Outer handle device for vehicle door

Abstract

To effectively prevent a person moving around an outdoor area or a driver of a vehicle from contacting an outside handle without noticing the outside handle in a pop-up position in an outside handle device in a situation where visibility is reduced such as at night, the outer handle device being configured such that an outer handle having an operating part is attached to a support case fixed to an outer panel of a vehicle door for movement between a stored position in which the outer handle is housed within the support case and the pop-up position in which the operating part protrudes outward from the outer panel, and an actuator is provided for driving the outer handle from the stored position to the pop-up position, and the outer handle is attached to the support case so as to be manually operated in a full stroke from the pop-up position to a full stroke position closer to the outside.SOLUTION: A light reflection surface R is provided on at least a part of an end rear surface on at least a vehicle rear side of an exposed surface exposed to the outside at a pop-up position of an outer handle 17 / 117.SELECTED DRAWING: Figure 9

Description

[Technical field]

[0001] The present invention relates to an outer handle device for a vehicle door, and in particular to an outer handle device in which an outer handle having a manually operable operating unit is attached to a support case fixed to the outer panel of the door so that it can move between a stored position where the outer surface of the outer handle is substantially flush with the outer surface of the outer panel and a pop-up position where the operating unit protrudes outward from the outer panel, and an actuator is provided that can drive the outer handle from the stored position to the pop-up position, and the outer handle is attached to the support case so that it can be manually operated over a full stroke from the pop-up position to a full stroke position further outward. [Background technology]

[0002] The above-mentioned outer handle devices have been publicly known (see, for example, Patent Documents 1 and 2), and these devices have been useful in preventing tampering and theft because the outer handle is normally stored in a stored state where it is approximately flush with the outer panel (i.e., does not protrude outward from the outer panel). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2001-40913 A [Patent Document 2] Patent No. 6629724 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the conventional devices disclosed in the above Patent Documents 1 and 2, the outside handle protrudes outward from the outer surface of the outer panel to a considerable extent when in its popped-up position. As a result, in situations where visibility is reduced, such as at night, people moving around outdoors or drivers of vehicles may not notice the outside handle in the popped-up position, and there is a concern that the people or vehicles may come into contact with the outside handle.

[0005] The present invention has been made in view of the above circumstances, and has an object to provide an outer handle device for a vehicle door that is capable of effectively avoiding the above-mentioned contact with a simple structure. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the present invention provides an outer handle device for a vehicle door, comprising a support case fixed to an outer panel of a door, an outer handle having a manually operable operating unit attached so as to be movable between a stored position in which the outer surface of the outer handle is substantially flush with the outer surface of the outer panel and a pop-up position in which the operating unit protrudes outward from the outer panel, and an actuator capable of driving the outer handle from the stored position to the pop-up position, and the outer handle is attached to the support case so that it can be manually operated over a full stroke from the pop-up position to a full stroke position further outward, wherein a first feature of the device is that a light reflective surface is provided on at least a part of the rear surface of at least the end portion of the outer handle that is exposed to the outside in the pop-up position.

[0007] A second feature of the present invention is that an outer handle having a manually operable operating unit is attached to a support case fixed to an outer panel of a door so as to be movable between a stored position in which the outer surface of the outer handle is substantially flush with the outer surface of the outer panel and a pop-up position in which the operating unit protrudes outward from the outer panel, and an actuator is provided which is capable of driving the outer handle from the stored position to the pop-up position, and the outer handle is attached to the support case so that it can be manually operated a full stroke from the pop-up position to a full stroke position further outward, wherein at least a portion of an upper surface of the outer handle that is exposed to the outside in the pop-up position is provided with a light reflective surface. Effect of the Invention

[0008] According to the first feature of the present invention, a light reflective surface is provided on at least a part of the rear surface of at least the end portion of the exposed surface of the outer handle that is exposed to the outside in the popped up position toward the rear of the vehicle. Therefore, even if the outer handle protrudes somewhat outward from the outer surface of the outer panel in the popped up position, people moving around outdoors or drivers of vehicles in situations where visibility is reduced, such as at night, can easily notice the presence of the outer handle in the popped up position due to the light reflected from the light reflective surface on the rear surface of the outer handle, and can effectively avoid contact with the outer handle.

[0009] Furthermore, according to the second feature, a light reflective surface is provided on at least a part of the upper surface of the outer handle that is exposed to the outside in the popped up position. Therefore, even if the outer handle protrudes somewhat outward from the outer surface of the outer panel in the popped up position, people moving around outdoors or drivers of vehicles in situations where visibility is reduced, such as at night, can easily notice the presence of the outer handle in the popped up position due to the light reflected from the light reflective surface on the upper surface of the outer handle and can effectively avoid contact with the outer handle.

[0010] According to the third feature, a cover that covers at least a part of the upper surface of the outer handle that is exposed to the outside in the pop-up position is removably attached, and the cover can be colored in a different color from the paint color of the outer surface of the outer handle or plated to provide variations, and can be easily replaced to suit the user's preferences. Moreover, a light reflecting surface is provided on at least the rear surface of this cover, so the variations in the light reflecting surfaces to be provided on the outer handle can be easily and at low cost increased.

[0011] According to the fourth feature, a rotating shaft is inserted into the outer handle to guide and support its rotation when it is rotated from the pop-up position to the full stroke position, and an engagement portion is provided on the cover to engage with this rotating shaft to prevent the rotating shaft from coming off the outer handle. Therefore, the cover can also be used as means to prevent the rotating shaft that guides and supports the rotation of the outer handle from coming off the outer handle, which simplifies the structure and contributes to cost reduction.

[0012] According to the fifth feature, the outer handle is provided with an LED that illuminates the light reflecting surface, thereby further improving the visibility of the light reflecting surface. [Brief description of the drawings]

[0013] [Figure 1] 1A is a side view showing a main part of a door with an outer handle in a stored position, FIG. 1B is a side view showing a main part of a door with an outer handle in a pop-up position, and FIG. [Diagram 2] FIG. 2 is a cross-sectional view taken along line 2-2 in FIG. [Diagram 3] FIG. 3 is an exploded perspective view of the portion shown in FIG. 2. [Figure 4] 4 is a view taken along the arrow 4 in FIG. 2 with the cover member omitted to show a state in which the drive lever is in an initial position. [Diagram 5] 4 is a view corresponding to FIG. 3 in a state where the drive lever has been rotated to an operating position. [Figure 6] 4 is a view corresponding to FIG. 3 in a state where the outer handle has been rotated to a full stroke position. FIG. [Figure 7] FIG. 7 is a cross-sectional view taken along line 7-7 in FIG. [Figure 8] FIG. 8 is a cross-sectional view taken along line 8-8 in FIG. [Figure 9] 2 is an enlarged perspective view corresponding to FIG. 1(b), showing the location where the light reflecting surface is provided on the outer handle in the pop-up position. [Figure 10] 10 is an enlarged plan view (a plan view taken along arrow 10 in FIG. 9) showing an installation location of a light reflecting surface on an outer handle in a pop-up position. [Figure 11] FIG. 5 is a view showing a modification of the first embodiment, corresponding to FIG. 3, in a state in which the drive lever is in an initial position. [Figure 12] 12 is a view corresponding to FIG. 11 in a state where the drive lever has been rotated to an operating position. [Figure 13] FIG. 4 is a vertical cross-sectional view of the holding means as viewed from the support case side. [Figure 14] 12 is a view corresponding to FIG. 11 in a state where the outer handle has been rotated to a full stroke position. FIG. [Figure 15] 11 is a side view of a main part of a door showing a second embodiment, in which (a) shows the outer handle in a stored position, (b) shows the outer handle in a pop-up position, and (c) shows the outer handle in a full stroke position. [Figure 16] FIG. 11 is a plan view showing a main part of an outer handle of a second embodiment with the reflector omitted. [Figure 17] 13A to 13C are longitudinal sectional views showing the movement of each part of the outer handle drive device D and the guide device G when the outer handle of the second embodiment is in the stored position (a), the pop-up position (b) and the full stroke position (c). [Figure 18] FIG. 17(b) is an enlarged cross-sectional view of a main part of FIG. [Figure 19]1A is a perspective view of the transmission frame 170 alone, which is a main part of the interlocking mechanism I, as viewed obliquely from above, and FIG. 1B is a perspective view of the second arm A2 alone, as viewed obliquely from above. [Figure 20] 20(a) is an exploded perspective view showing the main part of the front part of the outer handle, (b) is a cross-sectional view taken along line bb in FIG. 20(a), and (c) is a cross-sectional view taken along line cc in FIG. 20(a). [Figure 21] 19 is an enlarged perspective view of the cross section taken along line 21-21 in FIG. 18, as seen obliquely from above. [Figure 22] FIG. 4 is an exploded perspective view showing a main part of a rear portion of the outer handle. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[0015] First, the first embodiment will be described with reference to Figures 1 to 10. In Figure 1, an outer panel 16 of a side door 15 of a passenger vehicle is provided with an outer handle 17 that is long in the fore-and-aft direction of the vehicle. This outer handle 17 can be changed between a stored position in which the outer surface of the outer panel 16 and the outer surface of the outer handle 17 are flush with each other as shown in Figure 1(a), a pop-up position in which an operating part 18a at one end of the outer handle 17 protrudes laterally from the outer surface of the outer panel 16 as shown in Figure 1(b), and a full stroke position in which the outer handle 17 is rotated further outward from the pop-up position by grasping and operating the operating part 18a as shown in Figure 1(c).

[0016] Referring to Figures 2 and 3 together, the outer handle 17 is composed of a handle main body 18 which has a recess 20 facing the inside side of the outer panel 16, extends long in the fore-and-aft direction of the vehicle, and has the operating part 18a at one end (the rear end in the illustrated example), and a handle base 19 which is fastened to the handle main body 18 from the outer panel 16 side so as to close the recess 20, and a board 21 on which electronic components such as a touch sensor and an antenna are mounted is attached to the inner surface of the handle base 19.

[0017] 9 and 10, a light reflecting surface R (shown by cross-hatching in Figs. 9 and 10 to make the reflective surface area easier to understand) that reflects external light (e.g., lights from other vehicles, city lights, etc.) is provided on the upper and rear surfaces of the outer handle 17 that are exposed to the outside in the pop-up position (i.e., the surfaces facing the rear of the vehicle). This light reflecting surface R can be provided on the upper and rear surfaces of the outer handle 17 (more specifically, the handle body 18 and the handle base 19) that are exposed to the outside in the pop-up position and full stroke position, for example, by attaching a light reflecting sheet or tape or by painting the upper and rear surfaces with light reflecting paint.

[0018] In this embodiment, of the surfaces of the outer handle 17 that are exposed to the outside in the pop-up position, at least a part (the entire surface in the illustrated example) of the rear surface and the top surface at least at the end portion on the vehicle rear side is provided with a light reflecting surface R. As a result, even if the outer handle 17 protrudes outward to a certain extent from the outer surface of the outer panel 16 in the pop-up position, people moving around the side door 15 or the driver of the vehicle in a situation where visibility is reduced, such as at night, can easily notice the presence of the outer handle 117 in the pop-up position by the light reflected from the light reflecting surface R, and therefore contact with the outer handle 117 can be effectively avoided.

[0019] The outer handle 17 is rotatably supported via a support shaft 23 on a support case 22 fixed to the outer panel 16. An opening 24 extending long in the vehicle front-rear direction is provided in the outer panel 16, and the support case 22 has a support plate portion 22a facing the inner surface of the outer panel 16 and a handle support portion 22b that is integrally provided on an upper portion of the support plate portion 22a and extends in the vehicle front-rear direction so as to close the opening 24 from the inner side of the outer panel 16, and is fastened to the inner surface side of the outer panel 16. A seal member 25 that seals the periphery of the opening 24 is interposed between the support case 22 and the outer panel 16.

[0020] The handle support portion 22b of the support case 22 has a storage recess 26 that extends elongatedly in the fore-and-aft direction of the vehicle corresponding to the opening 24 and is formed so as to be recessed inwardly of the outer panel 16. Most of the outer handle 17, except for the operating portion 18a, is stored in the storage recess 26 when the outer handle 17 is in the storage position where it is flush with the outer surface of the outer panel 16.

[0021] The support shaft 23 is attached to the handle support portion 22b of the support case 22 so as to cross the accommodating recess 26 in the vertical direction, and the support shaft 23 is inserted through a support portion 18b that is integrally provided with the handle body 18 near the other end of the outer handle 17 and disposed within the accommodating recess 26, via a pair of short cylindrical collars 27, 27. The outer panel 16 is also provided with a recess 28 that connects to the opening 24 and that accommodates the operating portion 18a of the outer handle 17 when the outer handle 17 is in the stored position.

[0022] A first elastic member 29 is attached to the handle support portion 22b of the support case 22 so as to be positioned within the storage recess 26, and the first elastic member 29 abuts against a thick abutment protrusion 19a that is integrally formed on the handle base 19 and adjacent to the operating portion 18a when the outer handle 17 is in the stored position, and a second elastic member 30 (see Figure 2) that abuts against the other end of the handle main body 18 of the outer handle 17 at the full stroke position is attached so as to be positioned within the storage recess 26.

[0023] The remainder of the accommodating recess 26, excluding the portion that accommodates most of the outer handle 17 in the storage position, is closed by a base cover 31 that is attached to the support case 22 adjacent to the other end of the outer handle 17 in the storage position, and a switch support portion 22c that protrudes into the accommodating recess 26 is integrally provided on the handle support portion 22b of the support case 22 at a position corresponding to this base cover 31.

[0024] 2, the switch support portion 22c supports a switch holder 33 that holds a tact switch 32 that is turned on and off by the vehicle user's operation to indicate the intention to lock the side door 15. Meanwhile, a rectangular window 34 that extends long in the vehicle front-rear direction is provided in the base cover 31 at a portion corresponding to the switch support portion 22c. Also, an intermediate cap 35 made of an elastic material that allows a pressing force to act on the pressed portion 32a of the tact switch 32 is attached to the switch holder 33 so as to cover the tact switch 32. A switch button 36 made of a hard synthetic resin and having a rectangular pressing operation portion 36a arranged in the window 34 is connected to the intermediate cap 35, and a flange portion 36b that abuts against the inner surface of the base cover 31 around the window 34 is integrally formed with the switch button 36. Moreover, the switch button 36 is biased by the elastic force exerted by the intermediate cap 35 to the non-operating position side where the flange portion 36 b is in contact with the inner surface of the base cover 31 .

[0025] 4 and 5, an actuator 39 is attached to the support plate portion 22a of the support case 22, which is capable of driving the outer handle 17, which is in a stored position stored on the support case 22 side, to a pop-up position in which the operating portion 18a projects outward from the outer panel 16. The actuator 39 is configured to include a drive lever 40 that can rotate between an initial position shown in Fig. 4 and an actuated position shown in Fig. 5, and an electric motor 41 as an electric drive source that, when energized, drives the drive lever 40 to rotate from the initial position to the actuated position and, in a de-energized state when the drive lever 40 is in the actuated position, allows the drive lever 40 to return from the actuated position to the initial position.

[0026] An actuator case 42 housing the electric motor 41 is attached to the lower part of the support plate part 22a of the support case 22 so as to protrude downward from the support plate part 22a. One end part of the drive lever 40 is fixed to a rotation shaft 43 which is rotatably supported on the upper part of the actuator case 42, and a transmission mechanism (not shown) provided between the electric motor 41 and the rotation shaft 43 is housed in the actuator case 42.

[0027] Furthermore, the support plate portion 22a of the support case 22 is provided with a holding means for mechanically holding the drive lever 40 in the operating position, and in this embodiment, the holding means is a torsion spring 44. A cylindrical spring support portion 45 protrudes from the support plate portion 22a of the support case 22 so as to be positioned above the drive lever 40 and below the handle support portion 22b, and the torsion spring 44 has a coil portion 44a surrounding the spring support portion 45, and first and second arm portions 44b, 44c extending from both ends of the coil portion 44a.

[0028] A first arm portion 44b of the torsion spring 44 abuts against and engages with the handle support portion 22b located above the spring support portion 45 from below. A second arm portion 44c is disposed so as to extend from the spring support portion 45 toward the drive lever 40, and a peak portion 44d is formed in an intermediate portion of the second arm portion 44c, the peak portion 44d being bent so as to protrude toward the drive lever 40.

[0029] On the other hand, the surface of the drive lever 40 facing the support plate portion 22a is integrally provided with a contact step portion 40a formed in a mountain shape so as to abut against the second arm portion 44c from below. When the drive lever 40 is in the initial position, the portion of the second arm portion 44c closer to the spring support portion 45 than the peak portion 44d resiliently abuts against the contact step portion 40a from above. When the drive lever 40 rotates from the initial position through the intermediate position shown by the dotted line in Figure 5 to the operating position shown by the solid line in Figure 5, the abutment step portion 40a pushes the second arm portion 44c upward and overcomes the peak portion 44d. When the drive lever 40 has rotated to the operating position, the drive lever 40 is mechanically held in the operating position by the peak portion 44d of the torsion spring 44 unless an external force acts on the drive lever 40.

[0030] In addition, an arc-shaped guide hole 46 centered on the axis of the pivot shaft 43 is formed in the support plate portion 22a of the support case 22, and a pin 47 that passes through the guide hole 46 is implanted in the drive lever 40, and the guide hole 46 is formed so as to allow movement of the pin 47 in association with the rotation of the drive lever 40 between the initial position and the operating position.

[0031] A connecting protrusion 18c that is continuous with the support portion 18b is integrally formed on the handle body 18 of the outer handle 17, and this connecting protrusion 18c passes through a long hole 48 that is provided in the handle support portion 22b in the support case 22 and extends long in the fore-and-aft direction of the vehicle, and the tip of the connecting protrusion 18c protrudes inward from the handle support portion 22b of the support case 22.

[0032] Further, a cylindrical lever support portion 49 is integrally formed on the support plate portion 22a of the support case 22 and is positioned below the handle support portion 22b at a portion corresponding to the long hole 48, and a handle lever 50 is rotatably supported on this lever support portion 49.

[0033] The handle lever 50 has, integrally, a first lever base 50b having a cylindrical first support tube portion 50a (see Figure 3) rotatably supported by the lever support portion 49, an outer handle side connecting arm portion 50c extending upward from the first lever base 50b, a driving lever side connecting arm portion 50d extending diagonally downward from the first lever base 50b towards the driving lever 40, and a sector gear portion 50e protruding from the first lever base 50b in the opposite direction to the torsion spring 44.

[0034] A connecting hole 52 extending long in the longitudinal direction is formed in the outer handle side connecting arm portion 50c, and the tip portion of the connecting protrusion 18c of the outer handle 17 is inserted into and connected to the connecting hole 52. In other words, the handle lever 50 is interlocked with and connected to the outer handle 17, and the handle lever 50 is biased in a direction returning the outer handle 17 to the stored position by the spring force of a first return spring 53 (see FIG. 3), which is a torsion spring provided between the handle lever 50 and the support plate portion 22a, surrounding the first support cylinder portion 50a.

[0035] An abutment pin 54 that abuts against the drive lever 40 in the initial position from the operating position side is implanted at the tip of the drive lever side connecting arm 50d so as to protrude toward the support plate portion 22a. As the drive lever 40 rotates from the initial position to the operating position, the abutment pin 54 is pressed by the drive lever 40, and the handle lever 50 rotates to drive the outer handle 17 from the stored position to the pop-up position.

[0036] Furthermore, when the outer handle 17 rotates from the pop-up position to the full stroke position, because the drive lever 40 is held by the torsion spring 44, the handle lever 50 rotates together with the outer handle 17, leaving the drive lever 40 in the operating position.

[0037] The sector gear portion 50e is meshed with a gear 56 of a rotary damper 55 fastened to the support plate portion 22a. This rotary damper 55 functions to rotate the outer handle 17, which is biased in the direction returning to the storage position, gently to the storage position even if the outer handle 17 is released after being rotated to the full stroke position.

[0038] In addition, a release lever 58 is rotatably supported on the support plate portion 22a of the support case 22. The release lever 58 rotates in response to the rotation of the handle lever 50 accompanying manual operation of the outer handle 17 from the pop-up position to the full stroke position, thereby releasing the hold by the torsion spring 44 and forcibly returning the drive lever 40 to the initial position.

[0039] This release lever 58 is disposed between the support plate portion 22a and the outer panel 16, and has, integrally therewith, a second lever base 58a which is rotatably supported on the support plate portion 22a via a first shaft 59 which is attached to the support plate portion 22a so as to be positioned below the handle lever 50, a drive lever side arm 58b which extends from the second lever base 58a towards the drive lever 40, and a latch mechanism side arm 58c which forms an approximately V-shape together with the drive lever side arm 58b and is connected to the second lever base 58a so as to protrude from the support plate portion 22a towards the opposite side to the mounting portion of the actuator 39.

[0040] A rectangular through hole 60 is formed in the support plate portion 22a and is positioned between the first lever base 50b of the handle lever 50 and the second lever base 58a of the release lever 58. A pressure-receiving portion 58d which is inserted into this through hole 60 is integrally provided at a right angle to the middle portion of the latch mechanism side arm portion 58c, and a handle side cap 61 made of an elastic material is attached to this pressure-receiving portion 58d. On the other hand, a pressing arm 50f is integrally connected to the driving lever side connecting arm 50d of the handle lever 50, and when the outer handle 17 is rotated from the stored position to the pop-up position, the handle lever 50 rotates together with the outer handle 17, thereby bringing its tip into contact with the handle side cap 61. When the outer handle 17 rotates from the pop-up position to the full stroke position, the handle lever 50 rotates together with the outer handle 17, and the pressing arm 50f presses the handle side cap 61, i.e., the pressure receiving portion 58d, and the release lever 58 rotates to the position shown in FIG. 6.

[0041] The side door 15 is provided with a latch mechanism 62 that can switch between a latched state in which the side door 15 is held closed by engaging with the vehicle body side, and an unlatched state in which the side door 15 can be opened. The rotation of the release lever 58 is transmitted to the latch mechanism 62 via a transmission rod 63, one end of which is connected to the tip of the drive lever side arm 58b.

[0042] The latch mechanism 62 is equipped with an electric motor (not shown) that switches between an unlocked state, in which the latched state can be released, and a locked state, in which the latched state cannot be released, and when a touch sensor in the outer handle 17 detects that the outer handle 17 is gripped by a legitimate vehicle user in the locked state, the latch mechanism 62 switches to the unlocked state.

[0043] When the latch mechanism 62 is in the unlocked state, it becomes unlatched by the force transmitted from the release lever 58 via the transmission rod 63 in response to the rotation of the outer handle 17 from the pop-up position to the full stroke position, and in this state the side door 15 can be opened.

[0044] On the other hand, the electric motor 41 of the actuator 39 drives the drive lever 40 to rotate from the initial position to the operating position when the electronic control device (board 121b described later) confirms that the vehicle user is a legitimate vehicle user through communication between the vehicle and a portable device carried by the vehicle user who is within a specified range of the vehicle.The vehicle user can then grasp the outer handle 17, which has reached the pop-up position in response to the rotation of the drive lever 40, and rotate it toward the full stroke position to open the side door 15.

[0045] Incidentally, the operation of the electric motor 41 of the actuator 39 may be started by an operation on the portable device side, rather than by prior authentication through communication with the portable device. Also, the electric motor 41 of the actuator 39 may be made capable of rotating forward and reverse, and when a predetermined time or more has elapsed while the outer handle 17 is in the pop-up position, the electric motor 41 may be operated in the reverse direction to return the drive lever 40 from the operating position to the initial position in order to return the outer handle 17 to the stored position.

[0046] A drive lever side cap 64 made of an elastic material is attached to the tip of the latch mechanism side arm 58c of the release lever 58, which abuts on the pin 47 of the drive lever 40, which is inserted into the guide hole 46, when the drive lever 40 is rotated from the initial position to the operating position. When the release lever 58 rotates in response to the rotation of the outer handle 17 from the pop-up position to the full stroke position, the pin 47, i.e., the drive lever 40, is pushed by the latch mechanism side arm 58c of the release lever 58. As shown in FIG. 6, the drive lever 40 is forcibly rotated so that the abutment step 40a overcomes the peak 44d of the second arm portion 44c while pushing the second arm portion 44c of the torsion spring 44 upward, and after climbing over the peak 44d, the elastic force acting from the peak 44d of the second arm portion 44c returns the drive lever 40 to its initial position.

[0047] A second return spring 65 (see Figure 3), which is a torsion spring surrounding the first shaft 59, is provided between the release lever 58 and the support plate portion 22a, and the spring force of this second return spring 65 urges the release lever 58 to rotate in a direction that brings the handle side cap 61 into contact with the pressing arm portion 50f of the handle lever 50.

[0048] Referring also to Figure 7, an inertia mechanism 68 is provided in the handle support portion 22b of the support case 22 to prevent the outer handle 17 from rotating to the full stroke position due to the impact of a side collision with the side door 15 when the outer handle 17 is in the stored position, causing the side door 15 to open undesirably.

[0049] This inertia mechanism 68 includes an inertia lever 70 that is rotatably supported on the handle support portion 22b via a second shaft 69 that is provided on the handle support portion 22b and has an axis parallel to the support shaft 23 that rotatably supports the outer handle 17 on the handle support portion 22b, and a third return spring 71 that is provided between the handle support portion 22b and the inertia lever 70.

[0050] The inertia lever 70 integrally comprises a third lever base 70b having a cylindrical second support tube portion 70a supported for rotation by a second shaft 69, a weight arm portion 70c extending from the third lever base 70b to the side opposite the handle side connecting arm portion 50c of the handle lever 50, and a regulating arm portion 70d extending from the third lever base 70b to the handle side connecting arm portion 50c side of the handle lever 50. When the inertia lever 70 is in a state in which it has been rotated to a position that allows the outer handle 17 to rotate to the full stroke position (the state shown by the solid line in Figure 7), a sponge 72 that abuts against the tip of the regulating arm portion 70d is affixed to the handle support portion 22b.

[0051] The third return spring 71 is a torsion spring that surrounds the second support cylinder portion 70a and is provided between the handle support portion 22b and the inertia lever 70. The spring force of this third return spring 71 urges the inertia lever 70 to rotate in the direction that brings the tip of the regulating arm portion 70d into contact with the sponge 72.

[0052] When the impact from the side collision acts on the side door 15, the inertia lever 70 rotates to the position shown by the dotted line in FIG. 7 faster than the rotation of the handle lever 50 so as to move its restricting arm portion 70d away from the sponge 72, and when the handle lever 50 rotates together with the outer handle 17, the handle side connecting arm portion 50c of the handle lever 50 abuts against the tip of the restricting arm portion 70d as shown by the dotted line in FIG. 7, thereby restricting the rotation of the handle lever 50 and preventing the rotation of the outer handle 17, which rotates together with the handle lever 50, toward the full stroke position.

[0053] Incidentally, the restricting arm portion 70d of the inertia lever 70 is formed with an abutment surface 70e against which the handle side connecting portion 50c of the handle lever 50 abuts in response to the outer handle 17 being rotated from the pop-up position to the full stroke position with the restricting arm portion 70d abutting against the sponge 72, and the abutment surface 70e is formed inclined so as to intersect obliquely with the moving direction of the handle side connecting portion 50c so that the inertia lever 70 can be rotated in a direction in which the sponge 72 is compressed by the restricting arm portion 70d by the pressing force acting from the handle side connecting portion 50c. As a result, the inertia lever 70 rotates slightly every time the outer handle 17 is rotated, and it is possible to prevent the inertia lever 70 from becoming stuck due to remaining stationary for a long period of time.

[0054] In preparation for the possibility that the inertia mechanism 68 may malfunction, it is also possible to use the rotary damper 55 to absorb the impact in the event of a side collision and prevent the outer handle 17 from rotating toward the full stroke position.

[0055] A light 75 that illuminates the operating part 18a of the outer handle 17 when in the pop-up position is attached to the support case 22 or the outer handle 17, and in this embodiment, a light 75 that illuminates the operating part 18a of the outer handle 17 when in the pop-up position is attached to the handle support part 22b of the support case 22.

[0056] This light 75 comprises a light case 77 formed from a translucent synthetic resin and fastened to the handle support portion 22b by, for example, a pair of screw members 76, 76, and an LED 79 provided on a substrate 78 inserted and supported within the light case 77.

[0057] The light case 77 is formed in a box shape having an insertion hole 80 that is open on the side opposite the outer panel 16, and the board 78 inserted into the insertion hole 80 is held by a grommet 81 that fits into the insertion hole 80. The light emitting diode 79 is provided on the underside of the end of the board 78 on the outer panel 16 side, and the open end of the insertion hole 80 is filled with potting material 83 for sealing the connection part of a conductor 86 to the board 78.

[0058] A through hole 82 that opens into the accommodating recess 26 at a position corresponding to the operating part 18a of the outer handle 17 is provided in the upper part of the handle support part 22b so as to be located below the light-emitting diode 79, and a light-guiding part 77a that guides light from the light-emitting diode 79 is formed integrally with the light case 77 and is fitted into the through hole 82, and a seal member 84 that endlessly surrounds the through hole 82 is interposed between the light case 77 and the handle support part 22b.

[0059] A case cover 85 is attached to the support case 22, which covers a part of the actuator 39, the torsion spring 44, the handle lever 50, the rotary damper 55, the inertia mechanism 68, etc. that are arranged in the support case 22. This case cover 85 makes it possible to prevent the adverse effects of water or dust that has entered the side door 15 through the gap between the outer panel 16 and the window glass from affecting the actuator 39, the torsion spring 44, the handle lever 50, the rotary damper 55, the inertia mechanism 68, etc.

[0060] Next, the operation of the first embodiment will be described. An actuator 39 is attached to a support case 22 attached to the outer panel 16. The actuator 39 is configured to include a drive lever 40 that can rotate between an initial position and an actuated position, and an electric motor 41 that, when energized, drives the drive lever 40 to rotate from the initial position to the actuated position, and allows the drive lever 40 to return from the actuated position to the initial position in a non-energized state when the drive lever 40 is in the actuated position. The actuator 39 is configured to drive the outer handle 17, which has a manually operable operating unit 18a at one end thereof, to a pop-up position in which the operating unit 18a protrudes outward from the outer panel 16 of the side door 15. The actuator 39 is configured to include a drive lever 40 that can rotate between an initial position and an actuated position, and an electric motor 41 that, when energized, drives the drive lever 40 to rotate from the initial position to the actuated position, and allows the drive lever 40 to return from the actuated position to the initial position in a non-energized state when the drive lever 40 is in the actuated position. The actuator 39 is configured to drive the outer handle 17, which is urged to rotate toward the stored position stored in the support case 22, to a full stroke position in response to manual operation from the pop-up position. A torsion spring 44 that mechanically holds the drive lever 40 in the operating position is attached to the support case 22, and a handle lever 50 that is pressed by the drive lever 40 to rotate in response to the rotation of the drive lever 40 from the initial position to the operating position, and is linked and connected to the outer handle 17 so as to rotate the outer handle 17 from the stored position to the pop-up position, is supported by the support case 22 so as to rotate together with the outer handle 17 while leaving the drive lever 40 at the operating position, when the outer handle 17 rotates from the pop-up position to the full stroke position, and a release lever 58 that rotates in response to the rotation of the handle lever 50 accompanying manual operation of the outer handle 17 from the pop-up position to the full stroke position, to release the hold by the holding means and forcibly return the drive lever 40 to the initial position, is supported by the support case 22.

[0061] Therefore, when the handle lever 50 is rotated by the drive lever 40 of the actuator 39 and the outer handle 17 is rotated from the stored position to the pop-up position, the drive lever 40 is held in the actuated position by the torsion spring 44, and in this state, even if the electric motor 41 of the actuator 39 is de-energized, the pop-up position of the outer handle 17 is maintained. Furthermore, the electric motor 41 of the actuator 39 allows the drive lever 40, which is in the operating position, to return to the initial position by the action of an external force when the holding by the torsion spring 44 is released, and when the vehicle user rotates the outer handle 17 from the pop-up position to the full stroke position to open the side door 15, the release lever 58 rotates by the handle lever 50 which rotates together with the outer handle 17, and this release lever 58 releases the holding of the drive lever 40 by the torsion spring 44 and forcibly returns the drive lever 40 to the initial position, so that even if the electric motor 41 of the actuator 39 malfunctions, the outer handle 17, which has been biased toward the stored position, can return to the stored position by releasing the hand from the outer handle 17. Therefore, even if the electric motor 41 on the actuator 39 side malfunctions, it is possible to return the outer handle 17 to the stored position, and power consumption for holding the outer handle 17 in the pop-up position can be reduced.

[0062] In addition, a light 75 that illuminates the operating part 18a of the outer handle 17 when it is in the pop-up position is attached to the support case 22, so that the operating part 18a of the outer handle 17 can be easily seen even in dark conditions such as at night.

[0063] Next, a modified example of the first embodiment will be described with reference to Figures 11 and 12. In this modified example, parts corresponding to those in the first embodiment are simply shown with the same reference numerals, and detailed description thereof will be omitted.

[0064] First, in FIG. 11, a support case 88 has a support plate portion 88a and a handle support portion 88b that rotatably supports the outer handle 17 (see the first embodiment), and an actuator 89 is attached to the lower portion of the support plate portion 88a.

[0065] The actuator 89 is configured to include a drive lever 90 that is rotatable between an initial position shown in FIG. 11 and an actuated position shown in FIG. 12, and an electric motor 41 that, when energized, drives the drive lever 90 to rotate from the initial position to the actuated position and, in a non-energized state when the drive lever 90 is in the actuated position, allows the drive lever 90 to return from the actuated position to the initial position, and a base of the drive lever 90 is fixed to a rotating shaft 43 that is actuated to rotate by the electric motor 41.

[0066] Referring also to Figure 13, the support plate portion 88a of the support case 88 is provided with a retaining means 91 for mechanically retaining the drive lever 90 in the operating position, the retaining means 91 being positioned between the drive lever 90 and the support plate portion 88a.

[0067] This holding means 91 includes a guide tube 92 fixed to the support plate portion 88a so as to extend radially from the rotating shaft 43, a moving piece 93 slidably fitted into the guide tube 92, and a spring 94 compressed between the guide tube 92 and the moving piece 93.

[0068] The guide tube 92 is configured to have a first end wall portion 92a at one end portion on the rotating shaft 43 side and a second end wall portion 92b at the other end portion remote from the rotating shaft 43, and the spring 94 is provided between the first end wall portion 92a and the moving piece 93. A through hole 95 is formed in the center of the second end wall portion 92b, through which an engaging protrusion 93a provided integrally with the moving piece 93 movably passes.

[0069] On the other hand, the surface of the drive lever 90 facing the support plate portion 88a is integrally provided with an engagement recess 96 with which the engagement protrusion 93a of the holding means 91 can engage, and first and second peaks 97, 98 which are arranged on both sides of the engagement recess 96 and bulge toward the guide tube 92. When the drive lever 90 is in the initial position, as shown in Figure 13, the engagement protrusion 93a is in a position spaced apart from the engagement recess 96 and the first and second peaks 97, 98. When the drive lever 90 rotates from the initial position to the operating position shown by the dotted line in Figure 13, the engagement protrusion 93a climbs over the first peak 97 and engages with the engagement recess 96, thereby mechanically holding the drive lever 90 in the operating position.

[0070] A handle lever 100 is rotatably supported on the support plate portion 88a. The handle lever 100 integrally comprises a lever base 100a rotatably supported by an axis 101 provided on the support plate portion 88a, an outer handle side connecting arm 100b extending upward from the lever base 100a, a drive lever side connecting arm 100c extending diagonally downward from the lever base 100a towards the drive lever 90, and a sector gear portion 100d protruding from the lever base 100a in the direction opposite to the actuator 89.

[0071] A connecting hole 1022 extending long in the longitudinal direction is formed in the outer handle side connecting arm portion 100b, and the tip end of the connecting protrusion 18c of the outer handle 17 is inserted into and connected to the connecting hole 102, so that the handle lever 100 is interlocked and connected to the outer handle 17. Moreover, the handle lever 100 is biased by a return spring (not shown) in a direction returning the outer handle 17 to the stored position.

[0072] A contact protrusion 100e that abuts against the drive lever 90 in the initial position from the operating position side is integrally formed at the tip of the drive lever side connecting arm 100c so as to protrude toward the support plate portion 88a. As the drive lever 90 rotates from the initial position to the operating position, the contact protrusion 100e is pressed by the drive lever 90, and the handle lever 100 rotates to drive the outer handle 17 from the stored position to the pop-up position.

[0073] Furthermore, when the outer handle 17 rotates from the pop-up position to the full stroke position, the drive lever 90 is held by the holding means 91, so the handle lever 100 rotates together with the outer handle 17, leaving the drive lever 90 in the operating position.

[0074] Moreover, the sector gear portion 100e is meshed with a gear 56 of a rotary damper 55 fastened to the support plate portion 88a.

[0075] In addition, a release lever 103 is rotatably supported on the support plate portion 88a of the support case 88. The release lever 103 rotates in response to the rotation of the handle lever 100 accompanying manual operation of the outer handle 17 from the pop-up position to the full stroke position to release the hold by the holding means 91 and forcibly return the drive lever 90 to the initial position.

[0076] This release lever 103 is integrally formed with a lever base 103a which is rotatably supported on the support plate portion 88a via a shaft 104 which is attached to the support plate portion 88a so as to be positioned below the handle lever 100, a drive lever side arm 103b which extends from the lever base 103a towards the drive lever 90, and a latch mechanism side arm 103c which is connected to the lever base 103a so as to protrude toward the side opposite the mounting portion of the actuator 89.

[0077] A pressure receiving portion 103d is integrally provided on the latch mechanism side arm 103c of the release lever 103 so as to face the drive lever side connecting arm 100c of the handle lever 100, and a handle side cap 105 made of an elastic material is attached to this pressure receiving portion 103d. On the other hand, a pressing arm 100f is integrally provided on the drive lever side connecting arm 100c of the handle lever 100, and the handle lever 100 rotates together with the outer handle 17 when the outer handle 17 rotates from the stored position to the pop-up position, so that the pressing arm 100f presses the handle side cap 105, i.e., the pressure receiving portion 103d, and the release lever 103 rotates to the position shown in FIG.

[0078] The rotation of the release lever 103 is transmitted to a latch mechanism 62 disposed on the side door 15 via a transmission rod 63 having one end connected to the tip of the latch mechanism side arm portion 103c.

[0079] A drive lever side cap 106 made of an elastic material is attached to the tip of the drive lever 90 when the drive lever 90 is rotated from the initial position to the operating position, and as the release lever 103 rotates in response to the rotation of the outer handle 17 from the pop-up position to the full stroke position, the drive lever 90 is pushed by the drive lever side arm 103b of the release lever 103, and the first hill 68 pushes the moving piece 93, forcing the drive lever 90 to rotate so that the engagement protrusion 93a overcomes the first hill 68, and the drive lever 90 returns to its initial position.

[0080] The release lever 103 is urged by a spring (not shown) to rotate in a direction in which the handle side cap 105 comes into contact with the pressing arm portion 100f of the handle lever 100.

[0081] A pressing portion 103e that is inserted into an opening 107 formed in the support plate portion 88a is integrally provided on the latch mechanism side arm portion 103c of the release lever 103, and a switch 108 that changes its switching mode when pressed by the pressing portion 103e in response to the rotation of the release lever 103 accompanying manual operation of the outer handle 17 from the pop-up position to the full stroke position is attached to the surface of the support plate portion 88a opposite to the side on which the release lever 103 is disposed. When the switching mode changes as a result of being pressed by the pressing portion 103e, this switch 108 outputs a signal to open the window of the side door 15 (see the first embodiment) to allow outside air to flow into the vehicle interior.

[0082] An inertia mechanism 68 is provided in the handle support portion 88b of the support case 88 to prevent the outer handle 17 from rotating to the full stroke position due to the impact of a side collision with the side door 15 when the outer handle 17 is in the stored position, causing the side door 15 to open undesirably, and a light 109 is attached to illuminate the operating portion 18a (see first embodiment) of the outer handle 17 when it is in the pop-up position.

[0083] According to the modified example of the first embodiment described above, it is possible to obtain the same effects as those of the first embodiment, and in addition, in response to the rotation of the release lever 103 accompanying the manual operation of the outer handle 17 from the pop-up position to the full stroke position, the window of the side door 15 is opened to allow outside air to flow into the vehicle interior, thereby reducing the air pressure difference between the inside and outside of the side door 15 and facilitating the opening operation of the side door 15.

[0084] Next, a second embodiment of the present invention will be described with reference to Figures 15 to 22. In the description of the second embodiment, front, rear, left and right correspond to the front, rear, left and right of the vehicle to which the side door 15 is attached.

[0085] First, in Fig. 15, an outer handle 117 formed long in the vehicle front-rear direction is disposed on an outer panel 16 of a side door 15 of a passenger vehicle facing a handle hole 16h with a decorative border on the outer panel 16. The outer handle 117 can be moved among a stored position in which the outer surface of the outer panel 16 and the outer surface of the outer handle 117 are flush with each other as shown in Fig. 15(a), a pop-up position in which a main portion including an operating part 117a for manual operation protrudes laterally from the outer surface of the outer panel 16 as shown in Fig. 15(b), and a full stroke position in which the outer handle 117 is rotated further outward from the pop-up position by gripping and operating the operating part 117a as shown in Fig. 15(c).

[0086] 16, the outer handle 117 is composed of a handle body 118 that extends long in the front-rear direction of the vehicle and has a recess 120 facing the inside of the outer panel 16, and a handle base 119 that is long in the front-rear direction and is detachably connected to the handle body 118 from the outer panel 16 side so as to close the recess 120. The handle body 118 and the handle base 119 may be connected to each other by engaging / disengaging means (not shown) provided therebetween (for example, an elastic engaging claw and an engaging hole that can be engaged and disengaged therewith), or may be connected by a plurality of bolts (not shown).

[0087] The portion of outer handle 117 that the vehicle user can grip with the hand when it is in the pop-up position (i.e., the portion where the fingers of the hand rest when performing a full stroke operation from the pop-up position) serves as operating part 117a. More specifically, a portion of outer handle 117 that is located midway between front and rear bulges 119f, 119r (described later) and extends in the front-rear direction, and a portion rearward of rear bulge 119r function as operating part 117a.

[0088] A touch sensor 121a for indicating an intention to lock / unlock the side door 15 and a board 121b incorporating an antenna and an electronic control device are attached to the inner surface of the handle base 119 (i.e., the concave surface facing the handle body 118), and the touch sensor 121a is configured, for example, as a non-contact sensor capable of detecting a change in capacitance. Also, a shallow recess 118o is recessed in the outer surface near the rear end of the handle body 118 at a position corresponding to the touch sensor 121a, and when the vehicle user touches this recess 118o, it becomes possible to lock / unlock the latch mechanism 62 and pop up the outer handle 117 substantially simultaneously, as described below.

[0089] For example, when a vehicle user within a specified range of the vehicle has been confirmed by substrate 121b to be a legitimate user through communication between the vehicle and a portable device carried by the user, and the user touches recess 118o, touch sensor 121a outputs a detection signal to substrate 121b based on a change in the surrounding capacitance, and substrate 121b responds by operating actuator 139 to extend outer handle 117, which is in the stored position, to the pop-up position.

[0090] A pair of front and rear bulges 119f, 119r are integrally formed on the back surface of the handle base 119 (i.e., the surface opposite to the handle body 118) and protrude inwardly from the door panel 16. Each of these bulges 119f, 119r is formed in a rectangular tube shape that tapers slightly away from the handle body 118. Front and rear covers Cf, Cr that cover the upper surfaces of the front and rear bulges 119f, 119r are detachably attached to the front and rear bulges 119f, 119r, respectively, and a fixing structure of the front and rear covers Cf, Cr to the front and rear bulges 119f, 119r will be described later.

[0091] Meanwhile, the outer handle 117 is attached to the support case 122 fixed to the outer panel 16 so that it can take the above-mentioned stored position (see FIG. 15(a)), pop-up position (see FIG. 15(b)), and full stroke position (see FIG. 15(c)). That is, between the outer handle 117 and the support case 122, there are interposed a drive device D capable of driving the outer handle 117 from the stored position to the pop-up position, and a guide device G that guides the manual rotation operation of the outer handle 117 from the pop-up position to the full stroke position.

[0092] The support case 122 is divided into two parts, upper and lower, by a pair of upper and lower case halves 122a, 122b whose respective opening ends are detachably connected to each other via connecting means (e.g., bolts) not shown, and only the lower case half 122b is shown in Figures 17 and 18.

[0093] The drive device D comprises a support case 122, an actuator 139 (e.g., an electric motor) having a rearward-facing output bar 139b and stored and fixed to the front part of the support case 122, a first arm A1 whose base end A1b is supported so as to be swingable left and right about a first axis J1 installed between the upper and lower case halves 122a, 122b, a second arm A2 whose base end (the rear end of the upper and lower connecting rods 203, 204 described later) is pivotally connected to the tip of the rear bulge 119r of the handle base 119 via a second axis J2 so as to be capable of relative rotation, and an interlocking mechanism I which interlocks the first and second arms A1, A2 with the output movement (rearward movement) of the output bar 139b to extend the outer handle 117 from the stored position to the pop-up position.

[0094] A tip end portion A1a of the first arm A1 is pivotally connected to a base portion of the front bulge portion 119f of the handle base 119 via a third axis J3 as a rotation support shaft so as to be relatively rotatable. A first return spring S1 (e.g., a torsion coil spring) is interposed between the first arm A1 and the support case 122 to constantly bias the first arm A1 inward (toward the vehicle interior), i.e., toward the stored position.

[0095] 18 and 19(b), the second arm A2 is composed of a rectangular frame formed by integrally connecting front and rear connecting shafts 201, 202 and upper and lower connecting rods 203, 204, each of which extends in the vertical direction. The front connecting shaft 201 is formed in a shaft shape, and its middle part is slidably fitted into and supported by a guide member 210 (specifically, a guide hole H provided in the member 210) fixed to the bottom part of the support case 122. The guide hole H has a front half straight hole part Hs extending in the front-rear direction, and a rear half curved hole part Hr connected to the rear end of the straight hole part Hs and curved rearward and outward.

[0096] 18, the interlocking mechanism I includes a transmission frame 170 extending in the front-rear direction so as to link the tip of the output bar 139b of the actuator 139 and the front connecting shaft 201 of the second arm A2, and a cam surface 180 formed on the inner surface of the middle part of the first arm A1 and inclined forward and outward. This cam surface 180 faces the output bar 139b across a front transmission shaft 171 of the transmission frame 170, which will be described next, and the cam surface 180 and the front transmission shaft 171 in sliding contact therewith form a cam mechanism that converts the rearward movement of the output bar 139b into an outward swing around the first shaft J1 of the first arm A1.

[0097] As is clear from Figures 18 and 19(a), the transmission frame 170 is composed of a rectangular frame that is long in the front-to-rear direction and is formed by pivotally connecting adjacent ends of front and rear transmission shafts 171, 172, each extending in the vertical direction, and upper and lower links 173, 174, each located outside the support case 122 and extending long in the front-to-rear direction.

[0098] Both upper and lower ends of the front transmission shaft 171 extend outside the support case 122 through front openings (not shown) of the upper and lower case halves 122a and 122b, and the front ends of the upper and lower links 173 and 174 are detachably fitted and connected to the extended ends. A pair of upper and lower guide projections 171t are integrally provided on the outer periphery of a middle portion near the upper and lower ends of the front transmission shaft 171, which engage with and are supported so as to be movable (slidable) relative to guide rails 176 provided on the inner walls of the upper and lower case halves 122a and 122b only in the front-rear direction.

[0099] On the other hand, both upper and lower ends of the rear transmission shaft 172 extend outside the support case 122 through rear openings (not shown) of the upper and lower case halves 122a and 122b, and the rear ends of the upper and lower links 173 and 174 are detachably fitted and connected to the extended ends. Also, the middle part of the rear transmission shaft 172 passes through and is supported by the rear openings of the upper and lower case halves 122a and 122b and the guide hole H (particularly the straight hole portion Hs) of the aforementioned guide member 210 so as to be slidable back and forth.

[0100] As is clear from Figures 17 and 18, when the outer handle 117 is in the stored position or before the pop-up position, the outer periphery of the middle portion of the rear transmission shaft 172 is in a state in which it is able to come into and out of contact with the front connecting shaft 201 of the second arm A2 within the straight hole portion Hs, and in this state the driving force of the actuator 139 can be transmitted to the front connecting shaft 201 via the transmission frame 170.

[0101] Therefore, for example, when the actuator 139 is activated when the outer handle 117 is in the stored position, and the driving force of the actuator 139 moves the transmission frame 170 (and therefore the rear transmission shaft 172 and the front connecting shaft 201) rearward, the second arm A2 swings outward around the axis of the front connecting shaft 201, and at the same time, the front transmission shaft 171 of the transmission frame 170 slides against and presses against the cam surface 180, causing the first arm A1 to swing outward around the first axis J1.

[0102] Then, due to the outward swing of the first and second arms A1, A2 described above (see the white arrow in Figure 17 (b)), the outer handle 117 is extended and held in the pop-up position while keeping its outer surface approximately parallel to the outer panel 16.

[0103] Furthermore, when the outer handle 117 is in the pop-up position, if the vehicle user attempts to rotate the outer handle 117 to the full stroke position, for example by placing their hand on the operating part 117a of the outer handle 117, the front connecting shaft 201 is guided and slid outward within the curved hole portion Hr so as to move away from the rear transmission shaft 172, and at the same time, the outer handle 117 swings outward around the third shaft J3 (see the white arrow in Figure 17(c)) and moves to the full stroke position.

[0104] Thus, the guide hole H with the curved hole portion Hr, the second arm A2, and the third shaft J3 cooperate with each other to configure the guide device G.

[0105] 18, front and rear lever shafts Jf, Jr are installed at a distance from each other in the front-rear direction between the upper and lower case halves 122a, 122b around the guide hole H of the guide member 210. Among them, the rear lever shaft Jr rotatably supports a relay lever 150 having integrally a first arm 150a which can be engaged with and releasably attached to the outer periphery (particularly the rear side) of the middle part of the front connecting shaft 201 of the second arm A2, and a second arm 150b which can be engaged with and disengaged from a locking projection 158a at the rear of a release lever 158 which will be described next.

[0106] In particular, the first arm 150a is inserted into the internal space of the second arm A2 so as to be able to engage with the front connecting shaft 201 of the second arm A2. A second return spring S2 made of a torsion coil spring is interposed between the relay lever 150 and the guide member 210, and this second return spring S2 constantly biases the relay lever 150 in the direction in which it engages with the second arm A2 (specifically, the front connecting shaft 201) of the first arm 150a, that is, in the counterclockwise direction in FIG.

[0107] A release lever 158 is rotatably supported on the front lever shaft Jf, and a latch mechanism 62 of the side door 15 is interlocked with the release lever 158 via a transmission rod 163. Since the latch mechanism 62 of the second embodiment has the same structure and function as the latch mechanism 62 of the first embodiment, it is given the same reference numeral and further functional description will be omitted.

[0108] In this manner, in the second embodiment, the transmission rod 163 connected to the latch mechanism 62 is linked to the relay lever 150 via the release lever 158. However, depending on the arrangement of the latch mechanism 62, the release lever 158 may be omitted and the transmission rod 163' connected to the latch mechanism 62 may be directly connected to the second arm 150b of the relay lever 150, as exemplified by the two-dot chain line in Figure 18.

[0109] In the second embodiment, the latch mechanism 62 is in an unlocked state in response to the touch sensor 121a and the substrate 121b in the outer handle 117 detecting that a regular vehicle user has touched the outer handle 117 (specifically, the recess 118o) while in the locked state. At substantially the same time, the actuator 139 is actuated to drive the first arm A1 to swing outward about the first axis J1 and the second arm A2 to swing outward about the axis of the front connecting shaft 201, thereby displacing the outer handle 117 outward from the stored position to the pop-up position (see FIG. 17(b)). In this case, when the outer handle 117 is displaced to the pop-up position, the first arm A1 engages with the inner wall of the support case 122, thereby restricting further outward swing.

[0110] In this state, when the vehicle user places his / her hand on the operating portion 117a of the outer handle 117 to pull out the outer handle 117 from the pop-up position to the full stroke position, the operating force causes the outer handle 117 to swing outward about the third axis J3 and move to the full stroke position. During this time, the front connecting shaft 201 of the second arm A2 is slidably guided by the curved hole portion Hr of the guide hole H and moves outward, so that the second arm A2 swings upright about the axis of the front connecting shaft 201 while being displaced further outward than when in the pop-up position.

[0111] 17(c), the first arm 150a of the relay lever 150 is engaged with the front connecting shaft 201, and so the relay lever 150 rotates clockwise (FIG. 17) around the rear lever shaft Jr in conjunction with the outward movement of the front connecting shaft 201 along the curved hole Hr. Accordingly, the second arm 150b of the relay lever 150 engages with the locking protrusion 158a of the release lever 158, causing the release lever 158 to rotate counterclockwise (FIG. 17) around the front lever shaft Jf, and operates the transmission rod 163 in the unlatch direction of the latch mechanism 62.

[0112] Thus, the manual operating force applied to the outer handle 117 from the pop-up position to the full stroke position is transmitted sequentially through the second arm A2, the relay lever 150, the release lever 158 and the transmission rod 163 to the latch mechanism 62, causing the latch mechanism 62 to enter an unlatched state, making it possible to open the side door 15.

[0113] As mentioned above, the front and rear covers Cf, Cr are removably attached to the upper surfaces of the pair of front and rear bulges 119f, 119r protruding from the handle base 119, and the fixing structure of the front and rear covers Cf, Cr to the front and rear bulges 119f, 119r will be described below with reference to Figures 16 to 22.

[0114] The front and rear covers Cf, Cr each have a trapezoidal flat cover body Cfm, Crm placed on and overlapping the flat upper surface of the front and rear bulging portions 119f, 119r, and a pair of front and rear support pieces Cff, Cfr, Crf, Crr that are integrally connected to the front and rear end edges of the cover body Cfm, Crm and cover the upper front and rear side surfaces of the front and rear bulging portions 119f, 119r, respectively. The pair of front and rear support pieces Cff, Cfr, Crf, Crr smoothly curve and protrude downward from the front and rear end edges of the cover body Cfm, Crm, and engage with the corresponding front and rear bulging portions 119f, 119r so as to sandwich their upper portions from the front and rear.

[0115] 20 and 21, the third shaft J3 is inserted upward from below into the base of the front bulging portion 119f, and the third shaft J3 has an outward flange portion 301 at the lower end of its outer periphery and an annular engagement groove 302 at the upper end of its outer periphery. The outward flange portion 301 engages with the lower wall of the front bulging portion 119f and determines the lift limit of the third shaft J3 relative to the front bulging portion 119f.

[0116] 20 and 21, a semi-cylindrical engaging portion 303 that engages with the engaging groove 302 to prevent the third shaft J3 from slipping out of the outer handle 117 (specifically, the front bulging portion 119f) is integrally provided on the lower surface of the cover body Cfm of the front cover Cf at an end closer to the handle body 118. A pair of front and rear engaging projections 304, 305 and a single engaging claw 306 between the engaging projections 304, 305 are integrally provided on the lower surface of the cover body Cfm at an end opposite to the handle body 118. Furthermore, an elongated recessed surface 310 that slidably receives the engaging portion 303 is provided on the upper surface of the cover body Cfm.

[0117] In the process of assembling the front cover Cf, the front cover Cf is placed on the upper surface of the front bulge 119f and slid toward the handle main body 118, so that, as is clear from FIG. 21, the front end edge portion Cmfe of the cover main body Cfm in the sliding direction engages with the side edge 118e of the handle main body 118, and the engagement portion 303 engages with the engagement groove 302 of the third shaft J3 serving as a pivot shaft.

[0118] At approximately the same time, a pair of front and rear engaging protrusions 304, 305 are engaged with a pair of front and rear notched engaging holes 307, 308 provided in the upper wall of the front bulge 119f, respectively, and the engaging claw 306 is engaged with a claw engaging hole 309 provided in the upper wall of the front bulge 119f.

[0119] Thus, the front cover Cf is releasably engaged with the upper surface of the front bulge 119f, and the third shaft J3 is prevented from coming off from the outer handle 117 by the front cover Cf (specifically, the engaging portion 303).

[0120] 16 and 22, a plurality of inward locking projections 311, 312 are respectively provided on opposing surfaces of a pair of front and rear support pieces Crf, Crr in the rear cover Cr. Corresponding to these locking projections 311, 312, engagement holes 313, 314 that can be engaged with and disengaged from the locking projections 311, 312 are provided on the upper portions of the front and rear side walls of the rear bulging portion 119r.

[0121] Therefore, when the rear cover Cr is pressed down so as to cover the rear bulging portion 119r from above, the front and rear support pieces Crf, Crr are elastically deformed so as to spread apart, and the locking projections 311, 312 can be locked into the engagement holes 313, 314, respectively. By this locking, the rear cover Cr is detachably fixed to the rear bulging portion 119r.

[0122] As described above, in the second embodiment, the front and rear covers Cf, Cr are detachably attached to the upper surfaces of the front and rear bulges 119f, 119r of the handle body 118 of the outer handle 117 and the handle base 119, which are exposed to the outside in the pop-up position, to cover at least a part of the upper surfaces (the entire surface in the illustrated example). As a result, even if the front and rear covers Cf, Cr are not provided with a light reflecting surface R described below, they can be colored differently from the paint color of the outer surface of the outer handle 117 or plated to provide variety, and can also be easily replaced to easily suit the preferences of the vehicle user.

[0123] Meanwhile, as is clear from Figures 15, 17 and 18, the top surface of the outer handle 117 exposed to the outside in the pop-up position, as well as the rear and front surfaces, are provided with a light reflecting surface R (shown by cross-hatching in Figures 15, 17 and 18 to clearly show the reflecting surface area) that reflects and shines external light (e.g., other vehicle's lamps, city lights, etc.). However, in Figures 16 and 20 to 22, the above-mentioned hatching of the light reflecting surface R that is actually provided has been omitted in order to clearly show the relative structure of the outer handle 117, particularly the handle body 118 and the handle base 119.

[0124] Thus, the light reflecting surface R is provided on the outer handle 117, for example, by attaching a light reflecting sheet or tape or by painting light reflecting paint on the upper, rear and front surfaces of the handle body 18 and the upper, rear and front surfaces of the front and rear covers Cf, Cr.

[0125] In this way, also in the second embodiment, the light reflecting surface R is provided on at least a part of the rear surface and the top surface of the outer handle 117 at the rear of the vehicle among the exposed surfaces that are exposed to the outside in the pop-up position (in the illustrated example, the entire top surface, rear surface, and front surface). As a result, the second embodiment can achieve the same effect as that achieved by the light reflecting surface R in the first embodiment. That is, even if the outer handle 117 protrudes outward to a certain extent from the outer surface of the outer panel 16 in the pop-up position, people moving around the side door 15 or the driver of the vehicle in a situation where visibility is reduced, such as at night, can easily notice the presence of the outer handle 117 in the pop-up position by the light reflected from the light reflecting surface R, and therefore contact with the outer handle 117 can be effectively avoided.

[0126] Furthermore, in the second embodiment, light reflecting surfaces R are provided not only on the top, rear, and front of the handle body 118, but also on the top, rear, and front of the front and rear covers Cf, Cr. This has the advantage that the variety of light reflecting surfaces R to be provided on the outer handle 117 can be easily and inexpensively increased by providing special light reflecting surfaces R on the front and rear covers Cf, Cr.

[0127] The above describes the embodiment of the present invention and its modified examples. However, the present invention is not limited to the above embodiment, and various design changes can be made without departing from the present invention described in the claims.

[0128] For example, in the first and second embodiments, an electric motor is used as the electric drive source for the actuators 39, 89, 139 used to drive the outer handle 17, 117 from the stored position to the pop-up position, but the electric drive source for the actuator is not limited to the embodiments, and electromagnetic drive means other than an electric motor (e.g., a solenoid) may be used.

[0129] In the second embodiment, an example was given of a vehicle user carrying an authentication portable device touching recess 118o of outer handle 117 with their hand to lock or unlock latch mechanism 62 and pop up outer handle 117 approximately simultaneously, but the locking / unlocking operation and the pop-up operation may also be performed by separate operating buttons.

[0130] In the first and second embodiments, the light reflecting surface R is provided on the top and rear surfaces of the outer handle 17, 117 that are exposed to the outside in the pop-up position (and also on the front surface in the second embodiment), but the light reflecting surface R may be provided only on either the top or rear surface (for example, the rear surface) of the outer handle 17, 117 that is exposed to the outside in the pop-up position. Alternatively, the light reflecting surface R may be provided only on at least a part of the top surface and / or at least a part of the rear surface of the outer handle 17, 117 that is exposed to the outside in the pop-up position.

[0131] In particular, in the second embodiment, the light reflecting surface R is provided not only on the upper surface, rear surface, and front surface of the handle body 118 of the outer handle 117, but also on the upper surface, rear surface, and front surface of each of the front and rear covers Cf, Cr that cover the upper surface of the handle base 119 (particularly the front and rear bulging portions 119f, 119r), but in the present invention, the light reflecting surface R may be provided only on either the upper surface or the rear surface of each of the front and rear covers Cf, Cr (for example, the rear surface). Alternatively, the light reflecting surface R may be provided only on either the front cover Cf or the rear cover Cr (for example, the rear cover Cr), or the provision of the light reflecting surface R on the front and rear covers Cf, Cr may be omitted.

[0132] In the first and second embodiments, the light reflecting surfaces R provided on each portion of the outer handle 17, 117 reflect only external light, but a lighting device (e.g., an LED) that illuminates the light reflecting surfaces R from the outside or inside may be attached to the outer handle 17, 117. In that case, the visibility of the light reflecting surfaces R can be further improved by the light from the lighting device. [Explanation of symbols]

[0133] Cf... front cover as cover, Cr... rear cover as cover, J3... third axis as pivot axis, R... light reflecting surface, 15... side door as door, 16... outer panel, 17, 117... outer handle, 18a, 117a... operation unit, 22, 88, 122... support case, 39, 89, 139... actuator

Claims

1. An outer handle (17, 117) having a manually operable operating unit (18a, 117a) is attached to a support case (22, 88, 122) fixed to an outer panel (16) of a door (15) so as to be movable between a stored position in which an outer surface of the outer handle (17, 117) is substantially flush with an outer surface of the outer panel (16) and a pop-up position in which the operating unit (18a, 117a) protrudes outward from the outer panel (16), and an actuator (39, 89, 139) is provided to drive the outer handle (17, 117) from the stored position to the pop-up position, and the outer handle (17, 117) is attached to the support case (22, 88, 122) so as to be manually operated from the pop-up position to a full stroke position further outward, An outer handle device for a vehicle door, characterized in that a light reflecting surface (R) is provided on at least a portion of the rear surface of at least the end portion of the outer handle (17, 117) on the rear side of the vehicle, among the exposed surfaces exposed to the outside in the pop-up position.

2. An outer handle (17, 117) having a manually operable operating unit (18a, 117a) is attached to a support case (22, 88, 122) fixed to an outer panel (16) of a door (15) so as to be movable between a stored position in which an outer surface of the outer handle (17, 117) is substantially flush with an outer surface of the outer panel (16) and a pop-up position in which the operating unit (18a, 117a) protrudes outward from the outer panel (16), and an actuator (39, 89, 139) is provided to drive the outer handle (17, 117) from the stored position to the pop-up position, and the outer handle (17, 117) is attached to the support case (22, 88, 122) so as to be manually operated from the pop-up position to a full stroke position further outward, An outer handle device for a vehicle door, characterized in that a light reflecting surface (R) is provided on at least a portion of an upper surface of the outer handle (17, 117) that is exposed to the outside in the pop-up position.

3. The vehicle door outer handle device according to claim 1 or 2, characterized in that at least one cover (Cf, Cr) covering at least a portion of the upper surface of the outer handle (117) exposed to the outside in the pop-up position is removably attached, and a light-reflecting surface (R) is provided on at least a rear surface of the cover (Cf, Cr).

4. 3. The vehicle door outer handle device according to claim 1, wherein a pivot shaft (J3) is inserted into the outer handle (117) to guide and support the rotation of the outer handle (117) when the outer handle (117) is rotated from the pop-up position to the full stroke position, and an engagement portion (303) is provided on the cover (Cf) to engage with the pivot shaft (J3) and prevent the pivot shaft (J3) from coming off the outer handle (117).

5. 3. The vehicle door outer handle device according to claim 1, wherein the outer handle is provided with a lighting device for illuminating the light reflecting surface.

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