Mechanical Pop-Out Handle for Vehicle Door Backup

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Solution Overview

Problem

Existing motor vehicle door opening control devices lack a reliable mechanical backup mechanism for scenarios where the electrical actuation fails, such as when the battery is depleted, preventing users from accessing the vehicle.

Innovation Solution

A compact and robust opening control device with a mechanism that accumulates mechanical energy during a push-in action, allowing automatic ejection and retraction of the handle without electrical assistance, featuring a drive member with a spiral spring, pop-out wheel, and kinematic chains for mechanical movement, enabling operation even without power.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an electrical ejection mechanism is used for the handle, then the handle can be remotely and electronically controlled, but the system fails when the battery is depleted or electrical power supply fails

Engineering Contradiction:

Improveremote electronic control of handleVSAvoidoperation reliability when battery is depleted

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The spiral spring is pre-loaded during the push-in action to accumulate mechanical energy in advance, so that when the blocking element releases, the stored energy automatically drives the handle to eject without requiring electrical power. This preliminary energy storage ensures the handle can operate even when the battery is depleted.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The blocking element acts as an intermediary between the manual push-in action and the automatic ejection mechanism. It temporarily stores the mechanical energy from the push-in action and then releases it to trigger the spiral spring-driven ejection, bridging the gap between manual input and automatic operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a mechanical backup mechanism is added to the opening control device, then reliability is improved, but the device complexity increases

Engineering Contradiction:

Improvebackup unlocking capabilityVSAvoidmechanism structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The push-in action serves dual purposes: it unlocks the blocking element to enable ejection, and simultaneously winds the spiral spring to store mechanical energy. This multi-functionality reduces the need for separate components and simplifies the overall mechanism while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mechanical backup mechanism is nested within the existing electrical actuation system. The spiral spring, blocking element, and kinematic chains are integrated into the handle assembly, with the manual push-in action utilizing the same structural space and components as the electrical system, thereby minimizing additional complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Shape

If the handle is designed as flush type, then the aesthetic appearance is improved, but the ease of grasping and operation is reduced

Engineering Contradiction:

Improveflush appearance with door surfaceVSAvoidgrasping ease

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The handle transitions dynamically between two states: a flush retracted position for aesthetic appearance, and an ejected position for easy grasping and operation. The automatic ejection mechanism provides the force needed to move the handle from the flush position to the ejected position, maintaining both aesthetic and operational requirements.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The spiral spring-driven mechanism automatically ejects the handle from its flush position when triggered by the push-in action, eliminating the need for the user to manually pull or grasp the handle to initiate ejection. The system serves itself by providing the ejection force internally.

Inventive Principle:

Principle #25Self-service

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

Enables secure and reliable manual operation of the door handle in the event of electrical failure, ensuring users can access the vehicle by automatically driving the handle from a pushed position to a flush or ejected position, providing a backup unlocking solution.

Implementation Method 1

the drive member comprises a shaft, a barrel and a drive spring housed within the barrel and wound into a spiral around the barrel shaft

Methodology Applied

Scientific EffectSpiral spring: Spring

Data Source

PatentUS11679651B2Opening control device with a mechanical pop-out

Publication Date: 2023.06.20 AKWEL VIGO SPAIN SL

AI summary

An opening control device including a case, a handle movably mounted between at least a flush position in which the handle is entirely or partially housed within the case and an ejected position in which the handle is at least partially emerged from the case. The opening control device includes a mechanism configured to be mechanically triggered in response to a push-in action into the case of the handle, the completion of the push-in action being adapted to cause the triggering of the mechanism. Furthermore, the mechanism is configured to automatically drive in movement the handle over all or part of a stroke starting from a pushed position of the handle to the flush position through the ejected position.