Exterior Door Handle Manufacturing with Post-Paint Electronics Integration
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Solution Overview
Problem
Existing methods for producing outside door handles for motor vehicles often result in damage to electronic units due to paint particles coming into contact with them during the painting process, leading to short circuits and making it difficult to repair any damage, as the units are integrated before painting and are hard to remove.
Innovation Solution
A method involving injection molding of mold parts, painting the surface without the electronic unit installed, disassembling the handle, and then integrating the electronics unit after painting, ensuring the paint is dry and preventing damage, while also allowing for easier quality control and reduced production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electronic unit is integrated into the molded parts before painting, then the assembly process is simplified and production time is reduced, but paint particles can come into contact with the electronic unit causing short circuits or damage
Solution Approach 1:
The manufacturing process is segmented into distinct phases: first producing the molded parts, then painting them, disassembling the handle, and finally integrating the electronic unit. This segmentation separates the painting operation from the electronic unit integration, preventing paint particle contact with the electronics while maintaining production efficiency through systematic process organization.
Solution Approach 2:
The molded parts are produced and painted before the electronic unit is integrated. This preliminary action sequence ensures that the painting process occurs when the electronic unit is not present, eliminating the risk of paint damage to the electronics. The electronic unit is integrated only after the painting and drying processes are complete.
2Manufacturing precision
If the electronic unit is integrated before painting, then quality control checks can be performed earlier, but any damage occurs cannot be repaired as removal is difficult
Solution Approach 1:
The process is divided into stages where the electronic unit is integrated after painting. This segmentation allows quality control checks to be performed on the painted handle before electronic integration, and any electronic unit replacements can be made easily after integration since the handle can be disassembled into its component parts.
Solution Approach 2:
Quality control checks are performed on the painted handle before the electronic unit is integrated. This preliminary quality control ensures that the painting and assembly are correct before the electronic unit is installed. If the electronic unit needs replacement, the handle can be disassembled and the unit replaced, as the integration is designed to allow for such modifications.
3Device complexity
If the electronic unit is integrated into the molded parts, then the assembly structure is simplified, but the production throughput time is increased due to repeated checks
Solution Approach 1:
The manufacturing process is segmented into sequential operations: producing molded parts, painting them, disassembling the handle, and integrating the electronic unit. This segmentation eliminates the need for repeated quality control checks after electronic integration, as the electronic unit is installed after painting. The process maintains structural simplicity while reducing production throughput time by eliminating redundant inspection steps.
Solution Approach 2:
The electronic unit is integrated after the painting and drying processes are complete. This preliminary completion of painting before electronic integration eliminates the need for repeated quality control checks that would otherwise be necessary. The process flow is optimized to perform checks at the appropriate stage, reducing overall production throughput time while maintaining assembly structure simplicity.
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
Prevents damage to electronic units during painting, reduces production time, and eliminates the need for repeated checks post-installation, resulting in a more efficient and reliable manufacturing process for outside door handles.
Implementation Method 1
injection molding of at least a first and a second mold part by means of a plastic compound
Implementation Method 2
introducing pressurized gas or pressurized liquid into the plastic mass in the first and second mold cavities
Implementation Method 3
allowing the plastic mass to solidify in the first and second mold cavities
Data Source
Figure 1
Figure 2
AI summary
The method involves injection moulding two mould parts (150, 151) using a plastic mass and constructing an exterior door handle from the two mould parts. A surface of the handle is painted, and the handle is disassembled into the two mould parts. An electronic unit is installed in one of the two mould parts. The two mould parts and the electronic unit are assembled to form the handle. The plastic mass is formed from plastic granules, where the poly carbonate, poly methyl methacrylate, acrylonitrile butadiene styrene and polyamide are used as the material for the granules.