Vehicle Door Handle Seal with Molded Bumper
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Solution Overview
Problem
Existing vehicle door handle assemblies lack adequate cushioning and noise reduction when the handle returns to its at-rest position, leading to a less comfortable user experience and increased noise levels.
Innovation Solution
A vehicle door handle assembly featuring a seal member with a molded bumper that provides cushioning and noise dampening, comprising a base member installed on the interior door surface, a handle member on the exterior, and a seal member with a rigid main body and flexible molded portion, where the molded bumper contacts the handle member upon return to the at-rest position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a traditional rigid door handle assembly is used, then structural strength is maintained, but noise and vibration increase during handle movement
Solution Approach 1:
The seal member is constructed as a composite structure with a rigid main body (providing structural strength) and a flexible molded portion (providing cushioning and noise reduction). This composite design allows the assembly to maintain structural integrity while reducing harmful noise and vibration during handle movement.
Solution Approach 2:
Different portions of the seal member have different material properties: the main body is rigid for structural support, while the molded portion is flexible for cushioning. This local differentiation of material quality allows simultaneous achievement of strength and noise reduction in different areas of the same component.
2Ease of operation
If no cushioning element is added to the door handle assembly, then device complexity is minimized, but user comfort deteriorates due to harsh handle return
Solution Approach 1:
The cushioning function is merged into the seal member itself by integrating the flexible molded portion with the rigid main body. This combination eliminates the need for separate cushioning components, thereby improving user comfort while avoiding significant increases in assembly complexity.
Solution Approach 2:
The seal member serves multiple functions: it provides sealing, structural support through its rigid main body, and cushioning through its flexible molded portion. This multi-functionality allows the single component to improve user comfort without requiring additional dedicated cushioning elements.
3Object-affected harmful factors
If a flexible cushioning material is added to the door handle assembly, then noise reduction is achieved, but manufacturing complexity increases
Solution Approach 1:
The flexible cushioning portion is molded directly onto the rigid main body in a single integrated manufacturing process. This merging of components into one piece reduces the number of separate manufacturing steps and assembly operations, thereby achieving noise reduction without significantly increasing manufacturing complexity.
Solution Approach 2:
The composite structure is manufactured as an integrated component using molding processes that can accommodate multiple material properties in a single part. This approach to composite manufacturing avoids the need for separate fabrication and assembly of rigid and flexible portions, simplifying the overall manufacturing process.
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 cushions the handle's return and reduces noise and vibration, enhancing user comfort and reducing noise within the vehicle.
Implementation Method 1
the seal member providing cushioning to the handle member as is returns to an at rest position from a door opening position
Data Source
AI summary
A vehicle door handle assembly includes a base member, a handle member and a seal member. The base member installs along an interior surface of a vehicle door. The handle member installs along an exterior surface of the vehicle door. The handle member is pivotally connected to the base member for movement between an at rest position and a door opening position. The seal member is attached to the base member with a first surface of the seal member overlaying a portion of the exterior surface of the vehicle door and a second surface opposite the first surface faces a section of the handle member, The first surface has at least one projection extending therefrom engaged with the base member. The second surface has at least one bumper extending therefrom toward the handle member. The at rest position the section of the handle member contacts the at least one bumper.