Motor Vehicle Door Handle With Partitioned Electronics Encapsulation

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Solution Overview

Problem

Existing motor vehicle door handles face issues with weight optimization and prolonged production times due to gas inclusions and excessive use of potting compounds, which can lead to corrosion and unnecessary encapsulation of electronic components.

Innovation Solution

A handle assembly with a partitioned handle body that separates electronic components into potted and non-potted sections, allowing for targeted use of potting compounds and maintaining accessibility for maintenance, while using integral partition walls to prevent compound overflow and facilitate assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire handle body is filled with potting compound to protect electronic components, then corrosion protection is improved, but weight increases and production time extends

Engineering Contradiction:

Improvecorrosion protectionVSAvoidhandle assembly weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The handle body is divided into multiple chambers using partition walls, allowing selective potting of only certain chambers containing corrosion-prone electronic components. This segmentation enables targeted protection rather than complete encapsulation, reducing overall weight while maintaining necessary corrosion protection for critical components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different chambers are treated differently regarding potting compound application. Chambers containing sensitive electronic components receive potting compound for corrosion protection, while chambers with less sensitive components or those requiring accessibility remain unpotted. This local differentiation optimizes weight while providing protection where actually needed.

Inventive Principle:

Principle #3Local quality

2Reliability

If the entire handle body is filled with potting compound to protect electronic components, then corrosion protection is improved, but production time extends due to curing requirements

Engineering Contradiction:

Improvecorrosion protectionVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of applying potting compound to the entire handle body, only the necessary chambers containing corrosion-prone components are filled. This partial action reduces the total volume requiring curing, thereby shortening production time while still providing adequate protection for the electronic components that require it.

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If the entire handle body is filled with potting compound to protect electronic components, then comprehensive protection is achieved, but maintenance accessibility deteriorates

Engineering Contradiction:

Improveprotection coverageVSAvoidcomponent accessibility

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #3Local quality

4Weight of moving object

If partition walls are added to create separate chambers, then selective potting and weight optimization are achieved, but device complexity increases

Engineering Contradiction:

Improvehandle assembly weightVSAvoidhandle body structure

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The partition walls are integrally formed with the handle body structure, combining the housing and separation elements into a single piece. This integration eliminates the need for separate assembly steps and additional fastening components, reducing overall complexity despite the added chamber divisions. The partition walls become an inherent part of the handle body design rather than add-on components.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2607581B1Motor vehicle door handle with encapsulated electronics component

Publication Date: 2019.06.05 HUF HÜLSBECK & FÜRST GMBH & CO KG

Figure 1~3
Figure 4~6

AI summary

A door handle assembly for motor vehicles with an elongated handle (1) comprising a handle body (3) and a handle cover (2). A cavity is formed in the handle body (3) in which electronic components (7, 8) are accommodated, the electronic components being at least partially encapsulated with potting compound (11). At least one partition (10) is arranged transversely to the longitudinal extent of the handle in the handle body, such that the partition divides the handle body into several chambers, each with at least one cavity. The cavities are open on the side facing the handle cover. At least one of the chambers accommodates electronic components (8) which are encapsulated with potting compound such that the partition (10) forms a boundary for the potting compound.