Vehicle Handle with Encapsulated Core for Weight Reduction

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Solution Overview

Problem

Vehicle weight reduction is necessary to enhance performance, speed, and mileage, as lighter vehicles tend to be quicker and more efficient, but existing solutions fail to effectively reduce weight while maintaining structural integrity and load capacity.

Innovation Solution

A vehicle interior handle is designed with a core element made from a lightweight material, such as natural fibers or polyamide, encapsulated within a thermoplastic olefin body, using an injection molding process to create a hollow, reinforced structure that reduces weight by approximately 300 grams compared to solid handles, while maintaining load capacity and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a solid handle structure is used, then structural integrity and load capacity are maintained, but vehicle weight increases

Engineering Contradiction:

Improvehandle weightVSAvoidload capacity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The handle is divided into two distinct parts: a core element and a handle body. The core element provides structural support while the handle body provides structural integrity and load capacity. This segmentation allows each component to be optimized for its specific function, reducing overall weight while maintaining strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The handle combines two different materials: a polyamide core element and a thermoplastic olefin handle body. This composite structure leverages the high strength-to-weight ratio of polyamide for the core and the durability and load-bearing properties of TPO for the body, achieving both weight reduction and maintained load capacity.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If a hollow handle structure is used, then weight is reduced, but structural integrity deteriorates

Engineering Contradiction:

Improvehandle weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of moving objectVSStability of the object's composition

Solution Approach 1:

The handle is divided into a hollow core element and an outer handle body. The core element's hollow cylindrical structure reduces weight while the surrounding handle body restores and maintains structural integrity, creating a lightweight yet strong composite structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the handle have different properties: the core element is hollow and lightweight, while the handle body is solid and structurally robust. This local differentiation optimizes weight in the core region while maintaining integrity in the outer region that bears the load.

Inventive Principle:

Principle #3Local quality

3Weight of moving object

If natural fiber materials are used for the core element, then weight is reduced and sustainability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvehandle weightVSAvoidmanufacturing process

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The core element is pre-formed as a hollow cylindrical structure from natural fiber-reinforced polyamide material before being placed in the mold. This preliminary preparation simplifies the injection molding process, as the core element is already shaped and ready for encapsulation, reducing manufacturing complexity despite the specialized material.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The core element uses a composite of natural fibers and polyamide, combining the weight-saving and sustainability benefits of natural fibers with the structural properties and manufacturability of synthetic polyamide, balancing eco-friendliness with ease of manufacture.

Inventive Principle:

Principle #40Composite materials

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 achieves significant weight reduction in vehicle handles while maintaining or improving load capacity and structural integrity, enabling better vehicle performance and mileage without compromising safety or durability.

Implementation Method 1

providing a vertically-oriented mold including a mold cavity, the mold located in an injection molding machine and adapted to allow suckage to occur at one or more locations in the mold

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

allowing the TPO to cool from the molten state to a solid state while in the mold

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS10960584B2Vehicle interior handle with encapsulated core and corresponding method of manufacture

Publication Date: 2021.03.30 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

One general aspect includes a method of manufacturing a handle, the method including: providing a core element; providing a mold; strategically positioning the core element within the mold such that a formable material can be injected into the mold (when in a molten state) to operatively encapsulate the core element and such that the core element remains stationary while being operatively encapsulated by the formable material; and injecting the formable material (when in the molten state) into the mold to operatively encapsulate the core element and be formed, by the mold, into a handle configured to be joined to a window support pillar of a vehicle interior.