Vehicle Door Lock Anti-Noise Inserts and Sensor Routing
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Solution Overview
Problem
Existing vehicle door locks suffer from noise issues due to the sliding movement of the catch and pawl, potential jamming, and difficulties in integrating sensors due to cable interference with the spring mechanism.
Innovation Solution
A vehicle door lock design featuring an intermediate plate with anti-noise inserts made of materials like rubber or Teflon to minimize friction and guide the catch and pawl smoothly, along with a microswitch to detect the catch's position without interfering with the spring mechanism, using a Bowden cable for actuation and strategically routed electric cables to avoid interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the catch and pawl slide inside the box of the lock, then the lock mechanism can operate, but noise is generated due to the sliding movement
Solution Approach 1:
A Teflon insert is introduced as an intermediary element between the catch/pawl and the box. This insert serves as a mediator that reduces friction and noise during sliding movement while still allowing the mechanical operation to function. The Teflon material acts as a buffer that minimizes direct metal-to-metal contact, thereby eliminating the harmful noise effect without compromising the operational ease.
2Reliability
If the catch and pawl are allowed to move freely, then the lock can operate, but they may get jammed due to inclination during movement
Solution Approach 1:
The box is equipped with specific guiding structures at critical locations where the catch and pawl move. These localized guiding features provide directional constraints precisely where needed to prevent inclination and jamming, rather than requiring a completely rigid or complex guiding system throughout. The Teflon insert also provides localized low-friction surfaces that facilitate smooth movement while maintaining reliability.
3Difficulty of detecting and measuring
If sensors are added to detect the position of the catch, then position detection is enabled, but the electric cable interferes with the spring that pushes the pawl
Solution Approach 1:
The electric cable for the sensor is extracted and routed through a dedicated cable guide structure that separates it from the spring mechanism area. This extraction of the cable from the problematic zone allows the sensor to be integrated for position detection without the cable interfering with the spring that pushes the pawl. The cable guide effectively removes the interference issue while maintaining the detection capability.
4Object-generated harmful factors
If anti-noise inserts are added to reduce friction, then noise is minimized, but the manufacturing complexity increases
Solution Approach 1:
The Teflon inserts are pre-formed and designed to fit into specific recesses or slots in the box. This preliminary preparation of the inserts allows for straightforward installation during assembly, minimizing the additional manufacturing complexity. The inserts can be pre-treated or pre-attached in a controlled manner before final lock assembly, making the overall manufacturing process manageable despite the added component.
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 results in a noiseless, reliable, and precisely guided lock that is easy to manufacture and install, ensuring smooth operation and accurate positioning detection while minimizing noise and jamming risks.
Implementation Method 1
anti-noise inserts made of materials like rubber or Teflon to minimize friction and guide the catch and pawl smoothly
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
The lock (100) comprises: a catch (3) and a pawl (4) hinged to an intermediate plate (1), and inserts (6) made of anti-noise material that is different from the material of the intermediate plate, disposed in the intermediate plate (1) around a first hole (F1) and a second hole (F2) of the intermediate plate. The inserts (6) are provided with an end (60) that 5 protrudes from a first side (1a) of the intermediate place to come in contact with the catch (3) and with the pawl (4), in such a way that, during their movement, the catch (3) and the pawl (4) slide on the ends (60) of the inserts, minimizing the noise.