Dual-Durometer Shift Boot Assembly for Cost-Effective Lever Flexibility

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Mechanical shift assembly mechanisms in vehicles require a cosmetic closeout to hide internal components while allowing gear shift position selection flexibility, but traditional dual durometer boots are often too expensive due to packaging constraints and lever motion requirements.

Innovation Solution

A shift boot assembly with a flexible section and a protective shield, where the flexible section is formed of a material with a first durometer and the protective shield, made of a harder second durometer material, is operatively coupled to the frame, controlling material flow and preventing binding during gear shift lever movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a traditional dual durometer boot is used, then cosmetic coverage and flexibility are achieved, but cost increases due to packaging constraints and lever motion requirements

Engineering Contradiction:

ImprovecostVSAvoidflexibility during gear shift selection

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The boot assembly is segmented into three distinct components: a frame portion, a flexible section, and a protective shield. This segmentation allows each component to be optimized independently - the frame provides structural support, the flexible section allows gear shift movement, and the protective shield prevents binding - while collectively achieving the function of a traditional dual durometer boot at lower cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protective shield acts as an intermediary component between the flexible section and internal components. It mediates the interaction by controlling material flow and preventing the flexible section from binding against internal components during lever movement, thus enabling flexibility without requiring expensive traditional dual durometer construction.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If packaging constraints and lever motion requirements are accommodated, then gear shift operation flexibility is achieved, but cost increases

Engineering Contradiction:

Improvegear shift position selection flexibilityVSAvoidcost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

Different portions of the boot assembly have different properties optimized for their specific functions. The flexible section has high flexibility for lever movement, the frame provides rigid structural support, and the protective shield has controlled flexibility to prevent binding. This local optimization allows the assembly to accommodate lever motion requirements without requiring expensive traditional dual durometer construction throughout.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The protective shield is designed with dynamic characteristics that allow it to control material flow during lever movement. The shield's properties enable it to adapt to the lever's motion path, preventing binding while maintaining cost-effectiveness compared to traditional expensive materials.

Inventive Principle:

Principle #15Dynamics

3Reliability

If a protective shield is added to control material flow, then binding prevention is achieved, but device complexity increases

Engineering Contradiction:

Improveprevention of binding during lever movementVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective shield serves multiple functions simultaneously: it controls material flow of the flexible section, prevents binding against internal components, and contributes to the overall structural integrity of the boot assembly. By making this single component multi-functional, the design achieves reliable binding prevention without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The protective shield is operatively coupled to both the frame and the flexible section, merging multiple functional requirements into a single integrated component. This consolidation allows the shield to simultaneously provide structural support, control material flow, and prevent binding, thereby achieving high reliability without excessive complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11506278B2Dual durometer shift boot with performance shield

Publication Date: 2022.11.22 STEERING SOLUTIONS IP HOLDING CORP

AI summary

A vehicle gear shift assembly includes a gear shift lever. The vehicle gear shift assembly also includes a shift boot assembly that at least partially defines an interior section and receives a portion of the gear shift lever therethrough. The shift boot assembly includes a frame. The shift boot assembly also includes a flexible section formed of a material having a first durometer. The shift boot assembly further includes a protective shield operatively coupled to the frame and the flexible section, the protective shield formed of a material having a second durometer that is harder than the first durometer of the flexible section.