Vehicle Door Handle Hall Sensor Positioning via Segmented Holder
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Solution Overview
Problem
The production of outside door handles for vehicles is complex and expensive due to the need for individually adapted printed circuit boards and Hall sensors to fit different vehicle types, especially when handles are curved, requiring costly and intricate manufacturing processes.
Innovation Solution
A rigid and flat printed circuit board is used with a separate holder to position the Hall element at a predefined location, allowing for the same electronic components to be used across various handle designs, reducing production and storage costs by using interchangeable holders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a curved printed circuit board is used to adapt to the curved handle shape, then the Hall element can be positioned at the correct location, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The system is divided into separate functional modules: a flat printed circuit board containing electronic components, and a separate holder component that positions the Hall element. This segmentation allows each part to be manufactured independently using simple processes, while the holder provides the necessary spatial relationship between the Hall element and the handle curvature without requiring a curved circuit board.
Solution Approach 2:
The holder acts as an intermediary component between the flat printed circuit board and the Hall element. It provides mechanical support and precise positioning for the Hall element at the required distance and orientation from the circuit board, enabling correct sensor placement without complicating the circuit board manufacturing.
2Manufacturing precision
If individually adapted printed circuit boards are produced for each vehicle type, then the Hall element can be positioned correctly for each application, but production and storage costs increase
Solution Approach 1:
A single universal printed circuit board design can be used across multiple vehicle types and handle configurations. The holder component is designed to accommodate the Hall element at the correct position regardless of the specific vehicle application, making the circuit board adaptable to different scenarios without requiring custom manufacturing for each case.
Solution Approach 2:
The system provides adaptability through the configurable holder rather than through different circuit board designs. The holder can be adjusted or selected in different configurations to suit various vehicle types, while the core electronic components remain on a standardized circuit board, reducing the need for individual adaptations.
3Device complexity
If the Hall element is integrated directly into the circuit board, then the structure is simplified, but the positioning precision and protection of electrical conductors are reduced
Solution Approach 1:
The Hall element is separated from the printed circuit board and mounted on a dedicated holder. This segmentation allows the Hall element to be precisely positioned at the required distance from the circuit board while maintaining structural simplicity through modular assembly. The holder provides mechanical support and conductor protection without adding significant complexity to the overall structure.
Data Source
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AI summary
The invention relates to an exterior door handle, particularly for vehicles, and to a method for the production thereof. The exterior door handle comprises a moveable handle in form of an at least regionally hollow housing, in which electronic components (31) can be accommodated. Furthermore, a printed circuit board (30) is provided, which is used to accommodate at least some of the electronic components (31). Furthermore, a Hall element (20), which is to be arranged in a predefined location in the handle, is provided in the handle. According to the invention, the printed circuit board (30) is designed in a rigid and flat manner and a separate holder (10) is provided. Said holder (10) carries the Hall element (20) and holds it in the predefined position thereof in the interior of the handle. The position is spaced from the printed circuit board (30).