Sealed Tailgate Handle Assembly Waterproofing
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Solution Overview
Problem
Tailgate handle assemblies in vehicles are exposed to moisture, dirt, and other elements, leading to potential damage and failure, especially when interacting with items like chains.
Innovation Solution
A sealed tailgate handle assembly featuring a housing with a circuit board, an electromechanical switch, and resin material to seal connections, along with a movable inner cover and deformable outer cover, which engages the switch to complete an electrical circuit and release the tailgate when force is applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional tailgate handle assembly is used, then the structure is simple and easy to manufacture, but the assembly is vulnerable to moisture, dirt, and external elements causing damage and failure
Solution Approach 1:
The patent combines multiple protective functions into a single integrated sealed housing structure that encloses the circuit board, switch, and electrical connections. The housing merges mechanical protection, moisture sealing, and contaminant barrier functions into one unified component, improving reliability without proportionally increasing complexity.
Solution Approach 2:
The patent introduces a resin material as an intermediary substance that fills and seals the spaces between electrical components (circuit board and switch) within the housing. This resin acts as a mediator that provides moisture and contaminant protection while allowing the electrical components to function, resolving the contradiction between sealing and electrical operation.
2Object-affected harmful factors
If the handle assembly is made sealed to prevent element damage, then protection against moisture and dirt is improved, but the complexity of the sealing structure increases
Solution Approach 1:
The patent employs a deformable outer cover made from flexible, waterproof material that conforms to the housing surface. This flexible shell provides effective sealing against moisture and contaminants while maintaining a relatively simple structure that adapts to the housing geometry, reducing the complexity of achieving comprehensive protection.
Solution Approach 2:
The patent uses composite construction combining rigid housing material with flexible waterproof outer cover material. This composite approach allows the structure to provide both mechanical strength and effective sealing against environmental factors, achieving high protection levels without overly complicating the design.
3Reliability
If a deformable outer cover is used to provide waterproof sealing, then the seal between outer cover and housing is improved, but the structural rigidity is reduced
Solution Approach 1:
The patent applies local quality by making only the outer cover deformable and flexible for sealing purposes, while the internal housing structure remains rigid to provide mechanical strength. This localized flexibility allows the system to achieve both good sealing and adequate structural integrity, as the rigid housing maintains strength while the flexible outer cover provides the seal.
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 solution provides a compact, waterproof design that prevents moisture and contaminants from entering, thereby enhancing the durability and reliability of the tailgate handle assembly by preventing damage from external elements.
Implementation Method 1
A resilient member extends between the inner cover and the resin material
Implementation Method 2
Resin material encompasses the circuit board, with the resin material configured to seal the connection between the circuit board and the switch
Implementation Method 3
An outer cover has a deformable upper wall. Upon an application of a force to the upper wall, the inner cover is moved from an initial position to the second position
Data Source
AI summary
An embodiment is directed to a sealed tailgate handle assembly having a housing and a circuit board positioned in the housing. A switch is positioned in the housing and is configured to complete an electrical circuit path on the circuit board. Resin material encompasses the circuit board, with the resin material configured to seal the connection between the circuit board and the switch. An inner cover is movable between an initial position and a second position. A resilient member extends between the inner cover and the resin material. An outer cover has a deformable upper wall. Upon an application of a force to the upper wall, the inner cover is moved from an initial position to the second position, causing the inner cover to engage the switch, causing the switch to complete an electrical circuit path on the circuit board to release a tailgate.