Vehicle Door Latch Assembly Rerouting Lock Rod
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Solution Overview
Problem
Conventional vehicle door lock mechanisms face issues with water leakage, freezing, and theft vulnerability due to the lock rod extending through a grommet and the inside locking lever being in a wet area, which also complicates assembly and increases costs.
Innovation Solution
The lock rod is rerouted to be entirely within the door inner panel, with a latch locking lever located in a dry cavity, eliminating the need for a grommet and shielding, thus preventing water leakage and theft attempts, while simplifying assembly and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lock rod extends through a grommet in the door inner panel, then the lock mechanism can be actuated from inside the vehicle, but water can leak through the grommet from the wet area to the dry area
Solution Approach 1:
The patent removes the grommet from the door inner panel entirely. Instead of having the lock rod pass through the grommet, the lock rod is now attached to the inside locking lever and extends upward to connect to the lock button, with the entire lock rod assembly located in the dry area behind the door inner panel. This extraction of the grommet eliminates the leak path while preserving manual lock actuation functionality.
Solution Approach 2:
The door inner panel itself serves as the intermediary structure that separates the wet and dry areas. The lock rod is positioned such that it connects to the inside locking lever through the door inner panel without requiring a separate grommet. The door inner panel's structure and sealing features act as the mediator that prevents water leakage while allowing lock rod operation.
2Ease of manufacture
If the lock rod changes direction to pass through the grommet, then the lock mechanism can be connected across the door panels, but this creates an accessible point for thieves to slide a device along the window glass to engage the rod
Solution Approach 1:
The patent removes the exposed lock rod configuration that extends through the door inner panel and is accessible from the outside. The lock rod is repositioned entirely behind the door inner panel in the dry area, connecting the lock button to the inside locking lever without any external exposure. This extraction of the lock rod from the accessible area eliminates the theft vulnerability while maintaining the connection function.
3Device complexity
If the inside locking lever is located in the wet cavity between door panels, then the lock mechanism can be integrated into the door structure, but the lever is subject to freezing issues during cold weather
Solution Approach 1:
The patent extracts the inside locking lever from the wet cavity and repositions it in the dry area behind the door inner panel. The locking mechanism is relocated to be inboard of the door inner panel, where it is shielded from water exposure and freezing conditions. This extraction resolves the freezing susceptibility while maintaining the integrated lock mechanism functionality.
4Device complexity
If the lock rod attaches to the inside locking lever between the inner and outer door panels, then the lock mechanism can be integrated into the door structure, but blind assembly of the two components is required at the vehicle assembly plant
Solution Approach 1:
The patent segments the lock mechanism assembly into distinct components that can be pre-assembled and then installed as a unit. The inside locking lever and lock rod are configured to be attachable to each other in a accessible location, allowing for pre-assembly or easier assembly at the vehicle plant. This segmentation reduces the complexity of blind assembly while maintaining the integrated door structure.
Data Source
AI summary
A vehicle door and a vehicle door latch assembly is disclosed. The vehicle door includes a door outer panel; a door inner panel affixed to the door outer panel and defining a door wet cavity, with the door inner panel including an access hole; and a door trim panel mounted to the door inner panel and defining a door dry cavity. A door latch is located in the door wet cavity; a latch locking lever is exposed to the door dry cavity and shielded from the door wet cavity, with the latch locking lever engaging the door latch; and a lock rod has a first end attached to the latch locking lever, with the lock rod extending through the access hole and between the door inner panel and the door trim panel, whereby the lock rod is not exposed to the door wet cavity.