Abstract:
A vehicle door construction having a 360° grab handle includes a fastener cover which conceals a fastener hole in an A-surface of the vehicle door and which provides a buckling path for the 360° grab handle. An L-shaped cover and a fastener hole configuration is provided in the lateral A-surface to reduce stiffness in the region and to absorb side impact loads.

Description:
TECHNICAL FIELD 
       [0001]    The disclosed invention relates generally to vehicle door constructions and to grab handles for such door constructions. More particularly, the disclosed invention relates to a fastener cover which conceals a fastener hole in an A-surface of a vehicle door and which provides a buckling path for the 360° grab handle. 
       BACKGROUND OF THE INVENTION 
       [0002]    Side impact events in vehicles have been identified as one of the top priorities for both research and regulation with government requirements continuing to become more stringent with new occupant sizes and test modes frequently being added to published regulations. Designers and manufacturers are thus constantly being challenged to rethink and often revise their approaches to several vehicle structures, particularly vehicle doors. 
         [0003]    While the vehicle door includes several features which combine both functionality and design and which must be configured so as to minimize vehicle-inward intrusion of the elements in a side impact event, one such feature is the door grab handle. According to the known thinking, consideration as to whether or not include grab handles on vehicle doors is often based on whether or not the grab handle will be situated in the impact zone. This careful consideration is made because a grab handle, by its very design, must have additional lateral walls that are also A-surfaces. Lateral walls increase the stiffness of the grab handle region which tends to have a negative affect on occupant performance. 
         [0004]    As in so many areas of vehicle technology, there is room in the art of vehicle interior door design for an alternative configuration to known grab handle configurations which will help to avoid some of the limitations of known designs. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention provides an alternative arrangement to known vehicle door handle and pull cup and support structure designs. According to the present invention, a vehicle door assembly is provided which comprises a door trim substrate, a map pocket cover attached to the door trim substrate, a lower A-surface associated with the door trim substrate, and a 360° door handle attached to the door trim substrate. Cut out areas are formed in the lower A-surface and in the cover whereby the cut out areas form a single cut our area. An L-shaped fastener cover having an extended second surface is fitted over the single cut out area. This arrangement minimizes the stiffness of the A-surface without sacrificing integrity needed to provide proper support for the 360° door handle. 
         [0006]    In a side impact event, the door trim substrate is pushed vehicle inward. Almost simultaneously the L-shaped fastener cover separates in part from the lower A-surface as the lower A-surface strokes relative to the extended second surface of the L-shaped fastener cover, thus reducing substantially or entirely eliminating the vehicle-inward movement of the associated grab handle close-out. 
         [0007]    Other advantages and features of the invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein: 
           [0009]      FIG. 1  is a perspective view of a grab handle close-out in position on a map pocket cover showing a fastener cover according to the prior art; 
           [0010]      FIG. 2  is a section view of an arrangement of a grab handle relative to a map pocket cover and door trim substrate with a fastener cover prior to an impact event according to the prior art; 
           [0011]      FIG. 3  is a sectional view similar to that of  FIG. 2  but illustrating the arrangement of the prior art after an impact event; 
           [0012]      FIG. 4  is a perspective view of a preferred embodiment of a grab handle close-out in position on a cover according to the disclosed invention; 
           [0013]      FIG. 5  is a back side perspective view of the fastener cover of the disclosed invention in place on the map pocket cover; 
           [0014]      FIG. 6  is a sectional view of an arrangement of a grab handle relative to a map pocket cover and door trim substrate with a fastener cover according to a preferred embodiment of the disclosed invention; 
           [0015]      FIG. 7  is a sectional view similar to that of  FIG. 6  but illustrating the arrangement after an impact event; 
           [0016]      FIG. 8  is a perspective view of a grab handle close out in position on a map pocket cover showing a fastener cover according to an alternate embodiment of the disclosed invention; 
           [0017]      FIG. 9  is a perspective view of a grab handle arrangement according to an additional alternate embodiment of the disclosed invention illustrating the grab handle close out shown in shadow lines and illustrating part of the handle cover broken away to reveal the foam insert; 
           [0018]      FIG. 10  is a partial top plan view of a grab handle arrangement incorporating the embodiment of  FIG. 9  prior to an impact event; and 
           [0019]      FIG. 11  is a partial top plan view similar to that of  FIG. 10  but illustrating the arrangement after an impact event. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0020]    In the following figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for different constructed embodiments. These specific parameters and components are included as examples and are not meant to be limiting. 
         [0021]    The prior art approach to the provision of a grab handle and cover design is illustrated in  FIGS. 1 through 3 . With reference to  FIG. 1 , a perspective view of a grab handle arrangement on a vehicle door, generally illustrated as  10 , is shown. More particularly, a perspective view of a grab handle close-out  12  in position relative to a lower A-surface  14  of a map pocket cover  15  and having a conventional fastener cover  16  is illustrated. The grab handle close-out  10  provides a base for the grab handle itself (not shown) and includes a forward lateral wall  18  and a rearward lateral wall  20 . The fastener cover  16  is conventionally provided and is generally of an “I” shape. The fastener cover  16  is provided to cover underlying fasteners that are hidden thereby. 
         [0022]    Referring to  FIG. 2 , a section view of the grab handle the grab handle arrangement  10  according to the prior art is shown. As shown therein, the grab handle close-out  12  is shown relative to the lower A-surface  14  of the associated map pocket cover  15 . Support for the map pocket cover  15  is provided by a door trim substrate  26 . A grab handle  28  is attached to the grab handle close-out  12 . 
         [0023]    In a side impact event, the lower A-surface  14 , required, according to the prior art, to provide lateral to support to the grab handle, increases stiffness of the overall grab handle region. This, as noted above, has a negative affect upon occupant performance in a side impact event.  FIG. 3  illustrates this situation. If a side impacting force is applied to the vehicle door, the door trim substrate  26  is pushed vehicle inward. The lower A-surface  14 , having characteristic stiffness, does buckle under the load as illustrated, but not before forcing the grab handle close-out  10  and its associated grab handle  28  vehicle inward toward the adjacent occupant. 
         [0024]    The disclosed invention in its various embodiments overcomes the limitations generally associated with current grab handle design which retains the requisite integrity to support the grab handle but which minimizes the lateral stiffness of the adjacent area, thus minimizing vehicle-inward movement of the grab handle assembly in the event of a side impact.  FIGS. 4 through 7  relate to a first preferred embodiment of the disclosed design.  FIG. 8  relates to a second preferred embodiment of the disclosed design.  FIGS. 9 through 11  relate to a third preferred embodiment of the disclosed design. 
         [0025]    With respect to the first embodiment and with specific reference to  FIGS. 4 and 5 , a grab handle arrangement on a vehicle door, generally illustrated as  30 , is illustrated. The grab handle arrangement  30  includes a grab handle close-out  32  attached to a door trim substrate  34 . The door trim substrate  34  includes a lower A-surface  36  formed on a map pocket cover  37 . The grab handle close-out  32  includes a forward lateral wall  38  and a rearward lateral wall  40 . 
         [0026]    An L-shaped fastener cover  42  is provided to cover the fastener hole on the A-surface  36 . The L-shaped fastener cover  42  is an advancement over the known I-shaped cover  16  illustrated in  FIGS. 1 through 3  of the prior art and adds to that standard cover an extended second surface  46 . As best viewed in  FIG. 5  which illustrates a back side perspective view of the grab handle arrangement  30 , a section has been removed from the lower A-surface  36  to accommodate the extended second surface  46  of the L-shaped fastener cover  42 , thus defining an aperture or hole in the lower A-surface  36 . The aperture or hole reduces the lateral stiffness of the region. 
         [0027]    As illustrated in  FIGS. 6 and 7 , a grab handle  48  is attached to the grab handle close-out  32 . In addition, and as also illustrated in  FIGS. 6 and 7 , the aperture or hole is defined in the lower A-surface  36  in the area generally below the extended second surface  46  of the L-shaped fastener cover  42 . The A lip  50  is optionally but preferably provided on the leading edge of the cut out area of the lower A-surface  36 . The lip  50  provides support for the extended second surface  46  of the L-shaped fastener cover  42 . 
         [0028]      FIGS. 6 and 7  further illustrate how the grab handle arrangement  30  responds in a side impact event. In  FIG. 6  the grab handle arrangement  30  is shown prior to the side impact event. The grab handle close-out  32  and its associate structures provide the integrity needed to serve the necessary function. The L-shaped fastener cover  42  provides the necessary coverage over the underlying fasteners (not shown) while interfering minimally or not at all in the integrity of the lower A-surface  36 . 
         [0029]    In a side impact event, as illustrated in  FIG. 7 , the door trim substrate  34  is pushed vehicle inward. Almost simultaneously the L-shaped fastener cover  42  separates in part from the lower A-surface  36  as the lip  50  of the lower A-surface  36  strokes relative to the extended second surface  46  of the L-shaped fastener cover  42 , thus reducing substantially or entirely eliminating the vehicle-inward movement of the associated grab handle close-out  32 . 
         [0030]    The embodiment disclosed in  FIGS. 4 through 7  and discussed in relation thereto illustrates a first, non-limiting embodiment of the invention. A second embodiment of the disclosed invention is set forth in  FIG. 8  in grab handle arrangement for a vehicle door, generally illustrated as  60 , is illustrated. The grab handle arrangement  60  includes a grab handle close-out  62  attached to a door trim substrate  64 . The door trim substrate  64  includes a lower A-surface  66  formed on a map pocket cover  68 . The grab handle close-out  62  includes a forward lateral wall  70  and a rearward lateral wall  72 . 
         [0031]    A conventional fastener cover  74  is provided to cover the fastener hole on the map pocket cover  68 . A map pocket extension  76  may be provided in a cut out area between the forward lateral wall  70  and the map pocket cover  68 . The cut out area reduces lateral stiffness of the forward lateral wall  70 . In a side impact event the forward lateral wall  70  strokes relative to the map pocket extension  76 . A map pocket extension (not shown) may also be provided in a cut out area between the rearward lateral wall  72  and the map pocket cover  68 . 
         [0032]    A third embodiment of the disclosed invention is set forth in  FIGS. 9 through 11  in which a grab handle arrangement for a vehicle door, generally illustrated as  80 , is illustrated. According to this embodiment the grab handle arrangement includes a 360° grab handle  82  having grab handle close-out  84  which is moved vehicle outward compared with known configurations. An armrest cover  86  is formed substantially over and around the grab handle close-out  84 . The outward positioning of the grab handle close-out  84  results in a gap being formed between the armrest cover  86  and the grab handle close-out  84 . A foam filling  88  is used to fill the gap left by the greater distance. 
         [0033]      FIG. 10  illustrates the grab handle arrangement  80  prior to a side impact event with an occupant  90  adjacent to the grab handle  82 .  FIG. 11  illustrates the grab handle arrangement  80  after a side impact event wherein the grab handle  82  and the occupant  90  have come into contact. However, because of the presence of the foam filling  88  between the grab handle close-out  84  and the armrest cover  86  the energy of the impact between the occupant  90  and the grab handle  82  is substantially absorbed by the foam filling  88  and is dissipated as is known in the art. 
         [0034]    Other embodiments of the disclosed invention may include the fastener cover extension hiding one or more apertures or holes in other areas of the grab handle A-surfaces. These lateral walls may include, but are not limited to, the armrest substrate, the grab handle close-out, the map pocket cover, and the door trim substrate. 
         [0035]    The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.