Vehicle Door Handle Assembly Interlocking Protrusion Design
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Solution Overview
Problem
Current vehicle door handle assembly processes are time-consuming, stressful on components, require many additional parts and tools, and increase global assembly and rework costs due to complex geometries and assembly procedures.
Innovation Solution
A handle assembly design featuring internal and external protrusions that are inserted and locked into each other, reducing the need for additional parts and tools, and minimizing stress on the bracket and door sheet, with a method that involves fixing a bracket on the door, placing the handle internal structure, and inserting external protrusions into internal ones for fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the handle mobile part is assembled from the external door side after bracket fixation, then the handle can be properly installed, but the assembly time increases and the complexity of the procedure increases
Solution Approach 1:
The handle assembly is divided into distinct components (bracket, mobile part, fastening elements) that can be independently manufactured and then quickly assembled together, reducing overall assembly time and simplifying the procedure
Solution Approach 2:
The bracket is pre-fixed to the door sheet before assembling the mobile part, preparing the mounting structure in advance to facilitate quicker subsequent assembly operations
2Reliability
If the handle is mounted through the door sheet and bracket, then the handle can be secured, but stress is caused on the bracket and its fixations
Solution Approach 1:
A bracket serves as an intermediary element between the door sheet and the handle mobile part, distributing the mechanical loads and reducing stress concentration on the door sheet fixations
Solution Approach 2:
The bracket is pre-fixed to the door sheet to establish a secure mounting structure before the handle mobile part is attached, ensuring proper load distribution from the beginning
3Reliability
If many additional parts such as screws, metallic holder, and pins are used, then the handle can be securely fixed, but the number of parts and tools required increases
Solution Approach 1:
Multiple fastening functions are merged into integrated fastening elements that combine securing, positioning, and locking actions in single components, reducing the total number of parts needed
Solution Approach 2:
The fastening elements are designed to perform multiple functions simultaneously (securing, positioning, and locking the handle), eliminating the need for separate specialized parts for each function
Data Source
Figure 1
Figure 2~3
Figure 4A~4C
AI summary
The invention relates to a handle assembly for a vehicle door handle, the handle assembly comprising: - a bracket (4), - a handle external structure (2), comprising at least one external protrusion (21, 22), - a handle internal structure (1) comprising at least one internal protrusion (11, 12), wherein - the internal (11, 12) and external (21, 22) protrusions are configured to be inserted in one another through the bracket (4), and - the internal (11, 12) and external (21, 22) protrusions comprise fastening means (13, 23) configured to fasten the handle external (2) and internal (1) structures to one another when the internal (11,12) and external (21, 22) protrusions are inserted in one another through the bracket (4). The invention further relates to a handle assembling method.