a main handle rotatably or otherwise pivotally secured within the handle pivot housing. The handle pivot housing includes handle engaging-walls defining a handle pivot cavity therebetween. At least one of the handle-engaging walls includes an integrally formed boss extending into the handle pivot cavity. The main handle includes an arm integrally formed with a pivot joint defining a pivot axis, and a counterweight. The pivot joint rotatably or otherwise pivotally secures to the boss. The counterweight and the arm are positioned on opposite sides of the pivot axis. The main handle may be configured to receive and retain a plurality of caps, which may be formed of a different material than said main handle. Each of the caps may differ in at least one of size, shape, structure, material, texture, and color.