Vehicle door handle

Abstract

The vehicle door handle consists of a housing (2a, 2b) comprising a gripping section (3) and a base section (4). The gripping section (3) is integrally formed with the base section (4) and extends from it at an angle. A support component (8) is accommodated within the housing (2a, 2b), extending at least partially into both the base section (4) and the gripping section (3) of the housing. The support component (8) is rigidly coupled or integrally connected to a coupling component (7). This coupling component (7) extends on one side out of the base section (4) of the housing (2a, 2b) to enable coupling with a body component of a motor vehicle. The support component (8) forms a potting tray (10) for a circuit board. The support component (8) has a frame (8a) that completely accommodates the circuit board (9) and, together with at least one wall of the support component (8), forms the potting tray (10). The circuit board (9) is encased in this potting tray (10) with a potting material (11).

Description

[0001] The application concerns a vehicle door handle. Specifically, the application concerns a vehicle door handle with a housing comprising a gripping section and a base section. The gripping section and base section are angled relative to each other.

[0002] Vehicle door handles exhibit a wide variety of designs and functionalities in the current state of the art. However, they all share the common feature of a mechanical access function that provides a mechanically stable access area for moving a door or hatch on the vehicle.

[0003] The base section of the vehicle door handle according to the invention is designed for placement on a body panel of a vehicle. The gripping section extends upwards or downwards from the base section in a curved or angled manner to allow easy access for the user and enable the operation of a vehicle hatch or door. The spatial orientation of the gripping section, namely projecting upwards or downwards, allows the user to grasp over or under the gripping section (depending on the type of attachment to the vehicle), thus ensuring convenient operation. The geometry, with a single-sided attachment to the vehicle and a flat shape projecting from the vehicle with an angled free end, is reminiscent of an aircraft wing. Therefore, such vehicle door handles are also called wing handles.

[0004] A vehicle door handle of the type described, particularly one with a single-sided mounting on the vehicle and a geometry extending from it that allows for gripping within a defined section, is used both as a fixed door handle with electronic user detection and with a mechanical emergency opening function. During normal vehicle operation, however, such a door handle is actuated in a fixed manner, i.e., without significant relative movement between the door handle and the vehicle. The handle thus serves to move a released door and to accommodate detection components that trigger a mechanical opening of the door via a signal path.

[0005] The vehicle door handle described here has a support component that extends section by section both inside the housing in the base section and inside the gripping section, as well as through the transition section between these two sections. The support component thus functions as a continuous mechanical connection within the gripping section and the base section. Furthermore, the support component is connected to a coupling component. The coupling component extends from one side of the base section of the housing and enables mechanical attachment or coupling to a door or hatch of a motor vehicle. The coupling component is equipped with connecting elements that allow the vehicle door handle to be attached to the vehicle by connecting to corresponding connecting elements on the vehicle. The support component is either rigidly coupled to the coupling component or integrally formed with it.

[0006] In addition to its mechanical operating function, the vehicle door handle also incorporates electronic components that enable the detection of a user's approach or the application of force to the handle. Furthermore, communication devices such as transmitting and receiving coils can be integrated into the door handle, allowing connections between vehicle keys or mobile communication devices and the door handle.

[0007] The limited space within a vehicle door handle presents a challenge for integrating electronic components. To ensure their long-term functionality, it is necessary to protect them from environmental influences through appropriate measures.

[0008] Document WO 2022 / 106080 A1 describes a vehicle door handle with an integrated electronic assembly. This assembly comprises detection devices such as capacitive sensors and communication elements for keyless entry, all positioned within a container integrated into the door handle. The electronic assembly is encased in a potting compound that provides a protective layer against moisture and dirt. The design of the door handle, which is secured to the vehicle door on both sides by a central gripping section, typically ensures high mechanical strength in this type of construction.

[0009] The present invention aims to provide vehicle door handles of the type mentioned above, which have optimized installation space requirements and improved mechanical stability. This is achieved by a vehicle door handle with the features of claim 1.

[0010] The vehicle door handle according to the invention has a receptacle in the carrier component in the form of a potting tray for a circuit board (printed circuit board). Conductive tracks and electronic components are arranged on the circuit board and coupled to one another.

[0011] The circuit board is directly received in the potting compound within the carrier component, which extends inside the housing of the vehicle door handle. This potting compound has a frame that completely encloses the circuit board and forms a potting basin with at least one wall of the carrier component. The circuit board is then encased in a potting compound within this basin.

[0012] Within the scope of the invention, the potting compound serves two essential purposes. On the one hand, the potting material improves the protection of the electronic components on the circuit board in a known manner. On the other hand, it improves the mechanical strength of the vehicle door handle. This is achieved by mechanically coupling the circuit board and the support component without gaps using the potting compound. This stiffens the support component and thus the vehicle door handle. The support component (along with the housing and the coupling component) is responsible for absorbing a significant portion of the mechanical forces acting on the vehicle door handle. Simultaneously, the resulting assembly of circuit board, potting compound, and support component creates a unit that determines the positioning of the circuit board within the housing. The circuit board thus becomes an integral part of a load-bearing and force-absorbing component of the vehicle door handle.

[0013] The potting compound, in its dual function, serves both a protective and a stiffening function for the circuit board, or at least for sections of it. During the potting process, a plastic layer is created that adheres seamlessly to the circuit board and its electronic components, as well as to at least one wall of the supporting component.

[0014] Before the circuit board is potted in the vehicle door handle's carrier component, it is populated with the necessary electronic components, including sensors, leads, and communication devices. The populated circuit board is then placed into the carrier component's recess, which has a frame and forms a potting trough with at least one wall of the carrier component. The recess may contain fasteners that ensure a reproducible alignment of the circuit board within the potting trough. These fasteners include, for example, locking devices and guides. The liquid potting compound is then poured into the trough, completely encasing the circuit board. The material flows around the circuit board, filling all cavities and creating a gap-free bond.Following the potting process, the material is cured, which can be achieved through various methods such as air drying, heating, or UV irradiation, depending on the type of potting compound used. Once fully cured, the potting compound forms a solid, protective stiffening layer around the circuit board and within the supporting component.

[0015] The choice of potting compound allows for influencing the mechanical stability. Epoxy resins are known for their high strength and excellent adhesion properties, offering protection against moisture, chemicals, and mechanical stress. Polyurethanes, on the other hand, are flexible and provide good protection against mechanical stress and vibration. Silicones are characterized by their high flexibility and resistance to extreme temperatures, while acrylonitrile butadiene styrene (ABS) offers a balanced combination of strength, toughness, and temperature resistance.

[0016] Multi-layer potting materials can optimize specific mechanical properties by, for example, combining an outer layer of a hard, resistant material with an inner layer of a flexible, shock-absorbing material.

[0017] Preferably, the frame that borders the potting tray extends into the gripping section of the housing.

[0018] As previously explained, the base section of the vehicle door handle extends from the vehicle and then transitions into a gripping section. This gripping section is therefore the part of the door handle that, when mounted, protrudes furthest from the vehicle and is readily accessible to the operator. Positioning the frame and the entire mounting within this gripping section of the support structure allows for improved detection of user access, as this is where the forces exerted are greatest. Due to leverage, this area is subject to the greatest deformation, making it possible to reliably detect any such deformation. Furthermore, stiffening the door handle in this area is particularly important.

[0019] The support component is preferably made of a metallic material, together with the frame for holding the circuit board, which extends into the gripping section. The metallic frame acts as mechanical protection for both the held circuit board and the potting compound embedded within it. The metal stiffening allows for a degree of elasticity, enabling force dissipation and distribution across the potting compound. This prevents localized mechanical stress on the circuit board.

[0020] The circuit board preferably contains electrical leads whose contact points are located within the reinforcing layer of potting material. This ensures the protection of the electrical connections from environmental influences and mechanical stress, thereby improving the reliability of the vehicle door handle's electrical functions.

[0021] It is advantageous if the circuit board has at least one sensor for detecting the operation of the vehicle door handle, which is covered by the reinforcing layer of potting compound. This protects the sensor from external influences, improving the accuracy and reliability of the sensor and defining its operating conditions. The reinforcing layer can be thinner in the sensor area than in the surrounding area, which is made possible by appropriately shaping the wall of the support component or frame that together form the potting compound. This ensures efficient sensor function and minimizes any impairment of the sensor's sensitivity by the reinforcing layer, without compromising the protective properties of the reinforcing layer.

[0022] It is advantageous to have a conductor coil for an inductive sensor mounted on the circuit board to detect housing deformations. The gap-free enclosure of the sensor by the stiffening layer of potting material ensures its mechanical stabilization and allows for reproducible detection of housing deformations. If the housing itself does not contain detectable metallic components, metallic targets can be positioned on the housing near the sensor for detection purposes.

[0023] In a further development of the invention, a capacitive sensor is used on the circuit board to detect the approach of an operator. The known advantages of capacitive sensors enable contactless, intuitive operation of the vehicle door handle, for example, by automatically unlocking the vehicle when the user approaches. At the same time, the capacitive sensor is protected by the gap-free stiffening layer made of potting material.

[0024] It is advantageous to have elastic sealants placed between the reinforcing layer of potting compound and the housing. These sealants protect against the ingress of water or dirt between the potting compound and the housing and contribute to improving the durability of the vehicle door handle. Furthermore, a supporting and damping effect can be achieved between the potted circuit board and the surrounding housing if the housing deforms or moves due to operation or environmental influences.

[0025] In a further development of the invention, the stiffening layer made of potting material is multilayered and composed of different types of plastic. This allows for the optimization of mechanical properties for specific requirements, such as flexibility or impact resistance, depending on the position and function of the layer. The layers can be applied in a multi-stage potting process and can also have different thicknesses and coverage areas on the circuit board.

[0026] Multi-layer encapsulation of a circuit board opens up numerous possibilities for optimizing the mechanical stability and protection of electronic components. One possibility, for example, is to use an outer layer of a hard, resistant material and an inner layer of a flexible, shock-absorbing material. This combination offers the advantage that the outer layer absorbs mechanical stresses such as shocks and vibrations, while the inner layer protects the sensitive electronic components and provides additional damping.

[0027] Additionally, a multi-layered potting compound can also include a combination of thermoplastic elastomers and other plastics. Thermoplastic elastomers offer excellent flexibility. An outer layer of this material could keep the door handle flexible for desired, minor deformations and cushion mechanical stresses, while an inner layer of polycarbonate or ABS provides the necessary mechanical strength in case of excessive deformation.

[0028] The advantages of these various multi-layer potting options lie in their optimized adaptation to specific requirements. A combination of hard and flexible materials can provide both mechanical protection and damping, thus extending the service life of the circuit board and electronic components. The use of different plastics makes it possible to utilize the best properties of each material to ensure comprehensive protection against mechanical, thermal, and chemical influences. By strategically employing materials with high strength and damping properties, the overall stability of the vehicle door handle can be improved, and the reliability of the electronic components increased.

[0029] The invention will now be explained in more detail with reference to the accompanying figures. Fig. Figures 1a to 1d show a vehicle door handle according to a first embodiment of the invention in different views from the outside; Fig. 2a shows components of the first embodiment with the housing removed; Fig. 2b shows components of the first embodiment with the housing removed in a sectional view; Fig. Figures 3a to 3b show the components of the Fig. 2a and Fig. 2b, with the circuit board removed; Fig. 4 shows the components in an orientation for filling with potting compound; Fig. Figure 5 shows components with an encapsulated circuit board in the carrier component;

[0030] In Fig. Figure 1 shows a vehicle door handle according to a first embodiment of the invention. The vehicle door handle is shown in a side view, i.e., the illustration shows a top view of the handle along a direction which, in the vehicle-mounted state, corresponds to the direction from the front of the vehicle to the rear along a lateral extension of the vehicle.

[0031] The vehicle door handle has a two-part housing 2a, 2b, which forms the outer part of the vehicle door handle and an actuating device for the user. The two housing parts form the housing 2a, 2b with a base section 4 extending away from the vehicle, to which the grip section 3 is formed at an essentially right angle. The transition between the base section 4 and the grip section 3 is formed by a curved transition area in the housing 2a, 2b. The dashed line 15 in Fig. Figure 1 schematically shows where the outer skin of a vehicle would be located after the installation of the vehicle door handle 1. A coupling component 7 protrudes from the base section 4 and is guided through an opening in the vehicle skin 15 into a corresponding coupling device on the inside of the door. The functionality of the coupling component 7 can extend beyond the purely mechanical attachment of the vehicle door handle 1 to a vehicle door. An example of a possible function of the coupling component is the triggering of emergency release functions when a significant mechanical force is exerted on the vehicle door handle. Since this aspect is not essential to the present invention, it will not be discussed further.

[0032] Fig. Figure 1b shows the vehicle door handle according to the first embodiment in a front view, i.e., when looking at the front face facing away from the vehicle. Fig. Figure 1c shows the vehicle door handle according to the first embodiment in an oblique view from the direction of the vehicle. It can be seen how the coupling component 7 extends from the base section 4 of the housing 2a, 2b along the extent of the vehicle door handle 1.

[0033] Fig. Figure 1d shows the vehicle door handle according to the first embodiment in a perspective oblique view, namely from the viewpoint of a user approaching a vehicle from a rear oblique angle. In this perspective, the front of the vehicle is on the left and the rear on the right, so that the vehicle door handle 1 has an oblique silhouette towards the front of the vehicle. A user can grasp the vehicle door handle 1 in the grip area 3 and exert an actuating force on the vehicle door handle 1 to move an unlocked door. The fixed mounting on one side of the vehicle and the leverage provided by the housing mean that the handle and its components must withstand significant actuating forces.

[0034] Fig. Figure 3A shows the components of the vehicle door handle according to the first embodiment, with the housing 2a, 2b removed to show the internal components. The support component 8 is an angled component that extends through both the base section and the gripping section of the housing 2a, 2b. The support component 8 is rigidly coupled to the coupling component 7 in the area of ​​the base section 4, in this example by means of screws. In the area of ​​the gripping section, the support component 8 extends freely upwards, so that it is positioned freely within the inner cavity of the housing 2a, 2b in the gripping section 3. In this way, when an actuating force is applied to the housing in the gripping section 3, the housing wall of the housing 2a, 2b can be displaced relative to the support component to a predetermined extent. This is necessary, for example, to detect deformations caused by the application of an actuating force.

[0035] The support component 8 has a shape designed such that it forms a frame 8a in which a circuit board 9 is received. The circuit board 9 is fixed to the support component 8 in the inner area of ​​the frame 8a by means of fasteners. The frame 8a, together with the other walls of the support component 8, forms a potting trough 10 in which the circuit board 9 is completely contained. The sectional view in Fig. Figure 2b shows that the frame and wall of the supporting component 8 form a closed basin 10. Partial openings are formed in the frame 8A through which connecting elements for the electronic coupling of the circuit board 9 to supply lines 9a are routed. The penetrations are sealed against the frame to ensure the basin's watertightness.

[0036] In Fig. In 3a, the circuit board 9 has been removed to allow a better view into the potting tray 10. It is evident that mechanical reinforcements are incorporated beneath the circuit board, which are filled with potting compound in the potting tray. This improves the stiffening of the supporting component through the potting material. Fig. 3B is the arrangement of Fig. Figure 3A shows the components in an orientation that allows filling with potting compound from the open side of the potting tray 10. In this orientation, the electronic connectors are accessible. The following Fig. Figure 4 illustrates the insertion position of the circuit board 9 into the potting tray 10. The inserted circuit board 9 covers part of the opening of the potting tray, leaving gaps around the perimeter for the passage of the potting material between the frame 8A and the circuit board 9. Fig.Figure 5 shows the components after potting. The potting material 11 forms a single or multi-layered stiffening and protective layer around the circuit board 10. The potting material 11 is contained without gaps in the support component 8, more precisely in the potting tray 10. This allows acting forces to be distributed within the support component.

[0037] Sensory components in the form of inductive or capacitive sensors can be arranged on the circuit board. The potting material does not significantly affect the function of these sensors. For example, inductive sensors on the circuit board 9 can detect deformations of the housing 2a, 2b relative to the support component 8, provided that the housing 2a, 2b has metallic components or metallic targets (foils or sheets) arranged on the housing.

[0038] The absorption of forces and the resulting stiffening of the support component 8 by the gapless potting to form the potting material 11 allow both the electronic and sensor components to be protected and the positioning of these sensors in the handle to be permanently fixed. The additional stiffening effect of the potting material allows the support component to be made with less thickness, resulting in a weight reduction. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 2022 / 106080 A1

[0008]

Claims

[1] Vehicle door handle with a housing (2a, 2b) which has a gripping section (3) and a base section (4), wherein the gripping section (3) is integrally formed with the base section (4) and extends at an angle from it, wherein a support component (8) is received in the housing (2a, 2b), which extends at least partially into both the base section (4) and the gripping section (3) of the housing, wherein the support component (8) is rigidly coupled or integrally connected to a coupling component (7), wherein the coupling component (7) extends on one side out of the base section (4) of the housing (2a, 2b) to allow coupling with a body component of a motor vehicle, characterized by , that a potting tray (10) for a circuit board is formed in the support component (8), wherein the support component (8) has a frame (8a) which fully accommodates the circuit board (9) and forms the potting tray (10) with at least one wall of the support component (8), in which the circuit board (9) is encased with a potting material (11). [2] Vehicle door handle according to claim 1, wherein the frame (8a) extends into the gripping section (3) of the housing (2a, 2b). [3] Vehicle door handle according to claim 1 or 2, wherein the support component (8) is made of a metallic material. [4] Vehicle door handle according to one of the preceding claims, wherein the circuit board (9) has electrical leads (9a), wherein the contact points of the electrical leads (9a) are arranged on the circuit board within the potting material (11). [5] Vehicle door handle according to one of the preceding claims, wherein the circuit board contains at least one sensor for detecting operation of the vehicle door handle, wherein the sensor is covered by the potting material. [6] Vehicle door handle according to one of the preceding claims, wherein the housing in the base section is fixed to the support component by means of connecting means without play and the support component extending in the gripping section of the housing extends at a distance from the housing. [7] Vehicle door handle according to one of the preceding claims, wherein at least one conductor coil with electronic means for forming an inductive sensor is arranged on the circuit board to detect a deformation of the housing, wherein at least one metallic target for sensory interaction with the conductor coil is formed in the housing, in particular on the inner wall of the housing and in a section opposite the conductor coil. [8] Vehicle door handle according to one of the preceding claims, wherein at least one capacitive sensor with a conductive surface is formed on the circuit board to detect an operator approaching the vehicle door handle. [9] Vehicle door handle according to one of the preceding claims, wherein elastic sealing means are arranged at least sectionally between the potting material and the housing, which are compressed between the potting material and the housing. [10] Vehicle door handle according to one of the preceding claims, wherein the potting material is formed in at least sections in multiple layers, wherein the layers differ in the type of potting material.

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