Vehicle Door Handle Integrated Circuit Board Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle door handle systems require complex assembly processes due to the need to connect electronic components to a control circuit board via wire harnesses, complicating the integration of electronic components within the door handle.
Innovation Solution
A door handle device with a resin-made first handle member featuring a housing portion that includes a connector protruding through the door panel, allowing the control circuit board to be connected directly to electronic components without wire harnesses, and a second handle member that covers the housing portion, simplifying assembly by eliminating the need for wire connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire harnesses are used to connect electronic components to the control circuit board, then reliable electrical connections are achieved, but assembly complexity increases and manufacturing efficiency decreases
Solution Approach 1:
The patent combines the electronic component housing and the control circuit board housing into a single integrated housing structure. This merging eliminates the need for separate wire harness connections between distinct components, as the electronic components are mounted directly on the control circuit board within the same housing, thereby reducing assembly complexity while maintaining reliable electrical connections
Solution Approach 2:
The patent extracts and eliminates the wire harness from the system by providing direct mounting surfaces and electrical contacts on the control circuit board. Electronic components are directly mounted on the board with their electrical connections made through soldering or other direct bonding methods, removing the intermediate wire harness connection layer and simplifying the overall assembly
2Reliability
If wire harnesses are used to connect electronic components to the control circuit board, then electrical connections are established, but manufacturing time and cost increase
Solution Approach 1:
The patent segments the door handle into distinct functional modules (handle outer portion, grip portion, rotating portion, operating portion) that can be manufactured separately and then assembled. The integrated housing is also segmented into components that can be pre-assembled with electronic components before final assembly, reducing overall manufacturing time while maintaining connection reliability
Solution Approach 2:
The patent implements preliminary action by pre-mounting electronic components on the control circuit board and pre-assembling the integrated housing structure before final door handle assembly. This preliminary preparation of sub-assemblies reduces the time required during final assembly operations while ensuring reliable electrical connections are already established
3Ease of manufacture
If a board with control circuit is provided outside the door handle, then electronic component connections are simplified, but the connector structure becomes more complex
Solution Approach 1:
The patent merges the control circuit board and its housing into an integrated unit that is part of the door handle assembly itself. The electronic components are mounted directly on this integrated board within the handle, eliminating the need for external boards and complex external connectors, thereby simplifying the overall connector structure while maintaining ease of manufacture
Solution Approach 2:
The integrated control circuit board housing serves multiple functions: it provides structural support, houses the electronic components, provides electrical connections, and integrates with the door handle mechanism. This multi-functionality reduces the need for separate specialized connectors and simplifies the overall structure while maintaining ease of manufacturing
Data Source
AI summary
A door handle device for a vehicle includes a first handle member made of resin and formed with a housing portion which houses an electronic component and is arranged opposing to the outer panel and a second handle member covering the housing portion and assembled to the first handle member. A first connector, which protrudes in a vehicle width direction penetrating through the outer panel, is provided at an end of the first handle member. A board mounted with a control circuit connected to the electronic component is housed in the housing portion in a state where the board is connected to a terminal of the first connector and a terminal of the electronic component.