Vehicle Door Handle Coupling Device for Manual Backup
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing vehicle door handle mechanisms can deteriorate due to increased friction and potential breakage from reverse actuation, especially in cases of motor or battery failure, affecting both manual backup and normal electrical operation.
Innovation Solution
A coupling device with a central shaft, push-push lever cylinder, and coupling gear featuring axial protrusions and circular arc recesses allows for free relative rotation, selectively uncoupling the lever and reduction stages, enabling the handle lever to move between positions without actuating the electric motor, reducing friction and potential damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the reduction mechanism is actuated in reverse during manual backup operation, then the handle lever can be moved from flush position to ready position, but the friction and temperature increase may cause the reduction mechanism to deteriorate or break
Solution Approach 1:
The coupling device is segmented into two independent functional parts: a coupling gear for electrical actuation and a push-push lever cylinder for manual operation. These parts are connected through a shaft but can rotate independently relative to each other via the circular arc protrusion-recess interface, allowing manual operation without necessarily actuating the electrical reduction mechanism
Solution Approach 2:
The circular arc protrusion and recess act as an intermediary mechanism between the coupling gear and push-push lever cylinder. This intermediary allows selective engagement and disengagement, enabling the manual push-push operation to occur independently without transmitting reverse actuation forces to the electrical reduction mechanism, thus protecting it from friction-induced deterioration
2Device complexity
If the coupling gear and push-push lever cylinder are rigidly connected, then the structure is simpler, but reverse actuation during manual operation causes friction and potential breakage
Solution Approach 1:
The connection between the coupling gear and push-push lever cylinder is made dynamic rather than rigid. The circular arc protrusion-recess interface allows relative rotation between the two components, enabling the system to adapt its connectivity based on the operational mode. During manual operation, the components can rotate independently, preventing friction-induced damage while maintaining structural integrity
3Power
If the axial protrusion engages in the circular arc recess with tight fit, then the transmission is more efficient, but the relative rotation needed for selective uncoupling is restricted
Solution Approach 1:
The engagement interface between the axial protrusion and circular arc recess exhibits local quality variation. In the engaged position, the interface provides sufficient constraint for efficient power transmission during electrical actuation. However, the circular arc geometry inherently allows controlled relative rotation when needed, providing selective uncoupling capability. The local geometry is optimized to balance transmission efficiency with adaptability
Data Source
Figure 1~2
Figure 3a~4c
Figure 5a~6c
AI summary
The invention relates to a coupling device for a vehicle door handle (1), the door handle (1) having a handle lever (3) movable between a flush position in which it is flush with an exterior door panel (100) surface and a ready position in which it is protruding and graspable by a user by an electric motor (7), and an inward clicking position in which a preloaded push-push unit (13) is released so as to bring the handle lever (3) in said ready position without actuation of the electric motor (7), comprising : • a central shaft (31), connected to the handle lever (3), • a push-push lever cylinder (29), rotatively coupled with the central shaft (19), interacting via a push-push lever (45) with the push-push unit (13) when the handle lever (3) is pushed inwards in the clicking position so as to release the preloaded push-push unit (13) and push the lever (3) in the ready position, • a coupling gear (27), rotatively coupled with the central shaft (31), interacting with the electric motor (7) to move the handle lever (3) from the flush position to the ready position on actuation of the electric motor, wherein the coupling gear and push-push lever cylinder (29) comprise for one an axial protrusion (41) and for the other a circular arc recess (43), the axial protrusion (41) engaging in the circular arc recess (43) so as to allow a free relative rotation of the coupling gear (27) and push-push lever cylinder (29) within an angular range corresponding at least to the angular distance between the ready position and the clicking position of the handle lever (3).