Vehicle Door Handle Plastic Force Transmitter
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Solution Overview
Problem
Existing vehicle door handles struggle to withstand high activation forces without deforming, particularly when users apply strong forces, which can damage the switch and printed circuit board.
Innovation Solution
A vehicle door handle assembly featuring a plastic intermediate force-transmitting member between the door panel and switch module, which transfers excessive forces to the rigid metal door panel, preventing deformation, and includes a trapezoidal shape for optimal surface contact and a retaining leg to prevent upward movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the switch module is mounted directly on the bracket behind the door panel, then the structure is simple and compact, but the switch module cannot withstand high activation forces without deforming or damaging the PCB
Solution Approach 1:
A plastic intermediate force-transmitting member is introduced between the door panel and the switch module. This intermediary component receives activation forces from the door panel and transmits them to the switch module, protecting the switch module and PCB from direct exposure to high forces up to 400N while maintaining structural simplicity.
2Reliability
If a rigid support structure is used to protect the switch module from high forces, then the switch module is protected, but the overall assembly becomes more complex and larger in footprint
Solution Approach 1:
The plastic intermediate force-transmitting member serves as a mediator that provides force distribution and protection without requiring complex rigid support structures. It absorbs and distributes forces evenly across the door panel, protecting the switch module while maintaining a compact assembly.
Solution Approach 2:
The solution uses a composite approach combining the plastic intermediate force-transmitting member with the metal door panel and bracket assembly. This composite structure leverages the strength of the metal panel and the force-distributing properties of the plastic component to achieve reliable protection without excessive complexity.
3Ease of operation
If the switch module is positioned closer to the door panel surface for easier activation, then ease of operation improves, but the switch module becomes more vulnerable to excessive force from users
Solution Approach 1:
The plastic intermediate force-transmitting member is positioned between the door panel and the switch module, allowing the switch module to be accessible for easy activation while the intermediary component absorbs and distributes excessive forces before they reach the switch module, protecting it from damage.
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 effectively distributes high activation forces to the door panel, preventing switch module deformation and ensuring durability while maintaining a streamlined design with reduced air drag.
Implementation Method 1
the plastic intermediate force-transmitting member being in contact with the door panel, at least along a contact surface of the plastic intermediate force-transmitting member, in order to transmit efforts coming from the switch module to the door panel
Data Source
Figure 1~2
Figure 3~4
AI summary
Vehicle door handle (1) assembly comprising: - a bowl (5) configured to be mounted in an opening (9) of a door panel (3), - a bracket (7) configured to fasten the bowl (5) to the door panel (3), - a switch module (15) mounted on the bracket (7) in an opening of the bowl (5) so that the switch module (15) can be activated by a finger of a user introduced within a recess of the bowl (5) to open the vehicle door, - a plastic intermediate force-transmitting member (17) inserted between the door panel (3) and the switch module (15), the plastic intermediate force-transmitting member (17) being in contact with the door panel (3), at least along a contact surface (19) of the plastic intermediate force-transmitting member (17), in order to transmit efforts coming from the switch module (15) to the door panel (3), to ' prevent the deformation of the switch module (15).