Vehicle Door Handle Fixing Mechanism Using Engagement Tabs and Stopper
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Solution Overview
Problem
The existing door handle apparatus for vehicles faces cost increases due to the need for metal nut members in fixing mechanisms and potential cracking issues with polycarbonate resin handle members when using bolt-based fixing methods, leading to unreliable fixation.
Innovation Solution
A two-piece resin handle structure with a fixing mechanism using engagement tabs, a pedestal portion, and a stopper member, where the stopper can be a metal screw or resin pin, reducing the number of components and avoiding direct screwing into resin material, thus minimizing cost and cracking risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal nut member is used in the fixing mechanism, then the fixation reliability is improved, but the product cost increases due to the nut member cost and attachment workload
Solution Approach 1:
The patent removes the metal nut member from the fixing mechanism, extracting only the essential function of securing the engagement tabs. This is achieved by using a resin stopper member with a simple hole structure that eliminates the need for threaded fasteners, thereby reducing cost and complexity while maintaining fixation reliability through the engagement tabs插入 into the stopper member's hole.
Solution Approach 2:
The patent changes the material parameter from metal (nut member) to resin (stopper member), and changes the fastening mechanism from threaded engagement to simple insertion through a hole. This parameter change reduces manufacturing cost and assembly complexity while the engagement tabs provide sufficient fixation reliability through their elastic deformation and engagement with the stopper member.
2Device complexity
If a bolt member is inserted directly into the boss portion, then the structure is simplified, but cracks may occur to the boss portion of the resin handle member
Solution Approach 1:
The patent segments the fixing function into two separate components: engagement tabs on one handle member and a stopper member with a hole on the other handle member. This segmentation avoids direct screwing into the resin boss portion, preventing cracks while maintaining structural simplicity. The engagement tabs elastic deformation provides additional fixation reliability.
Solution Approach 2:
The patent introduces the stopper member as an intermediary component between the two handle members. Instead of directly screwing into the resin boss portion, the bolt member passes through the stopper member's hole, which distributes the stress and prevents cracks in the resin handle member while maintaining fixation reliability.
3Shape
If polycarbonate resin material is used for the handle member, then the paintwork and plating quality is improved, but the material is easily cracked under stress
Solution Approach 1:
The patent changes the fastening method parameter from direct screwing (high stress concentration) to engagement tab insertion with stopper member (distributed stress). This allows the use of polycarbonate resin material that provides excellent paintwork and plating quality while the modified fastening approach prevents crack formation under stress.
Solution Approach 2:
The patent designs the engagement tabs with elastic deformation capability and the stopper member with a hole that allows stress distribution, providing beforehand cushioning against stress concentrations that would cause cracks in the polycarbonate resin material. This enables the use of high-quality resin material without compromising crack resistance.
Data Source
AI summary
A door handle apparatus for a vehicle includes an outside handle configured by a first handle member and a second handle member which are integrally fixed to each other via a fixing mechanism configured by a plurality of engagement tabs, a pedestal portion and a stopper member, the engagement tabs being provided at one of the first handle member and the second handle member, and arranged to be separated from each other by a space portion which is predetermined and to face each other, the pedestal portion being provided at the other of the first handle member and the second handle member, and including an engagement hole into which the engagement tabs are insertable, and the stopper member being inserted in the space portion between the plurality of engagement tabs which is in a state of being inserted in the engagement hole of the pedestal portion.