Two toned vehicle door handles

This disclosure details two toned door handles for vehicle doors. An exemplary two toned door handle may include a non-metallized portion and a metallized portion. The metallized portion may include a metallic layer that is transparent to signals sent and received by an antenna module packaged inside the two toned door handle. Exemplary methods for cost-effectively manufacturing the two toned door handle are also disclosed.

TECHNICAL FIELD

This disclosure relates generally to vehicle door handles, and more particularly to two toned vehicle door handles that provide both a non-metallized appearance and a metallized appearance.

BACKGROUND

Motor vehicles include doors with handles. The handles are provided on both the exterior and the interior of the doors and are utilized to open or close the doors. Manufactures may desire to imbed antenna modules within the door handles for tracking and/or authenticating authorized users of the vehicle. Door handles that include metallic materials typically do not include imbedded antenna modules because of the potential for the metallic materials to interfere with signal communications to and from the antenna modules.

SUMMARY

A vehicle according to an exemplary aspect of the present disclosure includes, among other things, a door and a two toned door handle secured to the door and including a non-metallized portion and a metallized portion. The metallized portion includes a metallic layer comprised of indium.

In a further non-limiting embodiment of the foregoing vehicle, the metallic layer is disposed between a base layer and an outer layer.

In a further non-limiting embodiment of either of the foregoing vehicles, the base layer includes an UV curable coating and the outer layer includes an UV based coating.

In a further non-limiting embodiment of any of the foregoing vehicles, the outer layer is tinted.

In a further non-limiting embodiment of any of the foregoing vehicles, the metallic layer comprises 99.99% pure indium.

In a further non-limiting embodiment of any of the foregoing vehicles, an antenna module is packaged within a handle body of the two toned door handle. The metallic layer is signal transparent to signals communicated to or from the antenna module.

In a further non-limiting embodiment of any of the foregoing vehicles, a molded-in ditch is formed in a thermoplastic substrate of the two toned door handle.

In a further non-limiting embodiment of any of the foregoing vehicles, the non-metallized portion is colored, and the metallized portion exhibits a chrome-like appearance.

In a further non-limiting embodiment of any of the foregoing vehicles, the two toned door handle is secured at an interior surface of the door.

In a further non-limiting embodiment of any of the foregoing vehicles, the two toned door handle is secured at an exterior surface of the door.

In a further non-limiting embodiment of any of the foregoing vehicles, the metallic layer includes a thickness between about 0.1 μm and about 5 μm.

In a further non-limiting embodiment of any of the foregoing vehicles, the thickness of the metallic layer is between about 0.1 μm and about 0.2 μm.

A method according to another exemplary aspect of the present disclosure includes, among other things, molding a door handle for a vehicle door in a single color, masking a first portion of the door handle, and metalizing a second portion of the door handle. The first portion of the door handle includes a non-metalized appearance and the second portion of the door handle includes a metallized appearance.

In a further non-limiting embodiment of the foregoing method, molding the door handle includes molding a single-piece thermoplastic substrate of the door handle via an induction heated injection molding process.

In a further non-limiting embodiment of either of the foregoing methods, an injection mold used in the induction heated injection molding process includes an induction heating element and a water cooling line.

In a further non-limiting embodiment of any of the foregoing methods, masking the first portion of the door handle includes applying a mask to the first portion of the door handle via a ditch formed in the first portion.

In a further non-limiting embodiment of any of the foregoing methods, metalizing the second portion of the door handle includes applying a metallic layer over the second portion of the door handle via a physical vapor deposition (PVD) technique.

In a further non-limiting embodiment of any of the foregoing methods, prior to applying the metallic layer, the method includes applying a base layer to the second portion of the door handle.

In a further non-limiting embodiment of any of the foregoing methods, after applying the metallic layer, the method includes applying an outer layer over the metallic layer.

In a further non-limiting embodiment of any of the foregoing methods, the metallic layer includes indium.

DETAILED DESCRIPTION

This disclosure details two toned door handles for vehicle doors. An exemplary two toned door handle may include a non-metallized portion and a metallized portion. The metallized portion may include a metallic layer that is transparent to signals sent and received by an antenna module packaged inside the two toned door handle. Exemplary methods for cost-effectively manufacturing the two toned door handle are also disclosed. These and other features of this disclosure are described in greater detail in the following paragraphs of this detailed description.

FIG.1schematically illustrates a vehicle10. The vehicle10may be a car, a truck, a van, a sport utility vehicle, or any other type of motor vehicle. The vehicle10could also be a conventional motor vehicle, a battery powered hybrid or electric vehicle, or an autonomous vehicle.

Although a specific component relationship is illustrated in the figures of this disclosure, the illustrations are not intended to limit this disclosure. The placement and orientation of the various components of the vehicle10are shown schematically and could vary within the scope of this disclosure. In addition, the various figures accompanying this disclosure are not necessarily to scale, and some features may be exaggerated or minimized to emphasize certain details of a particular component.

The vehicle10may include front and rear doors, which are collectively referred to herein as the doors12. In the illustrated embodiment, a four door vehicle is shown. However, this disclosure extends to vehicles having at least one door.

Each door12of the vehicle10may include a door handle14. The door handle14may be secured at an exterior surface16of the door12. Provided the door handle14is accessible and the door12is unlatched, a user can pull the door handle14to move the door12from the closed position shown inFIG.1to an open position. The user can gain ingress into the vehicle10when the door12is in the open position.

FIG.2illustrates an interior surface18of one of the doors12of the vehicle10ofFIG.1. An additional door handle20may be secured at the interior surface18of the door12. A user can push or pull on the door handle20to move the door12between open and closed positions from inside a passenger cabin of the vehicle10.

The door handles14,20ofFIGS.1-2may or may not be connected to a door latching mechanism. Therefore, the door handles14,20may be either movable handles or stationary handles. Thus, this disclosure is applicable to both movable and stationary door handles.

Some vehicle customers may desire that the door handles14,20provide a sleek and upscale appearance. Furthermore, manufactures may desire to embed antenna modules within the door handles14,20for tracking and/or authenticating authorized users of the vehicle10, such as via a radio frequency identification (RFID) system or passive entry passive start (PEPS) system, for example. However, depending on the materials and manufacturing processes used, the door handles14,20may not adequately transmit signals through the various materials and coatings of the door handles14,20. Accordingly, exemplary door handles that provide both an attractive appearance and that are capable of receiving and transmitting signals via embedded antenna modules are proposed within this disclosure.

FIGS.3,4, and5illustrate an exemplary two toned door handle22for a vehicle door. The two toned door handle22can be secured at either an exterior surface or an interior surface of a vehicle door to provide a sleek, upscale appearance.

The two toned door handle22includes a handle body24. In an embodiment, the handle body24is L-shaped and includes a curved contour that allows users to ergonomically push/pull the two toned door handle22when mounted to a vehicle door. However, the size and shape of the handle body24of the two toned door handle22are not intended to limit this disclosure.

The handle body24of the two toned door handle22may include one or more non-metallized portions26and one or more metallized portions28. Together, the non-metallized portion(s)26and the metallized portion(s)28provide the “two toned” appearance of the two toned door handle22.

In an embodiment, side surfaces of the handle body24are configured as the non-metallized portions26, and an upper and/or lower surface of the handle body24is configured as the metallized portion28. However, other configurations are also contemplated within the scope of this disclosure.

Each non-metallized portion26includes a non-metallized appearance established by exterior surfaces of a thermoplastic substrate30of the handle body24. The thermoplastic substrate30may be made of a high strength structural thermoplastic material that is tough enough to withstand daily usage of the two toned door handle22. Suitable materials for constructing (e.g., molding) the thermoplastic substrate30include, but are not limited to, polycarbonate (PC), nylon, or thermoplastic alloys such as PC/acrylic-styrene-acrylate terpolymer (ASA), PC/Acrylic alloy, PC/Acrylonitrile butadiene styrene (ABS), etc. The non-metalized portion26may provide a colored appearance, such as in black or any other desired accent color.

Each metallized portion28includes a metallic or chrome-like appearance established by plating portions of the thermoplastic substrate30with one or more metallic layers. The metallized portion(s)28therefore includes a different color and appearance than the non-metallized portion(s)26.

Referring now primarily toFIG.5, an antenna module32may be imbedded within or otherwise packaged inside the handle body24of the two toned door handle22. The antenna module32is configured to track the activities of and authenticate authorized users of a vehicle equipped with the two toned door handle22, such as for automatically locking or unlocking a door of the vehicle, for example.

In an embodiment, the antenna module32is packaged beneath the metallized portion28of the two toned door handle22. The metallized portion28may be made of a material or combination of materials that is transparent to signals, such as radio frequency (RF) signals, radar signals, infrared signals, Bluetooth low energy (BLE) signals, etc., that may be sent and received by the antenna module32.

The antenna module32may be a low frequency device that includes both a receiver and a transmitter, such as a Bluetooth Low Energy Antenna Module (BLEAM), for example. The antenna module32may be part of a capacitive or infrared sensor system, a radio frequency identification (RFID) system, a passive entry passive start (PEPS) system, etc.

The handle body24of the two toned door handle22may additionally include a ditch34formed in the thermoplastic substrate30. The ditch34may be a slight recess formed in an exterior portion of the thermoplastic substrate30, and as further discussed below, can be used during decorating steps to accommodate a mask that is applied to the handle body24prior to forming the metallized portion28on the thermoplastic substrate30.

FIG.6further illustrates select features of the metallized portion28of the two toned door handle22. The metallized portion28may include a base layer36, a metallic layer38, and an outer layer40that are applied over the thermoplastic substrate30of the handle body24.

The base layer36of the metallized portion28is configured for improving adhesion between the metallic layer38and the thermoplastic substrate30. The base layer36may be an UV curable coating, such as UVB315 basecoat sold by Red Spot Paint & Varnish Company, Inc. However, other suitable coatings could be employed as the base layer36within the scope of this disclosure depending on the respective materials of the metallic layer38and the thermoplastic substrate30, among other factors. In an embodiment, a thickness of the base layer36is between about 10 μm and about 15 μm. In this disclosure, the term “about” means that the expressed quantities or ranges need not be exact but may be approximated and/or larger or smaller, reflecting acceptable tolerances, conversion factors, measurement error, etc.

The metallic layer38is configured to provide the metallic or chrome-like appearance of the metallized portion28. In an embodiment, the metallic layer38includes indium, such as 99.99% pure indium. The use of indium within the metallic layer38may provide numerous advantages such as transparency to signals sent from or received by the antenna module32, a low vapor pressure, and providing for a bright, chrome-like appearance that forms a protective oxide layer over the handle body24. In an embodiment, a thickness of the metallic layer38is between about 0.1 μm and about 5 μm. In another embodiment, the thickness of the metallic layer38is between about 0.1 μm and about 0.2 μm.

The outer layer40of the metallized portion28is configured for sealing and protecting the metallic layer38from wear and tear, and in exterior door implementations, for protecting the two toned door handle22from the elements. The outer layer40may be an UV based coating, such as UVT783 topcoat sold by Red Spot Paint & Varnish Company, Inc. However, other suitable coatings could be employed as the outer layer40within the scope of this disclosure depending on the material make-up of the metallic layer38, among other factors. In an embodiment, a thickness of the outer layer40is between about 15 μm and about 20 μm.

As would be understood by persons of ordinary skill in the art, the respective thicknesses of the base layer36, the metallic layer38, and the outer layer40of the metallized portion28are not necessarily shown to the scale they would be in practice. Rather, these features have been exaggerated inFIG.6to better illustrate the various features of the metallized portion28of the two toned door handle22.

FIG.7schematically illustrates, in sequential order, an exemplary method50for manufacturing the two toned door handle22discussed above with reference toFIGS.1-6. It should be understood that fewer or additional steps than are recited below could be performed, and the specific recited order of steps shown inFIG.7is not intended to limit this disclosure.

First, at block52, the thermoplastic substrate30is molded in a molding process to form the handle body24of the two toned door handle22. The molding process may be an injection molding process or any other suitable molding process. The molding process may include forming the handle body24in-color (e.g., in black or any other desirable accent color) and in a single piece from a high gloss thermoplastic structural material. The ditch34may be formed in the thermoplastic substrate30during the molding process.

An exemplary molding process may include molding the thermoplastic substrate30in an induction heated injection mold. An exemplary injection mold42is illustrated inFIG.8. The injection mold42may be heated (e.g., via an induction heating element44) to a temperature that is within a few degrees of the melting temperature (typically between 140° and 160° C. (284° and 320° F.)) of the thermoplastic material of the thermoplastic substrate30and then held at that temperature until a cavity of the injection mold42is filled with the thermoplastic material. The injection mold42may then be rapidly cooled, such as via water cooling lines46formed within the injection mold42, for example. This combination of induction heating with rapid cooling increases the hardness of the thermoplastic substrate30, thereby resulting in a part having a relatively high scratch resistant outer surface.

Next, at block54, the thermoplastic substrate30may be prepped for subsequent decorating steps by masking select portions of the thermoplastic substrate30. An exemplary mask48for masking the thermoplastic substrate30is illustrated inFIG.9. The mask48may be secured to a first portion of the thermoplastic substrate30using the ditch34and is configured to cover the portions of the thermoplastic substrate30that will provide the non-metallized portions26of the two toned door handle22(i.e., to cover the portions of the thermoplastic substrate30where metallic plating is not desired). The ditch34provides a surface for establishing a clear break line in the mask48and simplifies the overall masking process. In an embodiment, the mask48is a molded or vacuum formed plastic mask. In another embodiment, the mask48is a die-cut adhesive masking tape.

A second portion (e.g., a non-masked surface) of the thermoplastic substrate30may be coated with the base layer36at block56. The base layer36may be applied using any known technique. The second portion of the thermoplastic substrate30may include a non-masked surface that is uncovered by the mask48and at which a metallized or chrome-like appearance is desired.

Next, at block58, the thermoplastic substrate30may be metalized. For example, the metallic layer38may be applied over top of the base layer36using a physical vapor deposition (PVD) technique to sputter a relatively thin metallic coating onto the thermoplastic substrate30. Other techniques may also be suitable for applying the metallic layer38. The metallic layer38establishes the metallic or chrome-like appearance of the two toned door handle22. The properties of the metallic layer38can be controlled during the PVD process to provide any number of surface finishes and appearances.

Finally, the outer layer40may be applied over the metallic layer38at block60. The outer layer40protects the metallic layer38. The outer layer40may be applied using any known technique. The outer layer40may be tinted to provide a near limitless portfolio of potential finishes. In addition, a gloss of the outer layer40can be varied from matte to high gloss to provide design flexibility. Together, the base layer36, the metallic layer38, and the outer layer40establish the metallized portion28, which provides the metallic or chrome-like appearance to select portions of the two toned door handle22.

The two toned vehicle door handles of this disclosure provide a sleek and attractive appearance that is aesthetically pleasing to customers. The exemplary two toned door handles can be manufactured cost effectively by avoiding the need to mold a separate metallized accent piece that must be attached to the thermoplastic substrate. Moreover, by using materials that are transparent to RF or radar frequency devices, antenna modules can advantageously be imbedded or otherwise housed within the exemplary two toned door handles for tracking user activities.