Abstract:
A push switch apparatus includes a switch case adapted to be a base member, a switch mounted on the switch case, a switch cap made of an elastic material and supported on the switch case for covering the switch, a switch button supported by the base member and having an actuating portion for pushing the switch and an switch plate mounted on the switch case and arranged between the switch cap and the switch button. The switch plate having a contact surface contacts the switch button when the actuating portion of the switch button pushes the switch.

Description:
[0001]    This application is based on and claims priority under 35 U.S.C. § 119 with respect to Japanese Application No. 2003-117205 filed on Apr. 22, 2003, and Japanese Application No. 2003-117214 filed on Apr. 22, 2003, the entire content of which is incorporated herein by reference.  
         FIELD OF THE INVENTION  
         [0002]    This invention generally relates to a push switch apparatus, more particularly for provided with a vehicle door handle device of a vehicle door.  
         BACKGROUND OF THE INVENTION  
         [0003]    A known push switch apparatus is disclosed in Japanese Patent Laid-Open Publication No. 2001-182459. The push switch includes a switch case, a switch, a switch cap and a switch button. The switch is arranged in a switch case. The switch cap is supported on the switch button and is fixed to the switch case. The switch cap cavers the switch for protects switch from a water. In such configuration, when the switch button is operates, the switch button pushes the switch through the switch cap. Therefore, the switch is generating a signal. However, the push switch is not considering a measure for releasing an excessive operation force relative to the switch, when the switch button is operates.  
           [0004]    A need thus exit for a push switch includes a measure for releasing an excessive operation force.  
         SUMMARY OF THE INVENTION  
         [0005]    In light of the foregoing, the present invention provides a push switch apparatus, which includes a switch case adapted to be a base member, a switch mounted on the switch case, a switch cap made of an elastic material and supported on the switch case for covering the switch, a switch button supported by the base member and having an actuating portion for pushing the switch and an switch plate mounted on the switch case and arranged between the switch cap and the switch button. The switch plate having a contact surface contacts the switch button when the actuating portion of the switch button pushes the switch. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING FIGURES  
       [0006]    The foregoing and additional features and characteristics of the present invention will become more apparent from the following detailed description considered with reference to the accompanying drawing figures in which like reference numerals designate like elements and wherein:  
         [0007]    [0007]FIG. 1 illustrates a cross sectional view indicating an inner configuration of a vehicle door handle device according to an embodiment of the present invention;  
         [0008]    [0008]FIG. 2 illustrates a perspective view indicating a vehicle door at which the vehicle door handle device shown in FIG. 1 is assembled;  
         [0009]    [0009]FIG. 3 illustrates a front view of the vehicle door handle device according to the embodiment of the present invention;  
         [0010]    [0010]FIG. 4 illustrates a diagram indicating a molding unit provided inside the vehicle door handle shown in FIG. 3;  
         [0011]    [0011]FIG. 5 illustrates a side view of the molding unit shown in FIG. 4;  
         [0012]    [0012]FIG. 6 illustrates a perspective view indicating a form of a switch case shown in FIG. 4;  
         [0013]    [0013]FIG. 7 illustrates a partial cross sectional view indicating an inner configuration of the molding unit shown in FIG. 5;  
         [0014]    [0014]FIG. 8 illustrates a partial cross sectional view indicating a configuration of a connecting portion of a terminal of the molding unit shown in FIG. 7;  
         [0015]    [0015]FIG. 9 illustrates a front view indicating a switch and a flexible circuit board before molded into the molding unit shown in FIG. 4;  
         [0016]    [0016]FIG. 10 illustrates a side view of the switch and the flexible circuit board show in FIG. 9;  
         [0017]    [0017]FIG. 11 illustrates a partial enlarged view indicating a electrically connecting portion between the switch and the flexible circuit board shown in FIG. 9;  
         [0018]    [0018]FIG. 12 illustrates a partial cross sectional view indicating an inner configuration of a door switch shown in FIG. 4;  
         [0019]    [0019]FIG. 13 illustrates an enlarged partial cross sectional view indicating an inner configuration of the door switch shown in FIG. 1, and  
         [0020]    [0020]FIG. 14 illustrates a partial cross sectional view along a center line of the door switch showing an another aspect of the inner configuration of the door switch shown in FIG. 12.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    A preferred embodiment of the present invention will be described hereinbelow in detail with reference to the accompanying drawings.  
         [0022]    [0022]FIG. 1 illustrates a cross sectional view indicating an internal configuration of a vehicle door handle device  1 . As shown in FIG. 2, the vehicle door handle device  1  is provided at the upper rear portion of a vehicle door  2  by which a user gets in or out of the vehicle, and the vehicle door handle device  1  includes an outside handle  3  (a handle body) being shaped as shown in FIG. 3.  
         [0023]    As shown in FIG. 1 and  2 , the vehicle door handle device  1  according to this embodiment of the present invention includes the outside handle  3  in which an antenna  5 , a sensor electrode  6  (an operation detecting sensor) for detecting an operation of the outside handle  3  and a door switch device  70  (a push switch apparatus) for requiring a locking action of a door lock device (not shown) of the vehicle door  2  are housed.  
         [0024]    The outside handle  3  includes a hinge portion  31 , a main body  32 , a limiting portion  33  and a handle cover  4 . The hinge portion  31  for rotating a rear portion of the vehicle door  2  (the right side in FIG. 1) in the vehicle width direction positioning a fulcrum at a front portion of the vehicle door  2  (the left side in FIG. 1). The main body  32  including a housing portion  3   a  in which the antenna  5 , the sensor electrode  6 , the door switch device  70  and the like are housed. The limiting portion  33  being reverse L-shaped in the cross sectional view shown in FIG. 1 for limiting an rotation angle of the outside handle  32  not to be exceed equal to or more than a predetermined angle.  
         [0025]    Further, a grip portion  34  being thin at the vehicle door side is formed at the main body  32 . The housing portion  3   a  opening outwardly is covered by the handle cover  4  and designing surface of the vehicle door handle device  1 . The handle cover  4  is made by a process of insert molding with two nuts inserted into a form block. The handle cover  4  is attached to the main body  32  by screwing screws  41  and  42  inserted through the main body  32  from the vehicle door side into the two nuts integrally formed at the handle cover  4 .  
         [0026]    As shown in FIG. 3, the front portion of the handle cover  4  becomes gradually narrower than the rear portion thereof. The handle cover  4  having a switch button  71  of the door switch device  70  at the rear portion thereof.  
         [0027]    Next, an inner configuration of the housing portion  3   a  formed at the main body  32  and components provided inside the housing portion  3   a  will be explained.  
         [0028]    As shown in FIG. 1, the housing portion  3   a  formed along the longitudinal direction of the main body  32  of the outside handle  3  includes an opening  35  at front portion thereof being rectangular for guiding harnesses  91  into a compartment of the vehicle. In addition, a depressed portion  36  at which a cup-shaped switch case  76  of the door switch device  70  for housing a push-type switch  7  of the door switch device  70  is formed at the rear portion of the housing portion  3   a . The depressed portion  36  is being more depressed toward the vehicle door side than a center portion of the housing portion  3   a.    
         [0029]    As shown in FIG. 1 and FIGS. 3 through 5, the door switch device  70  is positioned at a predetermined position of the depressed portion  36 . A molding unit  10  is provided at approximately center portion of the housing portion  3   a . The molding unit  10  includes a main unit portion  11 , the door switch device  70  and the five harnesses  91 . The molding unit  10  provided in the housing portion  3   a.    
         [0030]    The five harnesses  91  of the molding unit  10  is extending from one end of the main unit portion  11  of the molding unit  10 . In addition, a grommet  49  is fitted at the harnesses  91  for water-proofing, a tube  92  is provided for bundling the harnesses  91 , and a connector  93  is attached at the end of the harnesses  91  for water-proofing as shown in FIG. 1.  
         [0031]    On condition that the molding unit  10  is provided at the housing portion  3   a , the connecter  93  is penetrated through the opening  35  formed at the front portion of the main body  32  and extends inside of the vehicle door  2 .  
         [0032]    An external connector (not shown) is fitted at the connector  91  for transmitting signals to a control device (not shown). Such signals includes a lock requiring signal from the door switch device  70  provided at the housing portion  3   a  and a detecting signal indicating an electric capacitance between the sensor electrode  6  and the user, which is detected at the sensor electrode  6 . At the control device, the condition of such signals are determined by a CPU provided in the controlling device, then a drive signal is transmitted to the antenna  5  provided inside the molding unit  10 , and an electric wave (e.g. ID requiring signal) is transmitted to the outside of the vehicle (e.g. to the user having the portable station).  
         [0033]    As shown FIGS. 7 through 14, a configuration of the molding unit  10  provided at the housing portion  3   a  will be described below. The door switch device  70  is connected to one end of the main unit portion  11 , and the harnesses  91  are connected to the other end of the main unit portion  11 . The main unit  11  includes the antenna  5 , the sensor electrode  6  and a flexible circuit board  8 , the switch  7  of the door switch device  70  is connected to the flexible circuit board  8 . The flexible circuit board  8  being made of resin (polyurethane resin) and molded integrally with the antenna  5  and the sensor electrode  6 .  
         [0034]    A configuration of the antenna  5  will be described below. A ferrite  53  is housed in a rectangular solid antenna case  51  at which two faces are opened. The grommet  49  is attached to the one opening of the antenna case  51 , and the ferrite  53  is inserted through the other opening. A coil  52  is winded on the antenna case  51  in a direction being perpendicular to the longitudinal direction of the antenna case  51  at a predetermined winding number. In this case, the coil  52  is winded at an approximately center portion relative to the longitudinal direction of the antenna case  51  and electrically connected to two terminals  54  attached to one end of the antenna case  51  and extending in the longitudinal direction of the antenna case  51 . The antenna  5  outputs a predetermined electric wave (e.g. ID requiring signal) by applying the drive signal by the control device (not shown) and applying an electric current through the coil  52  winded on the antenna case  51 . Thus, the antenna  5  works as an output antenna, however, such antenna  5  may additionally includes a function as a receiving antenna.  
         [0035]    A configuration of the switch  7  of the door switch device  70  will be explained below. As shown in FIGS. 9 through 11, the switch  7  including a switch main unit  78 , a pressed portion  79 , and four terminals  72 ,  73 ,  74  and  75  is electrically connected to the flexible board  8 . The flexible board  8  includes conductive patterns  81  and  82  made of conductive material like tin. The conductive patterns  81  and  82  are integrally flattened by resin film such as polyethylene. The flexible board  8  also includes edge portions  83 ,  84 ,  85 ,  86  and  87  at which the conductive patterns  81  and  82  are exposed. As shown in FIG. 9, the exposed edge portions  86  and  87  on one side of the conductive patterns  81  and  82  are caulked at caulking portions thereof, then the two harnesses  91  are connected to the caulking portions by resistance welding. On the other hand, the edge portions  83 ,  84  and  85  on the opposite side of the conductive patterns  81  and  82  are connected to three terminals  72 ,  73  and  74  of the four terminals  72 ,  73 ,  74  and  75  by resistance welding as show in FIG. 11. Specifically, the edge portion  83  of the conductive pattern  81  is connected to the terminal  72  of the door switch device  70 . The edge of the conductive pattern  82  on the switch side is bifurcated into two and forms an edge portions  84  and  85  at the back side of the door switch device  70 , and the edge portion  84  is connected to the terminal  73  of the door switch device  70 , and the edge portion  85  is connected to the terminal  74  of the door switch device  70 . In this case, the terminals  72 ,  73  and  74  are connected by the resistance welding, however, the terminals may be connected electrically by soldering alternatively.  
         [0036]    The end portions  86  and  87  of the flexible board  8  are bent in orthogonal direction relative to the longitudinal direction of the flexible board  8  to be like a pair of parentheses in cross sectional view of FIG. 10, so that the end portions  86  and  87  become terminals at which the harnesses  91  are caulked respectively. The flexible board  8  also includes an adjusting portion  88  at which the flexible board  8  is bent to be approximately S-shaped in FIG. 10 for adjusting the position of the door switch device  70  connected to the rear (right) portion of flexible board  8 .  
         [0037]    As shown in FIGS. 4 through 7 and FIGS. 12 through 14, the switch  7  is housed in the switch case  76  being shaped as show in FIG. 6. The switch case  76  includes two openings at the bottom portion thereof (upper portion in FIG. 6), and a cylindrical projecting portion  89  being projecting outwardly at the center portion of the bottom portion of the switch case  76  for positioning the switch case  76  relative to the depressed portion  36  formed at the housing portion  3   a  of the out side handle  3 . Thus, the switch  7  is housed in the switch case  76  at a predetermined position. The switch case  76  also includes an opening at the opposite side where the two opening are provided, and the switch  7  is inserted through the opening from the above direction in FIG. 1. In addition, a switch cap  68  is fitted to the switch case  76  for covering the opening in order to dampproof the switch  7 .  
         [0038]    The center portion of the switch cap  68  being made of elastomer such as synthesized resin and rubber is thin, so that it is deformed being fitted into the switch case  76 . In addition, a switch plate  77  (intermediate member) is fitted to the switch case  76  being covered by the switch cap  68 . The switch plate  77  includes a depressed portion being approximately a cup-formed at which the switch case  76  is fitted. In this case, the switch case  76  including a pair of pawl portion  80  at both sides thereof as shown in FIG. 6 is integrally fixed to the switch plate  77  by the pawl portion  80  being fitted into a pair of groove-formed fitting portion  69  formed inside of the switch-plate  77 . In such condition, polyurethane resin fills inside the switch case  76  through two openings formed at the bottom portion of the switch case  76  next to the projecting portion  89 . The polyurethane resin fills around the switch main unit  78  of the switch  7  except the pressed portion  79 , in other words the pressed portion is uncovered by the polyurethane resin. Thus, the connecting portion between the switch  7  and the flexible board  8  are fixed with the polyurethane resin.  
         [0039]    As shown in FIGS. 1 through 14, the door switch device  70  is assembled as follows. First, the flexible board  8  is connected to the switch  7  shown in FIG. 9, then the switch case  76  and the switch cap  68  are assembled to the door switch device  70 . Next, the pawl portion  80  of the switch case  76  is engages with the switch plate  77 , thus the switch plate  77  is assembled to the switch case  76  to be a sub-assembly (sub-assay). The flexible board  8  of the sub-assay being engaged with the side surface of the ferrite  53  is engaged with two engaging portions  55  and  56  formed at the antenna case  51 . Thus the flexible board  8  is fixed to the antenna case  51 . The sensor electrode  6  is fixed to the opposite side of the bottom portion where the ferrite  53  of the antenna case  51  is housed by means of a double stick tape.  
         [0040]    The sensor electrode  6  includes a rectangular detecting portion  61  provided along the longitudinal direction of the antenna case  51  and a terminal portion  62  continually extending from the detecting portion  61 . A portion between the detecting portion  61  and the terminal portion  62  is bent to be crank-shaped, and the end portion of the terminal portion  62  further extends in the extending direction of the terminal  54  at which the end portion of the coil  52  is connected keeping a predetermined clearance therebetween. In this case, one of five harnesses  91  at which the grommet  49  is fitted is connected to the end portion of the terminal portion  62  of the sensor electrode  6  by resistance welding. Thus, the flexible board  8  at which the switch  7  is connected is fixed to the antenna case  51 , then an assembly unit including an antenna case  51  at which the sensor electrode  6  is mounted is made, and the assembly unit is housed into a rectangular molding case  58  having an opening at one side thereof. Polyurethane resin  59  fills into the molding case  58  housing the assembling unit. In this way, the molding unit  10  being resin molded is formed by integrally molded the flexible board  8  including the door switch device  70  at the one end thereof, the antenna  5  and the sensor electrode  6 . The grommet  49  if fitted at the harness side of the molding case  58  for preventing water coming into the molding case  58  from the periphery of the harnesses  91 . As shown in FIG. 4 and FIG. 5, the resin  59  fills the connecting portion between the harnesses  91  and the molding unit  10  and around the antenna for securing the electrically connection of the connecting portion. In addition, the door switch device  70  is also filled with the resin as aforementioned before. The switch case  76  is filled with the resin  67  being same polyurethane sealing as the resin  59  through the two openings formed next to the cylindrical projecting portion  89  of the switch case  76 . In this way, the switch main unit  78  of the switch  7  is fixed at the predetermined position inside the switch case  76 , at the same time, the switch  7  is sealed for preventing water coming inside thereof.  
         [0041]    The molding unit  10  having an aforementioned configuration is engaged with the bottom portion of the inner side of the grip portion  34  at the sensor electrode side thereof and provided inside the housing portion of the outside handle  3 . The door switch device  70  is positioned by the projecting portion  89  of the switch case  76  being engaged with a positioning portion at the center of the depressed portion  36  formed at the housing portion  3   a  of the outside handle  3 . Thud, the molding unit  10  is provided along the housing portion  3   a.    
         [0042]    A cushion material  9  is applied to the center portion of the molding unit  10  at the opposite side thereof where the sensor electrode  6  is provided. The switch button  71  made of rubber material includes an operating portion being approximately quadrangular-shaped and a boss portion  66  (actuating portion) at the lower center portion thereof in FIG. 1. The switch button  71  is assembled at the rear portion of the handle cover  4  from the vehicle door side.  
         [0043]    The handle cover  4  at which the switch button  71  is fitted is assembled to the outside handle  3  for covering the opening of the housing portion  3   a  of the outside handle  3 . The handle cover  4  is fixed to the main body  32  of the outside handle  3  by screwing the two screws  41  and  42  into the nuts integrally provided at the handle cover  4  from the vehicle door side of the outside handle  3 . Thus, the vehicle door handle device  1  is configured with the outside handle in which the antenna  5 , the sensor electrode  6 , the door switch device  70  are integrally mounted.  
         [0044]    An example of the operation of the vehicle door handle device will be explained as follows.  
         [0045]    When the user approaches the vehicle and being within the predetermined area, the vehicle and the user becomes a transmittable condition. In such condition, the vehicle outputs a predetermined signal (e.g. ID requiring signal) to the portable station possessed by the user from the antenna  5  for requiring the portable station to output a signal. The portable station receives the signal from the vehicle and outputs an ID signal (various kinds of signals depending on each vehicle) to the vehicle. The vehicle receives the signal from the portable station and compares to information registered in advance. If the controlling device determined that the received ID signal is the registered ID (the user is qualified), the sensor electrode  6  detects whether or not the user demands operating the outside handle  3 . In other words, generally the user puts their hand on the grip portion  34  of the outside handle  3  when the user opens or closes the vehicle door  2  (user demands operating), so that the sensor electrode  6  detects the user&#39;s intension to operates the vehicle door  2  depending on the electric capacitance between the user&#39;s hand an the sensor electrode  6 . When the control device determines a distance between the user&#39;s hand and the sensor electrode  6  becomes within the predetermined range, the control device determines that the user intends to open the vehicle door  2  and actuates the door lock device to be unlocked.  
         [0046]    On the other hand, when the user get out and close the vehicle door  2 , the vehicle door  2  is locked by pressing the switch button  71  without inserting the key into the key cylinder provided at the vehicle door  2  and rotating it. Once the switch button  71  is pressed by the user, the boss portion  66  being integrally provided with the switch button  71  is pressed, then the switch cap  68  provided below the boss portion  66  in FIG. 1 is also pressed. The pressure applied to the switch cap  68  is also applied to the pressed portion  79  of the switch  7  provided below the switch cap  68 . In this way, the pressed portion  79  is pressed. The contacting condition of the switch  7  is turned on or off depending on the number that the pressed portion  79  is pressed. When a signal indicating the contacting condition of the door switch device  70  is transmitted into the controlling device, the door lock device (not shown) is actuated depending on determined condition of the switch. Thus, the condition of the door lock device for prohibiting the open/close operation relative to the vehicle door  2  is locked.  
         [0047]    As shown in FIGS. 12 through 14, the door switch device  70  is structured to transmit an excessive pressure applied to the switch button  71  to an outside handle  3  efficiently when a user strongly presses the switch button  71 , the handle cover  4  being mounted to the main body  32  of the outside handle  3  includes the opening at the rear portion thereof, and the switch button  71  is fitted into the opening from the vehicle door side as shown in FIG. 13 and FIG. 14. The switch button  71  includes a fitting portion  27  being rectangular-formed and engaged with the handle cover  4 , an operating portion  28  being thick and formed inside the fitting portion  27 , a thin portion  21  provided between the fitting portion  27  and the operating portion  28 , and the boss portion  66  provided at the lower portion of the operating portion  28  in FIG. 13. The boss portion  66  being projecting toward the switch side has a smaller diameter than the operating portion  28  has. Once the operating portion  28  of the switch button  71  is pressed, the boss portion  66  penetrates through an opening formed at the switch plate  77  and having larger diameter than the diameter of the boss portion  66 . Then, a switch cap  68  is pressed by the boss portion  66 , and the pressed portion  79  of the switch  7  is pressed, as a result, the switch  7  is actuated.  
         [0048]    A surface of a switch case  76  at which the projecting portion  89  is formed engages with the bottom surface of the depressed portion  36  for positioning the switch case  76 . The switch cap  68  is provided between the switch case  76  and the switch plate  77  for preventing water coming inside the switch case  76 . When the operating portion  28  of the switch button  71  is pressed, the thin portion  21  of the switch button  71  is deformed, then the operating portion  28  of the switch button  71  can moved toward the switch side until a surface  23  of the switch plate  77  at which the opening is formed engages with a surface  22  being at inner side of the operating portion  28  of the switch button  71  as shown in FIG. 13.  
         [0049]    Thus, when the user pressed the switch button  71 , and excessive operation force being equal to or more than a predetermined load is applied to the operating portion  28 , the boss portion  66  presses and actuates the pressed portion  79  of the switch  7 , at the same time, the excessive operation force is applied to surface  23  provided at the peripheral edge of the opening formed at the switch plate  77  due to the engagement between the surface  22  of the operating portion  28  and the surface  23  of the switch plate  77 . The excess load applied to the surface  23  is further applied to the peripheral portion of the switch cap  68  in the direction which the pressed portion  79  of the switch  7  is moved, then the excess load is applied to one end portion (at which the switch cap  68  is engaged) of the switch case  76 . Because the switch case  76  is supported by the depressed portion  36  of the main unit portion  32 , the excess load escapes to a load receiving portion  26  of the main unit portion  32  being engaged with the switch case  76 .  
         [0050]    In this case, the switch case  76  are fitted into the approximately cup-shaped depressed portion of the switch plate  77 , and an outer peripheral edge of the depressed portion being cup-shaped works as a load loosing portion  24 . In this way, a stroke of the operation of the operating portion  28  is limited by the switch plate  77  for protecting the switch  7  by preventing the excessive load applied to the pressed portion  79  of the switch  7  depending on the moving amount of the operating portion  28 .  
         [0051]    As aforementioned above, a range of movement of the operating portion  28  becomes equal to a range of movement of the surface  22  of the operating portion  28  until it engages with the surface  23  of the switch plate  77 . When the operating portion  28  of the switch button  71  made of rubber is pressed and moved, a top end of the boss portion  66  of the switch button  71  firstly engages with the switch cap  68 . As the operating portion  28  is further pressed, the switch cap  68  is deformed by the boss portion  66  being deformed due to the engagement. The movement of the operating portion  28  is stopped when the pressed portion  79  of the switch  7  is pressed to the deepest position. In such condition, a movable area in which the contacting state of the switch  7  is not damaged can be set based on a tolerance of the component of the door switch device  70 .  
         [0052]    Alternatively, it may be set in advance that the door lock device is locked or unlocked depending on the number that the switch button  71  is pressed. In addition, a predetermined time may be provided between the last operation of the switch button  71  and the locking or unlocking operation of the vehicle door  2 .  
         [0053]    In the embodiment of the current invention, the grip-type outside handle is used, however, the type of the outside handle is not limited to such configuration. A pull-up type outside handle may be used alternatively.  
         [0054]    The principles, preferred embodiment and mode of operation of the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents which fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby.