Dual-Durometer Shift Boot Shield to Prevent Lever Binding
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Solution Overview
Problem
Mechanical shift assembly mechanisms in vehicles require a cosmetic closeout to hide internal components while allowing gear shift position selection flexibility, but traditional dual durometer boots are often cost-prohibitive due to packaging constraints and lever motion requirements, necessitating the use of expensive materials like leather or cloth.
Innovation Solution
A shift boot assembly with a frame and a flexible section made of a first durometer material, coupled with a protective shield of a harder second durometer material, which is strategically positioned to control material flow and prevent binding during gear shift lever movement, using a channel design to maintain component protection and seal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional dual durometer boot is used, then cosmetic closeout and flexibility are achieved, but cost increases due to packaging constraints and lever motion requirements
Solution Approach 1:
The boot assembly is segmented into three distinct components: a frame, a flexible section, and a protective shield. This segmentation allows each component to be optimized independently - the frame provides structural support, the flexible section provides movement flexibility, and the protective shield prevents material migration - while collectively solving the packaging and motion constraints at lower cost than traditional dual durometer boots
Solution Approach 2:
Different sections of the boot assembly have different material properties tailored to their specific functions. The flexible section uses a first durometer material for flexibility, while the protective shield uses a second, harder durometer material for protection. This local differentiation of material properties allows the assembly to meet both cosmetic and functional requirements without the high cost of traditional uniform leather or cloth constructions
2Reliability
If a protective shield is added to control material flow, then binding prevention is improved, but device complexity increases
Solution Approach 1:
The protective shield is operatively coupled to both the frame and the flexible section, merging multiple functions into a single component. It simultaneously protects internal components from material migration, guides flexible section movement to prevent binding, and maintains the cosmetic appearance. This consolidation reduces the need for separate guidance mechanisms and simplifies the overall assembly process
Data Source
AI summary
A vehicle gear shift assembly includes a gear shift lever. The vehicle gear shift assembly also includes a shift boot assembly that at least partially defines an interior section and receives a portion of the gear shift lever therethrough. The shift boot assembly includes a frame. The shift boot assembly also includes a flexible section formed of a material having a first durometer. The shift boot assembly further includes a protective shield operatively coupled to the frame and the flexible section, the protective shield formed of a material having a second durometer that is harder than the first durometer of the flexible section.