Vehicle door handle assembly

Abstract

To provide a handle structure having functionality and a smooth appearance when a movable door handle is in its deployed position.SOLUTION: A bracket inside a door panel includes a first lever having a first hole configured to receive a first shaft and a second lever 7b having a second hole configured to receive a second shaft 17. A movable handle flush with the outside of the door panel includes a first sleeve having a first recess configured to receive the first lever and the first shaft and a second sleeve 6b having a second recess 9 configured to receive the second lever 7b and the second shaft 17. The second recess 9 is a rectangular recess and includes an upper rectangular opening 11 having a narrower cross section than the rectangular recess 9. The second shaft 17 is disposed at a first end portion 17a and includes a non-circular flange configured to be introduced into the upper rectangular opening 11 and to be axially restrained by the upper wall of the second recess 9.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to the field of vehicle door handles that control the opening and closing of vehicle doors, and more particularly to a retractable vehicle door handle that is configured to move between a stowed position in which the movable handle is flush with the outside of the door panel to reduce drag when the vehicle is moving, and a deployed position in which a user can grasp the movable handle to open the vehicle door. [Background technology]

[0002] A vehicle door handle assembly typically includes a bracket secured to the inside of a vehicle door panel and a retractable or movable door handle secured to the bracket. The movable door handle is configured to move between a retracted position, where it is flush with the outside of the door panel, and an extended position, where it can be grasped by a user. When the user pulls the movable door handle, it rotates and opens the vehicle door.

[0003] In some cases, the movable door handle is fixed to a bracket, and then the bracket is fixed to the door panel, but in other cases, for technical reasons, the bracket is fixed to the door panel, and then the movable door handle is fixed to the bracket. The movable door handle includes a handle structure that includes the technical parts of the handle, such as the means for fixing the handle to the bracket, and a cover for providing the desired aesthetics. Usually, the cover is placed last, as it is used to cover the fixing means of the door handle. Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the case of a movable door handle that incorporates electronic components, a cover may need to be assembled to the door handle structure before the handle structure is fixed to the bracket in order to seal the electronic components inside the door handle and ensure electrical insulation. Because this sealing cannot be performed on a vehicle assembly line, the door handle structure and the cover must be fastened to each other before being fixed to the bracket. In such cases, it becomes difficult to conceal the technical components of the handle structure while ensuring normal operation of the movable door handle.

[0005] The object of the present invention is therefore to provide a solution that allows the entire door handle, including the handle structure and cover, to be fixed to a bracket while providing the user with similar functionality and a smooth appearance, especially in the deployed position of the movable door handle. [Means for solving the problem]

[0006] The present invention relates to a vehicle door handle assembly comprising the following components: a bracket configured to be secured to an inside of a door panel; a movable handle secured to the bracket and configured to move between a stowed position flush with the exterior of the door panel and an extended position; the bracket includes a first lever having a first hole configured to receive a first shaft and a second lever having a second hole configured to receive a second shaft; the movable handle includes a first sleeve having a first recess configured to receive the first lever and the first shaft, and a second sleeve having a second recess configured to receive the second lever and the second shaft; the second recess is a rectangular recess with an open top having an upper rectangular opening with a narrower cross section than the rectangular recess; the second shaft includes a non-circular flange disposed at a first end thereof and adapted to be introduced into the rectangular opening in the upper portion and to be axially restrained by an upper wall of the second recess; the second shaft also includes a non-circular removable cap configured to be secured to a second end of the second shaft opposite the first end; The non-circular removable cap is configured to prevent axial rotation of the second shaft relative to the second recess.

[0007] The second shaft, which includes a first end having a non-circular flange and a second end configured to receive a non-circular removable cap, can be used to connect the second lever of the bracket to the movable handle. This allows the movable handle to rotate relative to the second lever about the second axis and to move relative to the second lever by movement of the second axis along the rectangular recess. Furthermore, this configuration allows the second shaft to be positioned after the cover is assembled onto the movable handle structure.

[0008] According to another aspect of the invention, the movable handle is configured for rotational and translational movement relative to the second lever. According to another aspect of the invention, the second end of the second shaft is provided with a recess configured to receive a driver to allow axial rotation of the second shaft.

[0009] According to another aspect of the invention, the non-circular removable cap has a sharpened shape to break up ice that may be present in the bottom rectangular opening when the second axis translates within the second recess. According to another aspect of the invention, a non-circular removable cap is configured to clip onto the second end of the second shaft.

[0010] According to another aspect of the present invention, the first and second shafts are configured to be inserted from the underside of the movable handle when the movable handle is attached to a vehicle. Preferably, the first and second shafts are attached from the side that is not visible to a user when the user is pulling the movable handle. For example, as in the case of a truck, the visible area may be the underside and the invisible area may be the upper side. In this example, the first and second shafts can be inserted from the upper side. According to another aspect of the invention, the movable handle comprises a structure including a third recess configured to accommodate an electronic component, and a cover secured to the structure and configured to cover the third recess containing the electronic component.

[0011] The present invention also relates to a method for assembling the aforementioned vehicle door handle assembly to a door panel having an opening, the method comprising the steps of: fastening the bracket to the inside of the door panel, for example with screws; positioning the first lever and the second lever in the deployed position; positioning the movable handle such that the first sleeve is disposed around the first lever and the second sleeve is disposed around the second lever; a step of introducing a first shaft into a first hole of a first lever and crimping the first shaft; introducing a second shaft into the second hole of the second lever so that a first end of the second shaft is introduced into the upper rectangular opening; rotating the second shaft such that the non-circular flange is restrained by the top wall of the second recess; and Clipping a non-circular removable cap onto the second end of the second shaft to prevent axial rotation of the second shaft relative to the second recess.

[0012] According to another aspect of the invention, the method also includes the steps of, after securing the brackets, performing the following steps: Positioning the electronic component in a third recess of the handle structure; and Securing the cover to the handle structure. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a perspective view of a bracket of a vehicle door handle assembly according to an embodiment of the present invention. FIG. [Figure 2] 1 is a perspective view of a door handle according to an embodiment of the present invention. FIG. [Figure 3] FIG. 1 is a top perspective view of a door handle structure according to an embodiment of the present invention. [Figure 4] 2A and 2B are perspective and cross-sectional views of a portion of a door handle, a portion of a lever of a bracket, and a shaft according to one embodiment of the present invention. [Figure 5] FIG. 1 is a perspective view of a shaft according to one embodiment of the present invention. [Figure 6] FIG. 6 is a top view of the shaft of FIG. 5. [Figure 7] FIG. 6 is a bottom view of the shaft of FIG. 5. [Figure 8] 1A and 1B are perspective and cross-sectional views of a shaft disposed within a door handle assembly according to one embodiment of the present invention; [Figure 9] 9 is a top view of the shaft of FIG. 8 in a first position. [Figure 10] 9 is a top view of the shaft of FIG. 8 in a second position. [Figure 11] FIG. 6 is a bottom view of the shaft of FIG. 5. [Figure 12] FIG. 6 is a side view of the second end of the shaft of FIG. 5. [Figure 13] FIG. 10 is a bottom view of a removable cap according to one embodiment of the present invention. [Figure 14] FIG. 14 is a cross-sectional view of the removable cap of FIG. 13. [Figure 15] 1A and 1B are perspective and cross-sectional views of a shaft disposed within a door handle assembly according to one embodiment of the present invention; [Figure 16] FIG. 16 shows the shaft of FIG. 15 with a removable cap attached. [Figure 17] FIG. 10 is a bottom view of the second shaft attached to the door handle. [Figure 18]2 is a flow chart of the various steps of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0014] The following examples are illustrative. Although one or more embodiments are referred to herein, this does not imply that each reference refers to the same embodiment or that a feature applies only to a single embodiment. Simple features of different embodiments may be combined to provide other embodiments. In the following description, the terms "top," "upper," "low," "lower," "vertical," "horizontal," "bottom," and "upper" refer to relative positions or orientations when the door handle is assembled to a vehicle.

[0015] The present invention relates to a vehicle door handle assembly 1, which includes a bracket 3 configured to be secured to the inside of a door panel, and a movable handle 5 (see FIG. 2). The movable handle 5 is configured to be secured to the bracket 3 and is further configured to move between a retracted position, where it is flush with the outside of the door panel, and an extended position.

[0016] 1 shows a bracket 3 according to one embodiment of the present invention. The bracket 3 includes a first lever 7a that is movable between a retracted position and an extended position, and a second lever 7b that is also movable between a retracted position and an extended position. The first lever 7a has a first hole at its end for receiving a first shaft, and the second lever 7b has a second hole at its end for receiving a second shaft 17.

[0017] 2 shows a movable handle 5 (gripping member) according to one embodiment of the present invention. The movable handle 5 comprises a handle structure 5a containing the technical elements of the movable handle 5, and a cover 5b fixed to the handle structure 5a to conceal the technical elements and provide a smooth appearance. The cover 5b can be made of a plastic material. The handle structure 5a includes a first sleeve 6a fixed to a first lever 7a of the bracket 3 and a second sleeve 6b fixed to a second lever 7b of the bracket 3.

[0018] The first sleeve 6a has a first recess configured to receive the end of the first lever 7a. The first recess has a circular shape complementary to the end of the first lever 7a. The first recess of the first sleeve 6a has a through opening (referred to herein as the first opening) in its bottom wall. The top wall of the first recess has a blind hole for receiving the first end of the first shaft. The first shaft is inserted into a first hole of the first lever 7a through the first opening. The first shaft of the first lever 7a may be crimped so that its axial position is constrained. The first shaft allows the handle 5 to rotate relative to the first lever 7a. The first shaft may be cylindrical.

[0019] The second sleeve 6b of the movable handle 5 is provided with a second recess 9 (see Figures 3 and 4) configured to receive the end of the second lever 7b. This second recess 9 has a rectangular shape or a rectangular cross section so that the end of the second lever 7b can assume different positions within the second recess 9. The second recess 9 has an open top with an upper rectangular opening 11 having a narrower cross section than the second recess 9. The second recess 9 also has an open bottom with a lower rectangular opening 13 (see FIG. 8) located forward of the upper rectangular opening 11. The lower rectangular opening 13 has a flange 15 (see FIG. 17) surrounding the lower rectangular opening 13. The lower rectangular opening 13 is wider than the upper rectangular opening 11. A second shaft 17 can be inserted into a second hole in the second lever 7b through the lower rectangular opening 13.

[0020] Figure 5 shows an embodiment of the second shaft 17. The second shaft 17 has a first end 17a with a non-circular flange 21 (see the top view in Figure 6), a second end 17b opposite the first end 17a that may include a recess 19 configured to receive a driver (see the bottom view in Figure 7), and a cylindrical central portion 17c.

[0021] The width of non-circular flange 21 is narrower than the width of upper rectangular opening 11, and the length thereof is longer than the width of upper rectangular opening 11. Therefore, when non-circular flange 21 is arranged along the long side of upper rectangular opening 11, as shown in FIG. 9, this non-circular flange 21 can be inserted into upper rectangular opening 11. However, when the non-circular flange 21 is disposed perpendicular to the long side of the upper rectangular opening 11 as shown in FIG. 10, the non-circular flange 21 cannot be removed from the upper rectangular opening 11.

[0022] The second end 17b of the second shaft 17 includes two shaft flats 23 (see FIG. 11) and two grooves 25 (see FIG. 12). The second shaft 17 also includes a non-circular removable cap 27 (see FIG. 13) configured to be secured to the second end 17b of the second shaft 17. The non-circular removable cap 27 can be clipped onto the second end 17b. As shown in Figure 14, the non-circular removable cap 27 has two pins 29. These pins are respectively disposed on two flexible arms 31 and inserted into two grooves 25 to form clipping means.

[0023] As shown in FIG. 13, the non-circular removable cap 27 also includes two inner flats 33 configured to contact the shaft flats 23 at the second end 17b when the cap 27 is positioned on the second shaft 17. As shown in FIG. 17, the non-circular removable cap 27 also includes two outer flats 35 configured to abut the flange 15 of the bottom rectangular opening 13 . Additionally, the non-circular removable cap 27 also has two sharply shaped sides, referred to as acute sides 37, for breaking up any ice that may be present within the rectangular recess as the second shaft 17 moves within the second recess 9.

[0024] The handle 5 includes a third recess for accommodating electronic components, which is located in a graspable lever 39 of the handle structure 5a. To protect the electronic components and prevent electrical contact with the conductive parts of the handle structure 5a, the electronic components may be encapsulated using, for example, a resin. The third recess is closed by a cover 5b.

[0025] The cover 5b covers the top of the first sleeve 6a and the second sleeve 6b as shown in Figure 2. However, the cover 5b does not completely cover the bottom of the first sleeve 6a and the second sleeve 6b in order to introduce the first axis 17 of the first lever 7a and the second axis 17 of the second lever 7b and to allow access to the bottom opening of the first recess and the rectangular opening 13 at the bottom of the second recess 9.

[0026] Thus, the particular configuration of the vehicle door handle assembly 1, in particular the second axis 17 and the second recess 9, allows for positioning of the second axis after the cover 5b is assembled to the handle structure 5a, while at the same time ensuring rotational and translational movement of the movable handle 5 relative to the second lever 7b.

[0027] The present invention also relates to a method of assembling the vehicle door handle assembly 1 as described above. Figure 18 shows a flow chart of the various steps of this method. The first step 101 is to fasten the bracket 3 to the inside of the door panel, which can be done with screws. The bracket 3 includes a number of peripheral legs 30 with holes configured to receive screws for fastening the bracket 3 to the door panel. In a second step 102, the electronic component is positioned in a third recess in the handle structure, which may also include encapsulating the electronic component with a resin.

[0028] In a third step 103, the cover 5b is assembled or secured to the handle structure 5a. The cover 5b can be clipped and / or glued to the handle structure 5a. In a fourth step 104, the first lever 7a and the second lever 7b are positioned in the deployed position. In a fifth step 105, the movable handle 5 is positioned, in particular so that the first sleeve 6a, in particular its first recess, is disposed around the first lever 7a, and the second sleeve 6b, in particular its second recess 9, is disposed around the second lever 7b. The movable handle 5 is positioned so that the bottom opening of the first recess of the first sleeve 6a is located in front of the first hole of the first lever 7a, and the bottom rectangular opening 13 of the second recess 9 of the second sleeve 6b is located in front of the second hole of the second lever 7b.

[0029] In a sixth step 106, the first shaft is introduced into the first hole of the first lever 7a through the bottom opening of the first recess of the first sleeve 6a. In the sixth step 106, the first shaft may also be crimped to axially constrain it in place. This configuration allows the movable handle 5 to rotate relative to the first lever 7a. This rotation occurs around the first shaft. In a seventh step 107, as shown by arrow A in Figure 4, the second shaft 17 is introduced into the second hole of the second lever 7b through the lower rectangular opening 13. First, the first end 17a of the second shaft 17 is inserted into the lower rectangular opening 13. The second shaft 17 is inserted so that its first end 17a is inserted into the upper rectangular opening 11. As shown in FIG. 9, the non-circular flange 21 is disposed along the long side of the upper rectangular opening 11 so as to be insertable into the upper rectangular opening.

[0030] In an eighth step 108, the second shaft 17 is rotated, for example, 90°, so that the non-circular flange 21 is restrained by the upper wall of the second recess (located around the periphery of the upper rectangular opening 13), as shown in Figure 10. This rotation can be accomplished by a driver located in the recess 19 in the second end 17b of the second shaft 17.

[0031] In a ninth step 109, a non-circular removable cap 27 is clipped onto the second end 17b of the second shaft 17, as shown by arrow B in FIG. 16, a non-circular removable cap 27 can be positioned on the second end 17b of the second shaft 17 to prevent axial rotation of the second shaft 17 relative to the second recess 9. The second shaft 17 is therefore axially restrained by the non-circular flange 21 on its first end 17a. The non-circular removable cap 27 prevents rotation of the second shaft 17 by means of an inner flat 33 that contacts the shaft flat 23 at the first end 17a of the second shaft 17 on the one hand, and an outer flat 35 that contacts the flange 15 of the bottom wall surrounding the rectangular opening 13 at the bottom on the other hand.

[0032] With this configuration, the movable handle 5 can rotate about the second axis 17 relative to the second lever 7b and move in translation along the upper rectangular opening 11 and the lower rectangular opening 13 of the second sleeve 6b. This rotation is made possible by the rotation of the second lever 7b about the second axis 17, and the translation is made possible by the translation of the second axis 17 along the upper rectangular opening 11 and the lower rectangular opening 13 of the second sleeve 6b (see Figure 4).

[0033] Furthermore, with this configuration, the second shaft 17 can be positioned after the cover 5b is assembled to the handle structure 5a of the handle 5. Therefore, the movable handle 5 can be assembled to the bracket 3 after the cover 5b is assembled to the handle structure 5a of the handle 5, without impairing the function of the handle 5. Also, because the first shaft and the second shaft 17 are introduced from the underside of the handle 5, the cover 5b can cover the upper surfaces of the first sleeve 6a and the second sleeve 6b of the handle structure 5a (see FIG. 2), so the second shaft 17 can be positioned without impairing the aesthetic appearance of the handle 5.

[0034] The order of the steps in the above method may be different, for example, the second step 102 and the third step 103 may be performed before the first step 101. Some steps may be performed simultaneously. Also, some steps, such as the second step, may be optional. [Explanation of symbols]

[0035] 1 Vehicle Door Handle Assembly 3 Bracket 5 Movable handle 5a Handle structure 5b cover 6a First Sleeve 6b Second Sleeve 7a First lever 7b Second lever 9 Second recess 11 Upper rectangular opening 13 Lower rectangular opening 15 flange 17 Second axis 19 Recess 21 Non-circular flange 23 Axis flat part 25 groove 27 Removable cap 29-pin 30 Peripheral leg 31 Flexible Arm 33 Inner flat part 35 Outer flat area 37 acute side 39 Lever

Claims

1. A vehicle door handle assembly (1), comprising: a bracket (3) configured to be fixed to the inside of a door panel; a movable handle (5) fixed to the bracket (3) and configured to move between a stowed position flush with the exterior of the door panel and an extended position; The bracket (3) comprises a first lever (7a) having a first hole configured to receive a first shaft, and a second lever (7b) having a second hole configured to receive a second shaft (17); The movable handle (5) comprises a first sleeve (6a) having a first recess configured to receive the first lever and the first shaft, and a second sleeve (6b) having a second recess (9) configured to receive the second lever (7b) and the second shaft (17); The second recess (9) is a rectangular recess with an open top having an upper rectangular opening (11) with a narrower cross section than the second recess (9); the second shaft (17) has a non-circular flange (21) disposed at a first end (17a), the non-circular flange being adapted to be introduced into the upper rectangular opening (11) and to be axially restrained by an upper wall of the second recess (9); The second shaft (17) also includes a non-circular removable cap (27) configured to be secured to a second end (17b) opposite the first end (17a); 10. A vehicle door handle assembly, comprising: a removable cap (27) configured to prevent axial rotation of the second shaft (17) relative to the second recess (9).

2. 2. The vehicle door handle assembly of claim 1, wherein the movable handle (5) is configured for rotational and translational movement relative to the second lever (7b).

3. 2. The vehicle door handle assembly of claim 1, wherein the second end (17b) of the second shaft (17) is provided with a recess (19) configured to receive a driver to enable axial rotation of the second shaft (17).

4. 2. The vehicle door handle assembly of claim 1, wherein the non-circular removable cap (27) has a sharpened shape for breaking up ice that may be located in the bottom rectangular opening (13) when the second axis (17) translates within the second recess (9).

5. 2. The vehicle door handle assembly of claim 1, wherein the non-circular removable cap (27) is configured to be clipped onto the second end (17b) of the second shaft (17).

6. 2. The vehicle door handle assembly according to claim 1, wherein the first axis and the second axis are configured to be introduced from the underside of the movable handle when the movable handle is attached to the vehicle.

7. 2. The vehicle door handle assembly of claim 1, wherein the movable handle (5) comprises a handle structure (5a) including a third recess configured to accommodate electronic components, and a cover (5b) fixed to the handle structure (5a) and configured to cover the third recess containing the electronic components.

8. A method for assembling a vehicle door handle assembly (1) according to claim 1 or 2 to a door panel having an opening, comprising the steps of: Fixing the bracket (3) to the inside of the door panel (101), for example with screws; Positioning the first lever (7a) and the second lever (7b) in the deployed position (104); Positioning the movable handle (5) (105) so that the first sleeve (6a) is positioned around the first lever (7a) and the second sleeve (6b) is positioned around the second lever (7b); A step (106) of introducing a first shaft into a first hole of a movable first lever and crimping the first shaft; introducing (107) a second shaft (17) into a second hole in the second lever (7b) so that a first end (17a) of the second shaft (17) is introduced through the upper rectangular opening; Rotating the second shaft (17) so that the non-circular flange (21) is restrained by the upper wall of the second recess (9) (108); a step (109) of clipping a non-circular removable cap (27) onto a second end (17b) of the second shaft (17) to prevent axial rotation of the second shaft (17) relative to the second recess (9).

9. After the bracket (3) is fixed, Positioning (102) an electronic component in a third recess of the handle structure (5a); 9. The method of assembling a door handle assembly to a door panel according to claim 8, further comprising the step (103) of fixing a cover to the handle structure (5a).

Images