Handbrake Lever Integrated Spring Support
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Solution Overview
Problem
The existing handbrake levers for motor vehicles require increased assembly work due to additional components needed to support the compression spring, which complicates the assembly process and increases costs.
Innovation Solution
A handbrake lever design where the support element is integrated between the operating button and the handle part, eliminating the need for separate bushings and allowing the compression spring to be stored between the panel and the operating knob, with a one-piece covering and supporting element made of plastic, reducing assembly and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bushings are used to support the compression spring in the handle part, then the compression spring can be properly supported, but the assembly work and device complexity increase
Solution Approach 1:
The support element for the compression spring is integrated into the covering as a single-piece component, eliminating the need for separate bushings. The covering is produced using injection molding process that creates the support element as an inherent part of the covering structure, thereby reducing the number of components and assembly steps while maintaining reliable spring support.
Solution Approach 2:
The covering serves multiple functions: it provides the outer protective structure, acts as a support element for the compression spring through its integrated support feature, and eliminates the need for separate bushings. This multi-functional design reduces component count and assembly complexity.
2Ease of manufacture
If the handbrake lever is designed with traditional separate components for spring support, then each component can be manufactured independently, but the overall length increases and space is wasted
Solution Approach 1:
The covering and support element are merged into a single integrated component produced by injection molding. This eliminates the need for separate bushings and reduces the overall length of the handbrake lever by consolidating functions into a compact single-piece structure that optimizes space utilization.
Solution Approach 2:
The support element is nested within the covering structure as an integrated feature. The compression spring is nested within the handle part, with its ends resting on the integrated support element. This nested arrangement optimizes space and reduces the external dimensions of the handbrake lever.
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
This design reduces assembly work and costs by integrating the support for the compression spring, making the handbrake lever shorter and more stable, eliminating the need for greasing, and incorporating a damping element for noise reduction.
Implementation Method 1
a push rod (12) which extends in the longitudinal direction of the grip part (5) and can be displaced axially against the force of a compression spring (17)
Implementation Method 2
incorporating a damping element for noise reduction
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The handle (1) has a sleeve-shaped lining (18) extended in longitudinal direction of a gripping part (5). A pressing rod (12) with an end side arranged operation knob (13) is axially moved against the force of a pressure spring (17). The lining includes a radially directed supporting element that is extended in a direction of the pressing rod, where the supporting element is arranged in a longitudinal direction between the operation knob and the gripping part. An end section of the pressure spring is supported on the supporting element and turned toward the operation knob. The sleeve-shaped lining includes a damping element made of elastically deformed material i.e. foam material.