Vehicle Door Handle Actuator with Mold-In-Metal Decorative Layer

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Solution Overview

Problem

Interior vehicle door handle components face challenges in achieving a metallic visual appearance without the health and environmental issues associated with chromium plating, and existing methods like mold-in metal color (MIMC) often result in surface defects such as flow lines and insufficient durability.

Innovation Solution

A two-component injection molding method is used to create an actuating member with a carrier substrate and a decorative layer, where the decorative layer is formed with a gate region that allows for homogenization of the injection molding compound, preventing surface defects and providing a durable, high-quality surface without the need for chromium plating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If chromium plating is used to achieve metallic visual appearance, then high-quality surface is obtained, but health and environmental problems occur

Engineering Contradiction:

Improvesurface qualityVSAvoidhealth and environmental impact

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces permanent chromium plating with a mold-in-metal-color plastic component that achieves metallic appearance through material selection and molding process rather than post-manufacturing coating, eliminating the need for harmful chromium plating while maintaining visual quality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the fundamental approach from surface coating (chromium plating) to material-intrinsic coloration (mold-in-metal-color plastic), altering the parameter of how metallic appearance is achieved from external coating to internal material property

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If mold-in metal color process is used to avoid chromium plating, then metallic visual appearance is achieved, but surface defects such as flow lines and voids occur

Engineering Contradiction:

Improveelimination of chromium platingVSAvoidsurface defects

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent divides the actuating member into two separate components: a carrier substrate made of durable plastic and a decorative layer made of mold-in-metal-color plastic. This segmentation allows each component to be optimized independently, with the decorative layer providing metallic appearance and the carrier substrate providing structural integrity and durability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent incorporates the gate region design into the decorative layer structure before final assembly, allowing the injection molding compound to be homogenized in the gate region and flow smoothly into the visible area, preventing surface defects like flow lines and voids in the final product

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If mold-in metal color plastic is used for actuating member, then design freedom and cost-effectiveness are improved, but durability and maximum breaking load are insufficient

Engineering Contradiction:

Improvecost-effectiveness and design freedomVSAvoidmaximum breaking load

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent segments the actuating member into a carrier substrate that provides structural strength and a decorative layer that provides metallic appearance. The carrier substrate is made of durable plastic with sufficient breaking load, while the decorative layer can be made of more brittle mold-in-metal-color plastic, allowing each material to be optimized for its specific function

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a composite structure combining two different plastic materials: a durable carrier substrate plastic and a mold-in-metal-color decorative layer plastic. This composite approach allows the final product to exhibit both the strength of the carrier substrate and the aesthetic qualities of the decorative layer

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12129692B2Actuating element, in particular a handle element, of an inner door handle arrangement of a vehicle and method for producing such an actuating element

Publication Date: 2024.10.29 ILLINOIS TOOL WORKS INC

AI summary

An actuating member (14), in particular a handle element, an interior door handle arrangement of a vehicle, wherein the actuating member (14) includes a carrier substrate (20) preferably made of plastic and a decorative layer (21) covering the surface of the carrier substrate (20). The decorative layer (21) includes a visible area (22) that in particular in the intended installed state, and in particular in the non-actuated state of the actuating member (14) forms a visible side of the actuating member (14), at least one gate region (2) in particular formed in a gate lip or gate tab (4), and at least one edge region or arcuate region (25, 26) by which the gate region (2) is preferably continuously connected to the visible area (22) of the decorative layer (21).