Abstract:
A pull cup in a vehicle door is fitted to a door trim panel substrate and is connected to the inner door panel of the vehicle door by way of a bracket. The bracket is oriented to resist vertical loads and tension loads such that the bracket is allowed to deflect in compression loading in the event of a side impact. In one embodiment the bracket has horizontal slots through which shoulder fasteners are fitted to attach the bracket to the inner door panel. This configuration allows deflection in compression loading. In another embodiment of the bracket a pair of arms is provided between the pull cup and the inner door panel. This configuration allows buckling of the arms on compression loading.

Description:
TECHNICAL FIELD 
     The present invention relates generally to a support structure for the pull cup of an armrest for use with a vehicle. More specifically, the present invention relates to a support structure for a pull cup which is strong and durable under tension during normal use but which will demonstrate compromised lateral stiffness under compression in the event of a side impact. 
     BACKGROUND OF THE INVENTION 
     It is known in vehicles to provide an armrest in a door having an integrated pull cup to allow the occupant to pull the door shut. According to the known arrangement, the pull cup, typically composed of a molded plastic, is anchored to the vehicle door inner panel by a variety of stamped steel structures, the most common of which is the “L-bracket” in which the vertical portion of the bracket is attached to the inner door panel with fasteners such as screws and the horizontal portion of the bracket is attached to the underside of the pull cup with screws or clips. In addition to being anchored to the inner door panel, the pull cup is also solidly connected to the armrest substrate. 
     Regardless of its configuration, the primary function of the door pull cup support bracket is to transmit the force generated by the user on the door pull cup to the inner door panel to create the moment to close the door and to actuate the door latch mechanisms. The secondary function of the door pull cup support bracket is to collapse or deflect when loaded by a side impact in a manner which assists in door trim system compliance. 
     The known approach to anchoring the pull cup to both the vehicle door inner panel with the traditional L-bracket as well as the armrest substrate provides a good degree of lateral door function to the vehicle occupant while opening and, particularly, closing the door. However, 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 pull cup support structures which, upon vehicle inward movement of the outer door panel during a side impact, will minimize or eliminate the transfer of forces to the occupant. 
     SUMMARY OF THE INVENTION 
     The tension-member automotive door trim pull disclosed herein includes a deformable support bracket for attaching the pull cup to the inner door panel. In general, the bracket geometry disclosed herein is modified over the traditional L-bracket geometry such that vertical and tension loads used by an operator in closing the vehicle door by pulling on the pull cup are resisted while transmission of forces to the occupant in the event of a side impact are minimized or are eliminated. In one embodiment of the bracket set forth herein a “leaf spring” bracket is provided that has horizontal slots defined at its ends through which shoulder bolts or similar fasteners are fitted to attach the bracket to the inner door panel. In another embodiment of the bracket a pair of relatively straight arms is provided between the pull cup and the inner door panel. This configuration allows buckling of the arms on compression loading. The embodiment of the support bracket utilizing the straight arms can be modified such that a scissors configuration is provided, the ends of the arms attached to the inner door panel being movable by provision of elongated slots as in the first-discussed embodiment. 
     In yet a further embodiment of the invention a support bracket having a substantially vertical mounting flange is attached at its first end to a first portion of the inner door panel. The support bracket includes a pull cup flange that is attached to the pull cup. The substantially vertical mounting flange includes a second end opposite the first end. The second end of the substantially vertical mounting flange is positioned adjacent the outside of a second portion of the inner door panel. While providing lateral strength on closure of the door by a user, the substantially vertical mounting flange may be bent in the event of a side impact such that the second end of the substantially vertical mounting flange is distorted and moves away from the inner door panel and thus becomes spaced apart from the outside of the second portion of the inner door panel. 
     Still another embodiment provides a support bracket having an inner door panel attachment flange, a pull cup attachment flange, and an intermediate portion disposed between the inner door panel attachment flange and the pull cup attachment flange. A bendable bridge is provided between the intermediate portion and the pull cup attachment flange. In this embodiment in the event of a side impact the bendable bridge is bent as the pull cup attachment flange is allowed to rotate relative to the pull cup about the z-axis. 
     Other features of the tension-member automotive door trim pull as disclosed herein 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 
       For a more complete understanding of the disclosed pull cup support structures, 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: 
         FIG. 1  illustrates a sectional view of a door assembly showing a typical door cup support bracket known in the prior art; 
         FIG. 2  illustrates a perspective view of a pull cup support bracket according to a first embodiment of the invention; 
         FIG. 3  illustrates a partially sectional view of a door assembly showing the first embodiment of the pull cup support bracket in place between the pull cup and the inner door panel; 
         FIG. 4  illustrates a top view of the pull cup support bracket of the first embodiment and a portion of the inner door panel to which it is attached before compression; 
         FIG. 5  illustrates the same view and embodiment as  FIG. 4  but shows the pull cup support bracket of the first embodiment after lateral compression; 
         FIG. 6  illustrates a top view of a pull cup support bracket according to the second embodiment of the invention and a portion of the inner door panel to which it is attached before compression; 
         FIG. 7  illustrates the same view and embodiment as  FIG. 6  but shows the pull cup support bracket of the second embodiment after lateral compression; 
         FIG. 8  illustrates a top view of a pull cup support bracket according to the third embodiment of the invention and a portion of the inner door panel to which it is attached before compression; 
         FIG. 9  illustrates the same view and embodiment as  FIG. 8  but shows the pull cup support bracket of the third embodiment after lateral compression; 
         FIG. 10  illustrates a partially sectional view of a door assembly which includes a support bracket fitted between the pull cup and the inner door panel, the support bracket representing the fourth embodiment of the present invention, the door assembly being illustrated before a side impact to the vehicle door; 
         FIG. 11  illustrates substantially the same view as shown in  FIG. 10  but shows the door assembly after side impact to the vehicle door; 
         FIG. 12  illustrates a partially sectional view of a door assembly in which a variation of the fourth embodiment of the invention is provided whereby a frangible clip is fitted between the pull cup support bracket and a portion of the inner door panel; 
         FIG. 13  illustrates a partially exploded view of a pull cup bracket attached to a portion of the inner door panel of a door assembly and positioned adjacent a pull cup, shown in partial view, the pull cup bracket being a fifth embodiment of the invention; 
         FIG. 14  is a partially sectional view of a door assembly in which the fifth embodiment of the pull cup bracket is fitted, the door assembly being illustrated before a side impact to the vehicle door; 
         FIG. 15  is a view similar to that of  FIG. 14  but the door assembly after a side impact to the vehicle door; and 
         FIG. 16  is a view similar to that of  FIG. 13  but illustrating the support bracket as it would appear following a side impact event. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     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. 
     With reference first to  FIG. 1 , a sectional view of a door assembly, generally illustrated as  10 , is shown. The door assembly  10  includes an outer door panel  12 , an inner door panel  14 , a door trim panel  16 , and a pull cup  18  fitted in the door trim panel  16 . A conventional L-bracket  20  is fastened at one end to the inner door panel  14  by a fastener  22  and at other end to the pull cup  18  by a fastener  24 . The L-bracket  20  is formed from stamped sheet metal. The fastener  22  has traditionally been a screw, whereas the fastener  24  has traditionally been a screw or a clip. 
     To overcome the challenges of known designs, five embodiments of an alternative arrangement are provided for connecting a pull cup to an inner door panel (also known as a door inner sheet metal component). The first of these embodiments is presented in  FIGS. 2 through 5 . With reference to  FIG. 2 , a pull cup support bracket, generally illustrated as  30 , is shown in perspective view and spaced apart from an inner door panel  32 . The pull cup support bracket  30  has a “leaf spring” configuration. The pull cup support bracket  30  includes a generally arcuate central portion  34  having two inner door panel attachment flanges  36  and  36 ′. A pull cup attachment flange  38  extends generally perpendicularly from the central portion  34  of the pull cup support bracket  30 . 
     The attachment flange  36  includes an elongated attachment slot  40  and the attachment flange  36 ′ includes an elongated attachment slot  40 ′. A shoulder bolt or similar fastener  42  is provided for attaching the pull cup support bracket  30  to the inner door panel  32  through the elongated attachment slot  40 . A shoulder bolt or similar fastener  42 ′ is provided for attaching the pull cup support bracket  30  to the inner door panel  32  through the elongated attachment slot  40 ′. When fixed in its assembled position, the shoulder bolt  42  is fitted generally within the distal or far end (relative to the central portion of the pull cup support bracket  30 ) of the elongated attachment slot  40  while the shoulder bolt  42 ′ is fitted generally within the distal or far end of the elongated attachment slot  40 ′. 
     It should be understood that one or more of the shoulder bolts  42  and  42 ′ as well as other fasteners discussed herein may be substituted for single detent push-pins positioned into sized holes. This arrangement would allow the fastener to unload or to pop off during compressive loading events. 
     A sectional view of a door assembly, generally illustrated as  44 , is shown in  FIG. 3 . The door assembly  44  includes an outer door panel  46 , the inner door panel  32 , and a door trim panel  48 . A pull cup  50  is provided substantially within the door trim panel  48 . The pull cup support bracket  30  of the first embodiment is fitted between the pull cup  50  and the inner door panel  32 . The pull cup support bracket  30  is attached to the inner door panel  32  by the shoulder bolts  42  and  42 ′ (of which only the shoulder bolt  42  can be seen in  FIG. 3 ), the pull cup attachment flange  38  of the pull cup support bracket  30  is attached to the pull cup  50  by a fastener  52 . 
     A top view of the pull cup support bracket  30  is illustrated in  FIG. 4  in which the pull cup support bracket  30  is fastened to the inner door panel  32 . The configuration of the pull cup attachment flange  38  is clearly shown in this view. In the event of a side or lateral impact on the vehicle door, the inner door panel  32  is pushed vehicle inward by lateral force in the form of impact energy IE as illustrated in  FIG. 5 . As shown, the central portion  34  of the pull cup support bracket  30  is compressed and the inner door attachment flanges  36  and  36 ′ are spread away from each other, such movement being allowed by the elongated slots  40  and  40 ′ with respect the shoulder bolts  42  and  42 ′ respectively fastened therethrough. On impact the occupant provides resistive force RF. However, according to the disclosed arrangement, the force of the impact energy IE is substantially or entirely transmitted away from the occupant. Particularly, as illustrated, while the inner door panel  32  has been moved vehicle inward upon application of the impact energy IE and while the pull cup support bracket  30  is compressed, the position of the pull cup attachment flange  38  (and thus the position of the pull cup  50  [shown in  FIG. 3  but not shown in  FIGS. 4 and 5 ]) is substantially unchanged. 
     The second embodiment of the pull cup support bracket set forth herein is shown in  FIGS. 6 and 7 . With respect to  FIG. 6 , a pull cup support bracket  60  having inner door attachment flanges  62  and  62 ′ is attached to the inner door panel  32  by shoulder bolts  42  and  42 ′. It is to be understood that the inner door attachment flanges  62  and  62 ′ may have the same elongated slots  40  and  40 ′ as set forth above with respect to the first embodiment of the pull cup support bracket disclosed herein. However, in addition to or in lieu of the movement made possible by the elongated slots, the pull cup support bracket  60  has an endpiece  63  and a pair of bendable legs  64  and  64 ′ which extend respectively between the attachment flanges  62  and  62 ′ and the endpiece  63 . The pull cup support bracket  60  further includes a pull cup attachment flange  66  extending vehicle outward from the endpiece  63  to be connected to the pull cup. In addition, the bendable leg  64  is provided with a bend initiator area  67  and the bendable leg  64 ′ is provided with a bend initiator area  67 ′. The initiator areas  67  and  67 ′ may be formed by a variety of methods including a channel (not shown) formed on one or both sides of each of the legs  64  and  64 ′. The channels are formed perpendicular to the long axis of the pull cup support bracket  60 . 
     Upon a side impact of the vehicle caused by a impact energy IE as shown in  FIG. 7 , the bendable legs  64  and  64 ′ buckle outwardly as illustrated at the initiator areas  67  and  67 ′. If fitted with elongated slots, the inner door attachment flanges  62  and  62 ′ are forced outwardly also as illustrated. Accordingly, while the inner door panel  32  is pushed inward and the legs  64  and  64 ′ of the pull cup support bracket  60  buckle at the initiator areas  67  and  67 ′, the pull cup attachment flange  66  remains generally in its initial position and vehicle-inward movement of the pull cup attachment flange  66  is prevented. 
     A further variation of the pull cup support bracket of the present invention is illustrated in  FIGS. 8 and 9  in which the third embodiment of the pull cup support bracket, generally illustrated as pull cup support bracket assembly  70 , is comprised of a first leg  72  and a second leg  74 . The first leg  72  includes a pull cup attachment flange  76  having a hole  78  for a pull cup fastener (not shown) at a first end and an inner door attachment flange  80  at its other end. An elongated slot like the slot  40  of the pull cup support bracket  30  is defined in the inner door attachment flange  80 . The second leg  74  includes a pull cup attachment flange  82  having a hole  84  for a pull cup fastener (not shown) at a first end and an inner door attachment flange  86  at its other end. An elongated slot like the slot  40  of the pull cup support bracket  30  is defined in the inner door attachment flange  86 . The inner door attachment flange  76  is attached to the inner door panel  32  by the shoulder bolt  42 . The inner door attachment flange  86  is attached to the inner door panel  32  by the shoulder bolt  42 ′. Both the pull cup attachment flange  76  and the pull cup attachment flange  82  are pivotably attached to the pull cup by fasteners. 
     In the event of a side impact by an impact energy IE shown in  FIG. 9 , the inner door panel  32  is moved inward while the inner door attachment flange  80  and the inner door attachment flange  86  both are moved outward as allowed by the travel of the shoulder bolts  42  and  42 ′ in the elongated slots. As set forth above with respect to the arrangement of  FIG. 5 , the resistive force RF is provided by the vehicle occupant while the force of the impact energy IE is substantially or entirely transmitted away from the occupant. Particularly, the pull cup attachment flange  76  and the pull cup attachment flange  82  are allowed to pivot as needed on the pull cup to allow movement of the first leg  72  and the second leg  74 . However, the pull cup is moved vehicle inward little if at all upon application of the impact energy IE, thereby reducing or minimizing the transfer of energy to the occupant. 
     As a variation of the pull cup support brackets shown in  FIGS. 2 through 9  and as represented by the three embodiments set forth above,  FIGS. 10 through 12  illustrate a fourth embodiment of the pull cup support bracket of the instant disclosure. With respect first to  FIG. 10 , a sectional view of a door assembly, generally indicated as  90 , is shown. The door assembly  90  includes an outer door panel  92 , an inner door panel  94  having an upper portion  96  and a lower portion  98 , and a door trim panel  100 . A pull cup  102  is substantially disposed within the door trim panel  100 . A pull cup support bracket  104  is provided and includes a substantially vertical portion  106  that is attached at its upper end to the upper portion  96  by a fastener  108  and a substantially horizontal portion  110  that is attached to the pull cup  102  by a fastener  112 . 
     The inner door panel  94  is preferably an integral piece and the upper portion  96  and the lower portion  98  define portions which are spaced apart such that an aperture is provided in which a portion of the vertical portion  106  of the pull cup support bracket  104  is provided. Specifically, the lower end of the vertical portion  106  extends vehicle outward of the lower portion  98  of the inner door panel  94  and is in contact with the outer side of the lower portion  98 . In this manner the pull cup support bracket  104  provides the necessary structure when in tension, that is, when the user pulls the vehicle door shut using the pull cup  102 . 
     When the vehicle is impacted by impact energy IE as illustrated in  FIG. 11 , the outer door panel  92  is pushed vehicle inward, as is the inner door panel  94 . As illustrated, the impact energy IE causes the vertical portion  106  of the pull cup support bracket  104  to be bent on compression. The pull cup support bracket  104  and the door trim panel  100  thus are not substantially displaced in spite of the impact energy IE while the impact energy IE is transmitted away from the occupant who provides a resistive force RF. 
     A variation of the embodiment of the pull cup support bracket  104  provided in  FIGS. 10 and 11  is illustrated in  FIG. 12  in which a sectional view of a door assembly, generally illustrated as  90 ′, is shown. The door assembly  90 ′ includes an outer door panel  92 ′, an inner door panel  94 ′ having an upper portion  96 ′ and a lower portion  98 ′, and a door trim panel  100 ′. A pull cup  102 ′ is substantially disposed within the door trim panel  100 ′. A pull cup support bracket  104 ′ is provided and includes a substantially vertical portion  106 ′ that is attached at its upper end to the upper portion  96 ′ by a fastener  108 ′ and a substantially horizontal portion  110 ′ that is attached to the pull cup  102 ′ by a fastener  112 ′. As set forth above with respect to the embodiment shown in  FIGS. 10 and 11 , the inner door panel  94 ′ is preferably an integral piece and the upper portion  96 ′ and the lower portion  98 ′ define portions which are spaced apart such that an aperture is provided in which a portion of the vertical portion  106 ′ of the pull cup support bracket  104 ′ is fitted. 
     The embodiment shown in  FIG. 12  includes a frangible clip  114  that connects the lower end of the vertical portion  106 ′ of the pull cup support bracket  104 ′ and the upper end of the lower portion  98 ′ of the inner door panel  94 ′. The frangible clip  114  is made of a polymerized material such as a plastic. A notch  116  is defined in the frangible clip  114  between the lower end of the vertical portion  106 ′ and the upper end of the lower portion  98 ′. On application of a lateral force against the vehicle door  90 ′, the vertical portion  106 ′ is bent such that the frangible clip  114  is broken into two pieces, allowing distortion of the pull cup support bracket  104 ′ in a fashion similar to that shown in  FIG. 11 . 
     A fifth embodiment of the pull cup bracket is shown in  FIGS. 13 through 16  in which a pull cup bracket  120  is provided. The bracket  120  may be formed from metal or from a plastic. The pull cup bracket  120  includes an inner door panel mounting flange  122  which is attached to an inner door panel  124  (of which only a portion is shown in  FIGS. 13 and 16 ) by a fastener  126 , a pull cup mounting flange  128  which is mounted to a pull cup  130  by a fastener  132 . The fastener  132  is preferably a shoulder bolt but any fastener that would allow rotation of the pull cup mounting flange  128  with respect to the pull cup  130  would be suitable for this purpose. 
     An intermediate portion  134  is provided between the inner door panel mounting flange  122  and the pull cup mounting flange  128 . The intermediate portion  134  is attached to the inner door panel mounting flange  122  along a pin joint. A bendable bridge  136  is provided between the intermediate portion  134  and the pull cup mounting flange  128 . 
     The pull cup support bracket  120  is shown in its installed position in  FIGS. 14 and 15  in which a door assembly, generally illustrated as  140 , is provided. The door assembly  140  includes an outer door panel  142 , the inner door panel  124 , a door trim panel  144 , the pull cup  130 , and the pull cup support bracket  120 . The door assembly  140  is shown in  FIG. 14  as being in its state prior to side impact. In  FIG. 15 , the door assembly  140  is shown after side impact. In this figure, impact energy IE has been applied to the door assembly  140  causing the outer door panel  142  and the inner door panel  124  to be pushed vehicle inward. The occupant provides a resistive force RF. As the inner door panel mounting flange  122  is pushed vehicle inward, the intermediate portion  134  pushes upon the bendable bridge  136  which, as illustrated in  FIG. 16 , effects rotation of the pull cup mounting flange  128  about the z-axis on the fastener  132 , thus preventing the pull cup mounting flange  128  from being moved vehicle inward while the impact energy IE is transmitted away from the occupant. During the vehicle inward movement of the inner door panel mounting flange  122  the intermediate portion  134  bends along the pin joint and tends to flatten out toward the inner door panel  124 , as illustrated in  FIG. 16 . 
     The foregoing discussion discloses and describes exemplary embodiments of pull cup support bracket of the instant disclosure. 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.