Door handle assembly with retention feature

A door handle assembly includes a bracket having a retention feature, an end cap connected to the bracket, and a handle pivotally connected to the bracket and moveable between a closed position and an open position, the handle having a pivot arm disposed within the bracket, the pivot arm having a pivot point and a lower portion, wherein the pivot arm engages the bracket and the lower portion is disposed on a side of the pivot point opposite the handle. The retention feature engages the lower portion when the handle is in the closed position and applies a force on the pivot arm in a rearward direction to maintain a gap distance between the handle and the end cap.

INTRODUCTION

The present disclosure relates to a door handle assembly with a retention feature for the handle, and more particularly to a door handle assembly on a motor vehicle with a retention feature for the handle that maintains a gap consistency between the handle and an end cap.

Motor vehicles generally include a door handle assembly mounted to an exterior of the motor vehicle door panel to allow easy access to the motor vehicle compartment. Typically, an end cap and a handle are on the exterior of the door handle assembly and are readily visible. The end cap is stationary relative to the door panel and may contain a door lock or other mechanism. The handle pivots with respect to the end cap when opened. A gap exists between the end cap and the door handle when the door handle is in the closed position. Due to stacking tolerances and movement of the door handle, this gap may be inconsistent and may negatively affect the aesthetic of the motor vehicle. Thus, while current door handle assemblies achieve their intended purpose, there is a need for a new and improved door handle assembly that maintains a consistent gap while not adversely affecting the operation and feel of the door handle.

SUMMARY

According to several aspects, a door handle assembly includes a bracket having a retention feature, an end cap connected to the bracket, and a handle pivotally connected to the bracket and moveable between a closed position and an open position, the handle having a pivot arm disposed within the bracket, the pivot arm having a pivot point and a lower portion, wherein the pivot arm engages the bracket and the lower portion is disposed on a side of the pivot point opposite the handle. The retention feature engages the lower portion when the handle is in the closed position and applies a force on the pivot arm in a rearward direction to maintain a gap distance between the handle and the end cap.

In one aspect, the retention feature is semi-flexible in a forward direction and the rearward direction.

In another aspect, the retention feature includes a lever extending into the bracket, the lever having a bent portion that extends toward the pivot arm.

In another aspect, the retention feature includes a curved surface on the lever that engages a matching curved surface on the lower portion of the pivot arm.

In another aspect, the retention feature does not engage the pivot arm when the pivot arm has rotated approximately 3 degrees from the closed position.

In another aspect, the handle includes a forward portion and a rearward portion, and the pivot arm is disposed at the forward portion of the handle.

In another aspect, the end cap is disposed adjacent the rearward portion of the handle.

In another aspect, the rearward portion of the handle is connected to the bracket by a leg.

In another aspect, a spring is connected to the leg, wherein the spring biases the handle to the closed position.

In another aspect, the bias of the spring exerts a force on the handle greater than the force on the pivot arm applied by the retention feature to keep the handle in the closed position when not moved to the open position by an operator of the door handle assembly.

In another aspect, the retention feature is integrally molded with the bracket.

In another aspect, the bracket defines a window through which the pivot arm of the handle is extended, and the retention feature is disposed adjacent the window.

In another aspect, the bracket includes an outer side on which the handle is disposed and an inner side through which the pivot arm of the handle extends.

According to several aspects of the present disclosure, a door handle assembly for a door of a motor vehicle includes a bracket connected to the door and having a retention feature, the retention feature having a lever extending from the bracket, the lever semi-flexible in a forward direction and a rearward direction, the lever having an engagement surface at an end thereof, an end cap connected to the bracket, and a handle pivotally connected to the bracket and moveable between a closed position and an open position, the handle having a pivot arm disposed within the bracket, the pivot arm having a pivot point and a lower portion, wherein the pivot arm engages the bracket and the lower portion is disposed on a side of the pivot point opposite the handle, and the lower portion has a contact surface matching a shape of the engagement surface of the lever. The engagement surface of the lever engages the contact surface of the lower portion when the handle is in the closed position and applies a force on the pivot arm in the rearward direction to maintain a gap distance between the handle and the end cap.

In one aspect, the engagement surface of the lever does not engage the contact surface of the lower portion when the handle is in the open position.

In another aspect, the bracket includes an inner side connected to the door and an outer side, the handle disposed on the outer side of the bracket, the pivot arm extending through a window in the bracket and the lever engaging the pivot arm on the inner side of the bracket.

In another aspect, the handle includes a forward portion and a rearward portion, and the pivot arm is disposed at the forward portion of the handle, and the end cap is disposed adjacent the rearward portion of the handle.

In another aspect, a spring biases the handle to the closed position and the bias of the spring exerts a force on the handle greater than the force on the pivot arm applied by the retention feature to keep the handle in the closed position when not moved to the open position by an operator of the door handle assembly.

According to several aspects of the present disclosure, a door handle assembly for a door of a motor vehicle includes a bracket connected to the door and having a retention feature, the retention feature having a lever extending from the bracket, the lever semi-flexible in a forward direction and a rearward direction, the lever having an engagement surface at an end thereof, an end cap connected to the bracket, and a handle pivotally connected to the bracket and moveable between a closed position and an open position, the handle having a pivot arm disposed within the bracket, the pivot arm having a pivot point and a lower portion, wherein the pivot arm engages the bracket at the pivot point and the handle pivots about the pivot point, the lower portion disposed on a side of the pivot point opposite the handle, and the lower portion having a contact surface matching a shape of the engagement surface of the lever. The engagement surface of the lever engages the contact surface of the lower portion when the handle is in the closed position and applies a force on the pivot arm in the rearward direction to maintain a gap distance between the handle and the end cap, and wherein the engagement surface of the lever does not engage the contact surface of the lower portion when the handle is in the open position.

DETAILED DESCRIPTION

Referring toFIGS. 1-3, a door handle assembly is generally indicated by reference number10. The door handle assembly10is shown mounted in an exemplary door panel12of a motor vehicle. The door panel12forms an exterior surface of the motor vehicle. The door panel12may be a driver's side door, passenger door, or any other door on the motor vehicle. The motor vehicle may be a passenger car, truck, sport utility vehicle, or any other vehicle that includes a door for accessing an interior of the vehicle such as a construction vehicle, aircraft, watercraft, etc. Generally, the door handle assembly10includes an end cap14, a handle16, and a bracket18.

The end cap14is fixedly connected to the bracket18at a rearward end of the door handle assembly10. In one aspect the end cap14houses a key lock/unlock mechanism (not shown) or an electronic push button lock/unlock device (not shown) that is mounted within a cylinder20formed in the bracket18. In another aspect, the end cap14is decorative and improves the aesthetic of the door handle assembly10.

The handle16is pivotally connected to the bracket18, as will be described in greater detail below, and is moveable between a closed position, shown inFIG. 1, and an open position, shown inFIG. 2. The handle16is interconnected to a door latch/unlatch mechanism (not shown) such that when the handle is in the closed position the door is latched and when the handle is in the open position the door is unlatched. The handle16includes a handle body22intended to be gripped by a user of the door handle assembly10. The handle body22includes forward portion22A and a rearward portion22B longitudinally opposite the forward portion22.

A pivot arm26extends out from an inner side28of the handle16at the forward portion22A. The pivot arm26includes a first section30that extends towards the bracket18and a second section32that extends in a forward direction. A pivot point34is formed on an outer surface36of the second section32. The pivot point34is generally cylindrical in shape to provide point contact between the handle16and the bracket18, as will be further described below. The second section32further includes a lower portion38that is disposed inwardly of the pivot point34. Thus, the lower portion38and the handle body22are disposed on opposite sides of the pivot point34. The lower portion38includes a contact surface40disposed between the transition of a forward surface42of the lower portion38and an inner surface44of the lower portion38. The contact surface40is preferably curved with a substantially circular cross-section.

A leg46extends out from the inner side28of the handle16at the rearward portion22B. As best seen inFIG. 4, the leg46is engaged with a counterbalance48connected to the bracket18and a counterbalance spring50. The counterbalance spring50exerts a force on the leg46, and thus the handle16, inwardly to bias the handle16to the closed position.

With reference toFIGS. 1 and 3, the handle16and the end cap14are separated by a gap52when the handle16is in the closed position. The gap52is defined as a distance from an edge54of the rearward portion22B of the handle16to a forward edge56of the end cap14.

The bracket18supports the various components of the door handle assembly10, as noted above, and generally includes an outer side58to which the end cap14and handle16are attached and an inner side60that is connected to a door frame or other structural member of the door (not shown).

Turning toFIGS. 5 and 6, the bracket18includes a window62that extends from the outer side58of the bracket18to the inner side60. The pivot arm30of the handle16is disposed through the window62. The pivot point34contacts a bearing surface64within the window62. Thus, the pivot point34rides on and pivots about the bearing surface64when the handle16is moved between the closed position and the open position.

A retention feature70is disposed on the inner side60of the bracket18. The retention feature70maintains a consistent gap52between the handle16and the end cap14when the handle16is in the closed position by engaging the lower portion38of the pivot arm30. The retention feature70is preferably formed integrally with the bracket18, though the retention feature70may be a separate component without departing from the scope of the present disclosure. The retention feature70is semi-flexible in a forward direction and the rearward direction.

The retention feature70is disposed adjacent the window62. The retention feature70includes a lever72extending inwardly from the bracket18. The lever72includes a bent portion74that extends toward the pivot arm30in a rearward direction. The retention feature70includes a curved engagement surface76on the bent portion74that engages the curved contact surface40on the lower portion38of the pivot arm30. In one aspect, the engagement surface76has a shape that substantially matches or substantially mates with the contact surface40.

With reference toFIG. 5, when the handle16is in the closed position, the counterbalance spring50exerts a force on the handle16inwardly and the lower portion38of the pivot arm30pivots about the pivot point34and engages the retention feature70. However, the semi-flexible nature of the retention feature70exerts a force on the lower portion38of the lever arm30in the rearward direction. Thus, the position of the handle16is maintained between these two forces and the gap52distance is maintained. To prevent the retention feature70from opening the handle16, the force exerted by the counterbalance spring50is greater than the force exerted by the retention feature70. With reference toFIG. 6, when the handle16is moved to the opened position by an operator, the lower portion38pivots away from the retention feature70and at approximately 3 degrees of rotation the retention feature70ceases to exert any force on the pivot arm30.

The door handle assembly10of the present disclosure offers several advantages. These include maintaining the gap52at a consistent distance when the handle16is closed to improve the aesthetics of the vehicle, prevention of the handle16sticking due to the semi-flexible nature of the retention feature70, minimizing the size of the gap52by keeping the gap52consistent, minimizing the addition of complex parts, and minimizing the effect on the “feel” of the operation of the handle16, to name but a few.

The terms “forward”, “rearward”, “inner”, “inwardly”, “outer”, and “outwardly” are terms used relative to the orientation of the door handle assembly10as shown in the drawings of the present application relative to a motor vehicle. Thus, “forward” refers to a direction toward a front of a motor vehicle, “rearward” refers to a direction toward a rear of a motor vehicle, “inner” and “inwardly” refers to a direction towards the interior of a motor vehicle, and “outer” and “outwardly” refers to a direction towards the exterior of a motor vehicle. Thus, while the orientation of the door handle assembly10may change with respect to a given use (driver's side door vs. passenger door, etc.), these terms are intended to still apply relative to the orientation of the components of the door handle assembly10as shown in the drawings.