Dual Hinged Flap for Vehicle Door Handle Noise Reduction
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Solution Overview
Problem
Existing flush vehicle door handle assemblies with sound dampening flaps are complex and labor-intensive to assemble due to their three-piece construction, requiring multiple tools and mechanical retaining components.
Innovation Solution
An integrated dual hinged sound dampening flap feature within the door handle assembly eliminates the need for a pivot pin or retaining components by using a dual hinged flap integral with the spring housing, which includes living hinges for bending operation, simplifying the construction process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a three-piece sound dampening arrangement is used, then noise reduction functionality is achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the sound dampening flap with the spring housing into a single integrated component. The flap is formed as one piece with the housing, eliminating the need for separate pivot pins, retaining clips, and multiple assembly steps. This integration maintains the noise dampening function while substantially reducing construction complexity.
Solution Approach 2:
The integrated flap-housing structure serves multiple functions simultaneously: it provides the sound dampening surface, supports the spring mechanism, and acts as a structural component of the door handle assembly. This multi-functionality eliminates the need for separate specialized components for each function.
2Object-affected harmful factors
If a three-piece sound dampening arrangement is used, then noise reduction functionality is achieved, but assembly time and labor requirements increase
Solution Approach 1:
By combining multiple components into a single molded part, the patent reduces the number of assembly operations from multiple steps to a single installation. The integrated structure is installed as one piece, dramatically reducing assembly time and labor requirements while maintaining the noise reduction function.
3Object-affected harmful factors
If a three-piece sound dampening arrangement is used, then noise reduction functionality is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent consolidates multiple manufacturing steps into a single molding operation. The integrated flap and housing are produced as one molded part, eliminating the need to manufacture, finish, and assemble multiple separate components. This substantially simplifies the manufacturing process while maintaining noise dampening capability.
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 dual hinged flap effectively reduces noise from metal-to-metal contact while maintaining functionality, offering a simpler and more efficient assembly method compared to prior art.
Implementation Method 1
The tension from the spring acts to bias the handle to its resting condition
Implementation Method 2
The dual hinged flap effectively reduces noise from metal-to-metal contact
Data Source
AI summary
An improved door handle assembly (10) having an integral sound dampening flap feature. The integral sound dampening flap feature incorporates an integrated dual hinged flap (52). This dual hinged flap (52) dampens vibration while adjusting to vertical movement and eliminating the need for any pivot pin or other retaining component.