Vehicle Door Handle Assembly With Concealed Bottom-Inserted Axis
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Solution Overview
Problem
Existing vehicle door handle assemblies face challenges in assembling covers over electronic components while maintaining functional and aesthetic integrity, particularly when potting is required before assembly on the vehicle line.
Innovation Solution
A vehicle door handle assembly design featuring a bracket with levers and axes, including a non-circular flange and removable cap, allows for the cover to be assembled after the handle is fixed to the bracket, enabling rotation and translation of the handle while concealing technical parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover is fastened to the structure before the structure is fastened to the bracket, then the electronic components can be potted for electrical insulation, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent divides the assembly process into separate stages: the cover is fastened to the structure in a first stage, and the structure (with cover already attached) is fastened to the bracket in a second stage. This segmentation allows the cover to be securely attached before final assembly, enabling proper potting of electronic components while maintaining a manageable assembly process through clear separation of operations.
2Reliability
If the cover is fastened to the structure before the structure is fastened to the bracket, then electrical insulation can be provided, but the assembly time increases
Solution Approach 1:
The cover is fastened to the structure in advance (preliminary action) before the structure is mounted to the bracket. This preliminary attachment of the cover allows electronic components to be potted for electrical insulation during the assembly process, rather than requiring a separate post-assembly step. The oblong recess design facilitates this preliminary cover attachment while maintaining efficient assembly flow.
3Ease of manufacture
If the second axis is inserted from the top side, then the assembly process is simplified, but the aesthetic appearance is degraded due to visible technical parts
Solution Approach 1:
Instead of inserting the second axis from the top side (which would be simpler but visible), the patent inverts the approach by inserting the axis from the bottom side of the door handle assembly. This inversion hides the technical parts (axis, flange, cap) on the non-visible bottom side, preserving the aesthetic appearance of the top side while still allowing straightforward assembly operations.
4Shape
If the second axis is inserted from the bottom side, then the aesthetic appearance is maintained, but the assembly process becomes more complex
Solution Approach 1:
The patent employs asymmetric design in the oblong recess and non-circular flange configuration, allowing the second axis to be inserted from the bottom side at a specific orientation. The asymmetric oblong recess with its narrower section and the non-circular flange work together to guide the axis insertion from the less accessible bottom side while maintaining aesthetic appearance on the visible top side. This asymmetric arrangement balances manufacturing complexity with aesthetic requirements.
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The present invention refers to a vehicle door handle assembly (1) comprising: - a bracket (3) configured to be fixed on an inner side of a door panel, - a movable handle (5) fastened to the bracket (3) and configured for moving between a retracted position wherein the movable handle (5) flushes with an outer side of the door panel and a deployed position, wherein the bracket (3) comprises a first lever (7a) comprising a first hole configured for receiving a first axis and a second lever (7b) comprising a second hole configured for receiving a second axis (17), the movable handle (5) comprises a first sleeve (6a) with a first recess configured to receive the first lever and the first axis and a second sleeve (6b) with a second recess (9) configured to receive the second lever (7b) and the second axis (17), the second recess (9) being an oblong recess and comprising an opened top with a top oblong opening (11) that has a narrower section than the oblong recess (9), the second axis (17) comprising a non-circular flange (21) arranged at a first end (17a) and configured to be introduced in the top oblong opening (11) and to be restrained axially by a top wall of the second recess (9), the second axis (17) also comprising a non-circular removable cap (27) configured to be fastened to a second end (17b) of the second axis (17), opposite to the first end (17a), the non-circular removable cap (27) being configured to prevent the axial rotation of the second axis (17) with respect to the second recess (9).