Steering wheel assembly for electric vehicle including mechanical switch

Abstract

To provide an automated vehicle door handle assembly which is inexpensive to manufacture and requires less space for installation and operation. The present invention provides - a housing (12) arranged flush against an outer panel (13) of the vehicle; - a rotatable flap (20) accommodated in said housing (12), extending along an axis of rotation (XX) and adapted to rotate about said axis of rotation (XX) between a rest position and a door open position; a mechanical actuation switch (28) that generates an electrical signal that is sent to a vehicle door controller to open a vehicle door, The vehicle door handle assembly (10) further comprises a cam holder (30) and a cam (32) supported by the cam holder (30), the cam holder (30) being connected to the rotatable flap (20) so as to be rotatable around the rotation axis (XX), the cam holder (30) being rotated by the rotation of the rotatable flap (20), and the cam holder (30) being rotated by the rotation of the cam holder (30), the cam (32) actuating the mechanical operation switch (28).

Description

[Technical Field]

[0001] The present invention relates to a door opening assembly for controlling the opening of a vehicle door, and more particularly to an automated door latch that is controlled by electrical means without the use of a mechanically actuated door handle lever or knob. [Background technology]

[0002] An automated door latch selectively locks or unlocks a vehicle door panel in an automated manner. As used herein, an automated door latch refers to a door latch that does not require a user to grasp and move a handle, lever, knob, or the like to provide energy to actuate the latch.

[0003] Once the door panel is released, a user or a power panel actuator can swing or slide the door panel to allow physical access to the vehicle. Automated door latches typically do not require a protruding handle lever on the vehicle's exterior, resulting in a streamlined appearance for the vehicle while reducing aerodynamic drag.

[0004] Most automated door latches include an electric actuator that operates a bolt, hook, or lever upon receiving an actuation signal to open the vehicle door. Such electric actuators can be activated using either an electrical switch or a mechanical switch. Compared to mechanical switches, electric switches have the advantage of saving space within the door assembly because they do not require the space required for the stroke of a displacing mechanical part. However, unlike mechanical switches, electric switches are costly and require complex electronic circuitry within the door assembly. Summary of the Invention [Problem to be solved by the invention]

[0005] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide an automated vehicle door handle assembly that is inexpensive to manufacture and requires less space for installation and operation. [Means for solving the problem]

[0006] To this end, the present invention provides a housing positioned flush against an exterior panel of the vehicle; a rotatable flap housed in said housing, extending along an axis of rotation and adapted to rotate about said axis of rotation between a rest position and a door open position; a mechanical actuation switch that generates an electrical signal that is sent to a vehicle door controller to release a vehicle door, The vehicle door handle assembly further includes a cam holder and a cam supported by the cam holder, the cam holder being connected to the rotatable flap so as to be rotatable around the rotation axis, the cam holder rotating upon rotation of the rotatable flap, and the cam operating the mechanical activation switch upon rotation of the cam holder.

[0007] Due to the fact that the vehicle door handle assembly includes a cam holder connected to a rotatable flap, and the cam holder is rotatable about a rotation axis, rotation of the rotatable flap rotates the cam holder and activates the mechanical activation switch. Even when there is very little space available for the rotatable flap to rotate, i.e., when there is almost no available stroke space, the mechanical activation switch can be activated. Such an arrangement indeed requires space only along the rotation axis, and not along the stroke direction of the rotatable flap.

[0008] The vehicle door handle assembly may be provided with one or several of the following features, either alone or in combination:

[0009] According to one embodiment, the cam holder comprises, for example, a longitudinally extending cam lever having a first end hinged to the pivot axis of the rotatable flap and a second end opposite the first end that supports the cam. This particular configuration allows the cam lever structure to convert very small pivotal movements of the rotatable flap into sufficient movement of the cam to actuate a mechanically actuated switch.

[0010] According to another embodiment, the rotatable flap is in particular substantially planar and bounded, on the one hand, by two parallel, straight longitudinal sides extending along the axis of rotation and, on the other hand, by two parallel, straight sides extending along a direction substantially perpendicular to the axis of rotation. A rotatable flap of this shape takes up little space, is easy to manufacture and is easy for the user to operate.

[0011] To further limit the space occupied by the vehicle door handle assembly, particularly in the stroke direction of the rotatable flap, cam movement is induced by rotation of the cam holder following the movement of the longitudinal sides of the rotatable flap.

[0012] To further limit the space occupied by the vehicle door handle assembly, particularly in the stroke direction of the rotatable flap, the cam lever is positioned approximately parallel to and adjacent to the side of the rotatable flap.

[0013] To further limit the space occupied by the vehicle door handle assembly, the rotation axis of the cam holder may, for example, include a first pin extending from the first end of the cam lever that is adapted to be inserted into a first flap hole drilled in the rotatable flap along the rotation axis (XX), thereby aligning the cam lever approximately parallel to the side of the rotatable flap.

[0014] According to a further aspect, a second pin inserted into a hole in the cam lever located adjacent a second end of the cam lever is also inserted into a second flap hole in the rotatable flap located opposite the first flap hole along the side of the rotatable flap.

[0015] To further limit the space occupied by the vehicle door handle assembly, the length of the cam lever is at least as long as the side of the rotatable flap.

[0016] According to a further aspect, the mechanically actuated switch includes a flexible blade, and during rotation of the cam holder, a contact surface of the cam contacts the flexible blade and pushes the flexible blade in at least one direction transverse to the axis of rotation.

[0017] According to another aspect, the flexible blade can be oriented substantially perpendicular to the axis of rotation of the rotatable flap. This particular configuration can also translate very small movements of the rotatable flap into movements sufficient to actuate a mechanically actuated switch.

[0018] According to another aspect, the mechanical actuation switch includes a push button, and during rotation of the cam holder, the flexible blade contacts and presses the push button, generating an electrical signal that is sent to a vehicle door controller to release the vehicle door.

[0019] Furthermore, the contact surface of the cam may provide an inclined surface connecting two substantially linear surfaces, with the gradient of the inclined surface determining the stroke speed of the push button.

[0020] The housing of the vehicle door handle assembly may, for example, comprise a bowl-shaped receiving surface that defines a volume that allows access to the rotatable flap (20).

[0021] The angle formed by the rotatable flap in the rest position and the rotatable flap in the door open position is, for example, 2° to 6°.

[0022] Furthermore, the distance between the rotatable flap in the rest position and the rotatable flap in the door open position is less than 6 mm, preferably less than 4 mm.

[0023] If for any reason electrical current becomes unavailable, the vehicle door handle assembly (10) also includes a backup release mechanism (46) including a cable (48) connected to the door latch mechanism for mechanically actuating the door latch mechanism to release the vehicle door, the backup release mechanism (46) being adapted to be activated by inserting a key into a keyhole located inside the receiving surface (15).

[0024] To provide a handle that is both user-friendly and sufficiently durable, the rotatable flap comprises a first section made of an elastomer such as rubber overmolded onto a second section made of a hard plastic, such as polypropylene. [Brief explanation of the drawings]

[0025] [Figure 1] 1 is a perspective view of a vehicle door handle assembly in accordance with certain embodiments of the present invention; [Figure 2] FIG. 2 is a cross-sectional view along plane II-II of FIG. [Figure 3] FIG. 2 is a perspective view of the components of the vehicle door handle assembly of FIG. 1. [Figure 4] FIG. 4 is an exploded view of the components of FIG. 3. [Figure 5] FIG. 2 is a side view of the mechanical switch, cam lever, and rotatable flap of the vehicle door handle assembly of FIG. 1. [Figure 6] 2 is a perspective view of a vehicle door handle assembly according to a specific embodiment of the present invention, viewed from another angle; DETAILED DESCRIPTION OF THE INVENTION

[0026] The invention will be better understood from consideration of the following description taken in conjunction with the accompanying drawings.

[0027] A vehicle door handle assembly 10 in accordance with a particular embodiment of the present invention is shown in FIGS.

[0028] The vehicle door handle assembly 10 includes a housing 12 that is mounted flush against an exterior panel 13 of the vehicle.

[0029] The housing comprises an upper casing 14 and a bowl-shaped receiving surface 15 that defines a volume V that allows access to the interior of the upper casing 14. As can be seen in Figure 1, the receiving surface 15 is defined by a receiving surface frame 15A that has a rectilinear cross section, the two ends of which are joined by a U-shaped cross section.

[0030] The upper casing 14 is generally rectangular in shape and includes a housing space 16 between an upper casing front wall 17 and an upper casing rear wall 18, the housing space 16 being generally parallel to the upper casing front wall 17. A rotatable flap 20 is received within the housing space 16.

[0031] 2, the front wall 17 of the upper casing comprises an upper section 17A that is substantially planar and flush with the vehicle exterior panel 13, and a lower section 17B that is also substantially planar but intersects the upper section 17A. More specifically, the lower section 17B connects the upper section 17A to the receiving surface 15 and is connected to the receiving surface 15 rearward of the straight section of the receiving surface frame 15A. Therefore, the distance between the lower section 17B of the front wall 17 and the rear wall 18 of the upper casing is shorter than the distance between the upper section 17A of the front wall 17 and the rear wall 18 of the upper casing.

[0032] As can be seen in Figure 2, the receiving surface 15 is extended by the rear wall 18 of the upper casing. The housing space 16 is connected to the volume V in such a way that the user's hand, using the handle, can be inserted into volume V and the rest of the housing space 16 in order to activate the rotatable flap 20. More precisely, the fingers of the hand are first inserted inside volume V and move upwards within the housing space 16. Here, the width of the housing space 16 is less than 50 mm and preferably greater than 20 mm.

[0033] Due to the limited space available, most of the housing space 16 is hollow to allow the user's hand to pass through, and the rotatable flap 20 is therefore positioned as close as possible to the front wall 17 of the upper casing.

[0034] 3 and 4, the rotatable flap 20 extends along an axis of rotation XX (perpendicular to the plane of FIG. 2). More precisely, as can best be seen in FIG. 4, the rotatable flap 20 is substantially planar and bounded, on the one hand, by two parallel, straight longitudinal sides 20L extending along the axis of rotation XX, and, on the other hand, by two parallel, straight sides 20I extending along a direction substantially perpendicular to the axis of rotation XX.

[0035] The rotatable flap 20 comprises a first section 22 made of an elastomer such as rubber overmolded onto a second section 24 made of a hard plastic, such as polypropylene. The first section 22 is positioned facing the housing space 16 so that a hand inserted into the housing space 16 first comes into contact with the pleasant-to-touch surface.

[0036] Preferably, on its longitudinal side 20L closest to the receiving surface 15, i.e. closest to the entrance of the housing space 16 and adjacent to the volume V, the rotatable flap 20 is provided with a boss 27 extending along the entire longitudinal side 20L. This boss 27 enables the user to easily feel and press the rotatable flap 20 as soon as he inserts his hand into the housing space 16. The distance between the entrance of the volume V and the boss 27 is preferably less than 15 mm.

[0037] The rotatable flap 20 is adapted to rotate about a rotation axis XX between a rest position corresponding to the position shown in the figure and an open door position (not shown).

[0038] In this embodiment, the width of the remaining space 26 between the rotatable flap 20 and the front wall 17 of the upper casing corresponds to the distance between the lower section 17B of the front wall and the rear wall 18 of the upper casing minus the width of the housing space 16 for inserting the user's finger and the width of the rotatable flap 20 itself, and is less than 6 mm. Therefore, the stroke of the rotatable flap 20 is limited within this distance. For example, the stroke of the rotatable flap 20, i.e., the distance between the rotatable flap 20 in the rest position and the rotatable flap 20 in the door-open position, is less than 6 mm, preferably less than 4 mm. The rotatable flap 20 in the rest position and the rotatable flap 20 in the door-open position form an angle of 2° to 6°.

[0039] However, the present invention allows the rotatable flap 20 to generate an electrical signal that is sent to a vehicle door controller (not shown) to activate the mechanical activation switch 28 and open the vehicle door, even if the stroke of the rotatable flap 20 is very limited. More specifically, the present invention allows the stroke of the mechanical activation switch 28 to be longer than the stroke of the rotatable flap 20.

[0040] To this end, the vehicle door handle assembly 10 also includes a cam holder 30 and a cam 32 supported by the cam holder 30. The cam holder 30 is connected to the rotatable flap 20 so as to be rotatable about a rotation axis XX.

[0041] In this embodiment, the cam holder 30 has a cam lever 34 extending along the longitudinal direction, the cam lever 34 having a first end 34A hinged to the rotation axis XX of the rotatable flap 20 and a second end 34B opposite the first end 34A and supporting the cam 32.

[0042] More specifically, the rotation axis of the cam holder 30 is formed by inserting a first pin 36 extending from a first end 34A of the cam lever into a first flap hole 37 formed in the rotatable flap 20 along the rotation axis XX. This positions the cam lever 34 substantially parallel to the side 20I of the rotatable flap 20. A second pin 38 inserted into a hole 34H of the cam lever 34 located adjacent to the second end 34B of the cam lever 34 is also inserted into a second flap hole 39 of the rotatable flap 20 located opposite the first flap hole 37 along the side 20I of the rotatable flap 20.

[0043] 3 and 4, the length of the cam lever 34 is at least as long as the length of the side 20I of the rotatable flap 20, and here it is approximately the same length.

[0044] 4 and 5, the vehicle door handle assembly 10 is configured such that rotation of the rotatable flap 20 causes rotation of the cam holder 30, which in turn causes the cam 32 to operate the mechanical activation switch 28.

[0045] More specifically, the mechanically actuated switch 28 includes a flexible blade 40 such that, during rotation of the cam holder 30, the contact surface 32S of the cam 32 contacts the flexible blade 40 and pushes the flexible blade 40 in at least one direction transverse to the rotation axis XX, where the flexible blade 40 extends along a longitudinal axis that is approximately perpendicular to the rotation axis XX of the rotatable flap 20. One end 41 of the flexible blade 40 is curved.

[0046] 5, contact surface 32S of cam 32 is formed by an inclined surface 42 connecting two substantially linear surfaces 43. With this configuration, the stroke speed at which push button 44 is pressed is determined by the gradient of inclined surface 42.

[0047] Flexible blade 40 initially contacts first linear surface 43, but does not yet activate mechanical activation switch 28. Activation of mechanical activation switch 28 is enabled when flexible blade 40 contacts inclined surface 42, which corresponds to the point at which flexible blade 40 also contacts push button 44 located on the opposite side of flexible blade 40. Thus, during rotation of cam holder 30, flexible blade 40 contacts and depresses push button 44. Depressing push button 44 generates an electrical signal that is sent to a vehicle door controller to open the vehicle door.

[0048] As can be seen in FIG. 6 , which shows the back side of the vehicle door handle assembly 10 in comparison to FIG. 1 , the vehicle door handle assembly 10 also includes a backup release mechanism 46 that allows a user to open the vehicle door when electrical current is not available, such as when the vehicle has a power outage.

[0049] The backup release mechanism 46 includes a cable 48 that is connected to a door latch mechanism (not shown) and mechanically activates the door latch mechanism to release the vehicle door.

[0050] The backup release mechanism 46 is adapted to be activated by inserting a key (not shown) into a keyhole located inside the receiving surface 15. Here, as can be seen in Figure 1, the keyhole is concealed by a concealing wall 50 which can be moved to access the keyhole.

[0051] It can therefore be clearly seen that, in the small housing space 16 between the rotatable flap 20 and the rear wall 18 of the upper casing 14, the present invention achieves a very compact design of the vehicle door handle assembly 10 for an electrically controlled door latch. This is achieved in particular by the specific position of the mechanical activation switch 28, i.e., the mechanical activation switch 28 being on one side of the rotatable flap 20 and oriented with its longitudinal axis perpendicular to the axis of rotation XX of the rotatable flap 20, and also by the elongated cam holder 30 which amplifies the small pivotal movement to obtain the stroke required to activate the push button 44 of the mechanical activation switch 28. [Explanation of symbols]

[0052] 10 Vehicle door handle assembly 12 Housing 13 Vehicle exterior panels 14 Upper casing 15 Receptive Aspects 15A Receptor Frame 16 Housing space 17 Upper casing front wall 17A Upper section of front wall 17B Lower section of front wall 18 Rear wall of upper casing 20 Rotatable Flaps 20L Rotatable flap longitudinal side 20I Rotatable flap side 22 Rotatable flap first section 24 Rotatable second section of flap 26 Remaining Space 27 Rotatable flap boss 28 Mechanically operated switch 30 Cam holder 32 Cam 32S cam contact surface 34 Cam lever 34A First end of cam lever 34B Second end of cam lever 34H Cam lever hole 36 First pin 37 First flap hole 38 2nd pin 39 Second flap hole 40 Flexible Blade 42 Slope 43 Straight Surface 44 push button 46 Backup release mechanism 48 Cable 50 Hidden Wall V is the volume bounded by the receiving surface

Claims

1. a housing (12) placed flush against the outer panel (13) of the vehicle; a rotatable flap (20) housed in said housing (12), extending along an axis of rotation (X-X) and adapted to rotate about said axis of rotation (X-X) between a rest position and a door open position; a mechanical actuation switch (28) that generates an electrical signal that is sent to a vehicle door controller to release the vehicle door, The vehicle door handle assembly (10) further comprises a cam holder (30) and a cam (32) supported by the cam holder (30), the cam holder (30) being connected to the rotatable flap (20) so as to be rotatable about the rotation axis (X-X), the cam holder (30) being rotated by rotation of the rotatable flap (20), and the cam (32) being operated by the mechanical operation switch (28) by rotation of the cam holder (30).

2. 2. The vehicle door handle assembly (10) of claim 1, wherein the cam holder (30) includes a cam lever (34) extending along a longitudinal direction, the cam lever (34) having a first end (34A) hinged to the rotation axis (X-X) of the rotatable flap (20) and a second end (34B) opposite the first end (34A) and supporting the cam (32).

3. 3. The vehicle door handle assembly (10) according to claim 1 or 2, characterized in that the rotatable flap (20) is substantially planar and bounded, on the one hand, by two parallel, straight longitudinal sides (20L) extending along the axis of rotation (X-X), and, on the other hand, by two parallel, straight sides (20l) extending along a direction substantially perpendicular to the axis of rotation (X-X).

4. 4. The vehicle door handle assembly (10) of claim 3, wherein rotation of the cam holder (30) induces movement of the cam (32) to follow movement of the longitudinal sides of the rotatable flap (20).

5. A vehicle door handle assembly (10) according to claim 3 or claim 4, which relies on claim 2, wherein the cam lever (34) is substantially parallel to the side of the rotatable flap (20) and is positioned adjacent to the side of the rotatable flap (20).

6. The rotation axis of the cam holder (30) is a first pin (36) extending from the first end (34A) of the cam lever (34) and adapted to be inserted into a first flap hole (37) drilled in the rotatable flap (20) along the rotation axis (X-X), thereby causing the cam lever (34) to be approximately parallel to the side of the rotatable flap (20).

7. 7. The vehicle door handle assembly (10) of claim 6, wherein a second pin (38) inserted into a hole (34H) of the cam lever (34) located adjacent the second end (34B) of the cam lever (34) is also inserted into a second flap hole (39) of the rotatable flap (20) located opposite the first flap hole (37) along the side (20I) of the rotatable flap (20).

8. A vehicle door handle assembly (10) according to claim 3 or any one of claims 5 to 7, with reference to claim 2, wherein the length of the cam lever (34) is at least as long as the side of the rotatable flap (20).

9. 9. The vehicle door handle assembly (10) of claim 1, wherein the mechanically operated switch (28) comprises a flexible blade (40), and during rotation of the cam holder (30), a contact surface (32S) of the cam (32) contacts the flexible blade (40) and pushes the flexible blade (40) in at least one direction transverse to the rotation axis (X-X).

10. The vehicle door handle assembly (10) of claim 9, wherein the flexible blade (40) is oriented substantially perpendicular to the axis of rotation (XX) of the rotatable flap (20).

11. 11. The vehicle door handle assembly (10) of claim 9 or 10, wherein the mechanical actuation switch (28) comprises a push button (44), and during rotation of the cam holder (30), the flexible blade (40) contacts and presses the push button (44), and pressing the push button (44) generates an electrical signal that is sent to a vehicle door controller to release the vehicle door.

12. The vehicle door handle assembly (10) according to any one of claims 1 to 11, characterized in that the contact surface (32S) of the cam (32) is formed by an inclined surface (42) connecting two substantially straight surfaces (43).

13. 13. The vehicle door handle assembly (10) of claim 1, wherein the housing (12) comprises a bowl-shaped receiving surface (15) defining a volume (V) that allows access to the rotatable flap (20).

14. 14. The vehicle door handle assembly (10) of claim 3, wherein the angle formed by the rotatable flap (20) in the rest position and the rotatable flap (20) in the door open position is between 2° and 6°.

15. 15. The vehicle door handle assembly (10) according to any one of claims 3 to 14, characterized in that the distance between the rotatable flap (20) in the rest position and the rotatable flap (20) in the door open position is less than 6 mm, preferably less than 4 mm.

16. 16. The vehicle door handle assembly (10) of claim 1, further comprising a backup release mechanism (46) including a cable (48) connected to the door latch mechanism and mechanically actuating the door latch mechanism to release the vehicle door, the backup release mechanism (46) being configured to be actuated by inserting a key into a keyhole located inside the receiving surface (15).

17. 17. A vehicle door handle assembly (10) according to any one of claims 1 to 16, characterized in that the rotatable flap (20) comprises a first section (22) made of an elastomer such as rubber overmolded onto a second section (24) made of a hard plastic, for example polypropylene.

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