Vehicle Door Handle Sensor Module With Foam-Sealed Actuation

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Solution Overview

Problem

Existing handle modules for vehicles lack a compact, easily assembled multi-sensor system that effectively protects sensors from environmental influences while ensuring safe and comfortable operation, particularly in harsh conditions like car washes.

Innovation Solution

A multi-sensor module with a compact structure, featuring an approach and/or gesture sensor and an actuation sensor encapsulated in foam material, integrated as a structural unit, which can be variably mounted on a handle module, providing protection from moisture and mechanical loads, and allowing for reliable operation even in harsh conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sensors are exposed in handle modules, then gesture detection and actuation functions are accessible, but sensors are vulnerable to environmental influences such as moisture, rain, and dirty water

Engineering Contradiction:

Improvesensor protection from environmental influencesVSAvoidsensor accessibility for gesture detection and actuation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent applies this principle by using a foam material that encapsulates the actuation sensor while maintaining its functionality. The foam acts as a flexible protective shell that shields the sensor from environmental influences like moisture and rain, yet allows the sensor to detect gestures and actuation forces through the material.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The foam material serves as an intermediary between the actuation sensor and the external environment. It mediates the interaction by providing mechanical protection while still allowing the sensor to detect external stimuli, thus resolving the contradiction between protection and accessibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If multiple sensors are integrated into a compact multi-sensor module, then space is saved and assembly is simplified, but manufacturing precision and integration complexity increase

Engineering Contradiction:

Improveintegration of multiple sensors into single moduleVSAvoidsensor alignment and integration accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent merges the approach sensor, actuation sensor, and electronics unit into a single integrated multi-sensor module. This combining of multiple components into one unified structure reduces device complexity and simplifies assembly, while the integrated design ensures proper alignment and manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multi-sensor module is designed as a universal component that can be mounted on various handle types (outside handles, inside handles, tailgates). This multi-functional design allows the same integrated module to serve multiple purposes and accommodate different mounting positions, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the actuation sensor is encapsulated in foam material, then protection from environmental influences is improved, but connection and assembly processes become more complex

Engineering Contradiction:

Improveactuation sensor protectionVSAvoidassembly of encapsulated sensor

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The actuation sensor is pre-encapsulated in foam material before final assembly into the multi-sensor module. This preliminary encapsulation protects the sensor during manufacturing and assembly processes, and the pre-prepared foam-encapsulated sensor can be easily integrated into the final module structure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The foam material provides self-sealing and self-protection properties for the actuation sensor. Once the sensor is encapsulated in the foam, the foam automatically provides environmental protection without requiring additional sealing steps or complex assembly procedures, thus simplifying the overall manufacturing process.

Inventive Principle:

Principle #25Self-service

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 solution ensures the multi-sensor module is protected from environmental stresses, preventing false triggering and enabling safe and comfortable operation of vehicle elements by combining external gesture detection with internal actuation, thus enhancing reliability and durability.

Implementation Method 1

the actuation sensor is designed as a component which is encapsulated and integrated by means of a foam material at least in some regions

Methodology Applied

Scientific EffectEncapsulation: Physical Containment

Implementation Method 2

a resilient material is provided as the foam material such that the movable sensor element is additionally resiliently mounted

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12123228B2Multi-sensor module, a handle module, and movable vehicle element

Publication Date: 2024.10.22 WITTE AUTOMOTIVE GMBH

AI summary

An outside door handle module for a vehicle may have one handle element having a handle outer side and a handle inner side. The module may also have one gesture sensor and an actuation sensor. The gesture sensor may be arranged on or in the handle outer side and the actuation sensor may be arranged on or in the handle inner side.