Mechanical Door Handle Actuation Without Electric Motor

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Solution Overview

Problem

Conventional flush door handles in vehicles rely on electric motors, which are cost-inefficient, complex, prone to wear and tear, and add weight, making them costly and cumbersome to maintain, with the added risk of being non-functional upon motor failure.

Innovation Solution

A door handle assembly using mechanical linkages for actuation, allowing the handle to move between flush and deployed positions without an electric motor, featuring a mechanical deployment unit with leading and trailing actuation components to simplify the mechanism and reduce weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If an electric motor is used to move the handle between flush and deployed positions, then the door handle can be automatically deployed, but the device complexity and cost increase

Engineering Contradiction:

Improveautomatic handle deploymentVSAvoidassembly complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent removes the electric motor from the door handle assembly, extracting the complex automated deployment mechanism and replacing it with a simpler mechanical linkage system that achieves the same functional result through pure mechanical means

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical linkage system is designed to automatically deploy the handle through mechanical advantage, where the actuation force applied by the user is mechanically amplified to move the handle between positions without requiring external power sources or complex control systems

Inventive Principle:

Principle #25Self-service

2Extent of automation

If an electric motor is used to move the handle, then the door handle can be deployed automatically, but the weight of the door increases

Engineering Contradiction:

Improveautomatic handle deploymentVSAvoiddoor weight

Core Design Contradiction:

Extent of automationVSWeight of moving object

Solution Approach 1:

The electric motor and associated power transmission components are completely removed from the door assembly, significantly reducing the weight of the moving door while maintaining the automatic deployment function through a lighter mechanical linkage system

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs simpler, lighter mechanical components that can be easily replaced if needed, rather than using heavy, complex electric motor assemblies that add significant weight to the door

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Extent of automation

If an electric motor is used for handle actuation, then automated deployment is achieved, but the cost of components and maintenance increases

Engineering Contradiction:

Improveautomatic handle deploymentVSAvoidmanufacturing cost

Core Design Contradiction:

Extent of automationVSEase of manufacture

Solution Approach 1:

The expensive electric motor, controller, and associated electronics are extracted from the system, replacing them with inexpensive mechanical linkages and springs that are cheaper to manufacture and maintain

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses simple, inexpensive mechanical components such as linkages, pivots, and springs that can be easily manufactured at low cost and replaced if necessary, eliminating the need for expensive electric motors and electronic control systems

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Extent of automation

If an electric motor is used, then the handle can be deployed automatically, but the reliability decreases due to wear and tear

Engineering Contradiction:

Improveautomatic handle deploymentVSAvoidoperational reliability

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The patent replaces the electric motor-driven mechanical system with a pure mechanical linkage system that has fewer moving parts, no electrical components subject to failure, and reduced wear and tear, thereby improving reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mechanical linkage system is designed to self-regulate and self-latch, with inherent mechanical advantage that ensures reliable operation without requiring external power sources or complex control systems that could fail

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11739572B2Door handle assembly

Publication Date: 2023.08.29 ILLINOIS TOOL WORKS INC

AI summary

A door handle assembly includes a frame, a mechanical deployment unit, and a handle. The frame is to be mounted to a door. The frame having a housing portion and an exterior surface having a cavity. The mechanical deployment unit is disposed in the housing portion. The handle is disposed in the cavity, pivoted to the frame and operably coupled to the mechanical deployment unit. The handle is flush with the exterior surface and locked with the mechanical deployment unit in an undeployed position. Upon a first actuation, the handle unlocks from the undeployed position to protrude from the cavity in a deployed position and moves back to the undeployed position upon a second actuation.