Abstract:
A door handle assembly for a door substrate having an aperture, said door handle assembly comprising: a bell crank capable of pivoting about an axis, the bell crank including a first arm, a second arm and a base therebetween; a door handle that operatively engages the second arm of the bell crank, wherein a free end of the second arm extends upward and outward away from the base such that the free end of the second arm sweeps around a generally conical shape as the bell crank pivots about the axis; means for securing the door handle to the bell crank including a pin and notch assembly, wherein the pin is inserted through an aperture in the door handle and engages a notch located on the second arm; and a plurality of ribs formed on one or more surfaces of the bell crank.

Description:
RELATED APPLICATION 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 11/189,282 filed on Jul. 26, 2006 (now U.S. Pat. No. 7,377,562 issued on May 27, 2008). 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention generally relates to door handles in a vehicle and in particular, to a door release assembly. 
       BACKGROUND OF THE INVENTION 
       [0003]    The automotive industry is increasingly focusing on improvements within the interior of the vehicle. As a result, the design and esthetics of the interior space of the vehicle is becoming more increasingly important to the manufacturer and the end customer. 
         [0004]    One particular area of interest within the interior space of the vehicle is the door assembly. The door assembly typically includes many trim components, such as, amongst others, an armrest, a door release handle, speakers, and a map pocket. These various trim components may be manufactured from several different materials, using a range of manufacturing processes. As a result, the door assembly is a conglomeration of several trim components with various aesthetic appearances and functions. Challenges arise in designing and manufacturing door assemblies to function properly and look aesthetically pleasing. 
       SUMMARY OF THE INVENTION 
       [0005]    The inventors of the present invention have recognized these and other problems associated with designing components for the interior of a vehicle. To this end, the inventors have invented a door assembly comprising a door substrate having an aperture, a bell crank including a first arm having a pivot axis, a second arm, and a base therebetween, wherein the second arm extends through the aperture of the door substrate, a door handle that operatively engages the second arm of the bell crank past the aperture of the door substrate, and a back plate secured to the bell crank. A further invention is a bell crank for a door handle comprising a first arm being capable of pivoting about an axis, a second arm, and a base connecting the first arm to the second arm, wherein the first arm and the base rotate about the axis in a planar direction. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is an isolated view of a vehicle door trim according to an embodiment of the invention. 
           [0007]      FIG. 2  is an isolated view of the bell crank according to an embodiment of the invention. 
           [0008]      FIG. 3  is a schematic view of the movement of a bell crank according to an embodiment of the invention. 
           [0009]      FIG. 4  is an isolated view of a back plate assembly according to an embodiment of the invention. 
           [0010]      FIG. 5  is a perspective view of the bell crank attached to the back plate assembly according to an embodiment of the invention. 
           [0011]      FIG. 6  is an isolated view of a door handle according to an embodiment of the invention. 
           [0012]      FIG. 7  is a perspective view of a partial handle assembly according to an embodiment of the invention. 
           [0013]      FIG. 8A  is a perspective view of a bell crank in accordance with an exemplary embodiment of the invention. 
           [0014]      FIG. 9A  is another perspective view of the bell crank of  FIG. 8A  in accordance with an exemplary embodiment of the invention. 
           [0015]      FIG. 8B  is a perspective view of a bell crank in accordance with an exemplary embodiment of the invention. 
           [0016]      FIG. 9B  is another perspective view of the bell crank of  FIG. 8B  in accordance with an exemplary embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Referring to the Figures, a vehicle door substrate (“substrate”) is generally shown at  10 . The substrate  10  comprises of an inner, or “A” surface  12 , visible to an occupant of the vehicle, and an outer, or “B” surface  14  that is not visible to the occupant. The substrate  10  includes, amongst other features, a door release handle assembly  16  (“handle assembly”). 
         [0018]    Handle assembly  16  comprises of a handle  18 , a bell crank  20  and a back plate assembly  21 . According to an embodiment of the invention, bell crank  20  is secured to back plate assembly  21 , and handle  18  is secured to bell crank  20 . 
         [0019]      FIG. 2  illustrates bell crank  20  according to an embodiment of the invention. The bell crank  20  comprises a first arm  22 , a second arm  24  and a base  26  therebetween. First arm  22  has an upper surface  28  and a lower surface  30 . Second arm  24  extends upward and outward away from upper surface  28  of first arm  22  and base  26  connects first arm  22  and second arm  24  to each other. In the illustrated embodiment, bell crank  20  is manufactured from steel. However, it can be appreciated that bell crank  20  may be manufactured from any material, including, for example, plastic. Further, while bell crank  20  is illustrated as being formed as one piece, it can be appreciated that first arm  22 , second arm  24  and base  26  of bell crank  20  may be manufactured as multiple pieces and assembled to form bell crank  20 . 
         [0020]    One end  32  of first arm  22  includes a means for securing a cable assembly  34  to bell crank  20 . The means for securing a cable assembly  34  is generally known in the art and may include, for example, a pin and lock assembly (not shown). As illustrated, means for securing a cable assembly  34  includes a cavity  36 , for engaging a pin (not shown) and a slot (not shown) for locking the pin. The means for securing a cable assembly  34  extends downward from lower surface  30  of first arm  22 . An opposing end  38  of first arm  22  may include a pivot pin  40  that extends downward from lower surface  30 . An open end  42  of pivot pin  40  may include a groove  44  that extends around the circumference of pivot pin  40 . 
         [0021]    Base  26  extends upwards and at an angle from upper surface  28  of first arm  22 . Thus, an edge  46  of base  26  lies upon the same plane as the first arm  22  and an opposing edge  48  of base  26  is located above upper surface  28  of first arm  22 , on a separate plane. A side  50  of base  26 , partially outlined by opposing edge  48  of base  26 , extends downward to upper surface  28  of first arm  22 . As illustrated, base  26  lies at an angle from upper surface  28 . As illustrated, base  26  lies at approximately a thirty-degree angle from upper surface  28  of first arm  22 . However, it can be appreciated that base  26  may lie at any angle from upper surface  28  of first arm  22 , or base  26  may be parallel to upper surface  28  of first arm  22 . 
         [0022]    Base  26  extends from pivot pin  40  of first arm  22  to second arm  24 . Second arm  24  comprises of a neck portion  52  and a free end  54 . As illustrated, neck portion  52  of second arm  24  extends from base  26  and gently curves upward and outward at approximately a forty-five-degree angle away from base  26 . Free end  54  of second arm  24  extends substantially outward from neck portion  52  and includes a notch  56  and a plurality of skives  58 . 
         [0023]      FIG. 3  illustrates the general movement of bell crank  20  according to an embodiment of the invention. As shown, first arm  22  and edge  46  of base  26  rotate about pivot pin  40  along plane A. Arrows  1   a ,  2   a  and  3   a  illustrate three locations along plane A in which first arm  22  and edge  46  of base  26  may rotate past. Second arm  24  connects to base  26  at a point on plane B. Second arm rotates around pivot pin  40  in a non-planar direction. Arrows  1   b ,  2   b  and  3   b  illustrate the general direction of second arm  24  as second arm  24  rotates around pivot pin  40 . 
         [0024]    Referring to  FIG. 4 , back plate assembly  21  comprises of a back plate  62 , a biasing member  64  and a stopper  66 . As illustrated, biasing member  64  may be a spring, coil, or the like. Back plate  62  may include a plurality of small apertures  68  and a cavity  70 . Cavity  70  further includes an aperture  72  surrounded by biasing member  64 . Back plate  62  may be manufactured from any material. For example, in the illustrated embodiment, back plate  62  is manufactured from a plastic material by an injection molding process. Further, it can be appreciated that the invention may be practiced without cavity  70 . 
         [0025]    As illustrated in  FIG. 5 , bell crank  20  may be attached to back plate assembly  60  by inserting pivot pin  40  into aperture  72  of cavity  70  of back plate  62 . Biasing member  64  provides a biasing force against first arm  22  of bell crank  20 , maintaining bell crank  20  in a rest position, illustrated by solid lines in the Figure. A washer assembly (not shown) may engage groove  44  of pivot pin, thereby securing bell crank  20  to back plate  62 . However, it can be appreciated that the invention may be practiced without groove  44  and that bell crank  20  may be secured to back plate  62  by any conventional means. 
         [0026]    Once bell crank  20  is secured to back plate  62 , back plate  62  may be attached to outer surface  14  of substrate  10 . Fasteners (not shown), such as, for example, screws, nuts and bolts, or the like, may be inserted into apertures of back plate  62  to secure back plate  62  assembly to outer surface  14  of substrate  10 . However, it can be appreciated that back plate  62  may be secured to outer surface  14  of substrate  10  by any conventional methods, including, for example, welding, riveting or the like, back plate  62  to outer surface  14  of substrate  10 . Accordingly, the invention may be practiced with back plate  62  being manufactured without apertures  68 . 
         [0027]    Referring to  FIGS. 6 and 7 , when back plate  62  is attached to outer surface  14  of substrate  10 , free end  54  of second arm  24  of bell crank  20  passes through an aperture  74  on substrate  10 . Handle  18  may then be secured to free end  54  of second arm  24 . Handle  18  may include a cavity  76  reinforced by a series of ribs  78  for securing handle  18  to free end  54  of second arm  24 . As handle  18  engages free end  54  of second arm, skives  58  of free end  54  burrow into the circumferential surface of cavity  76  of handle  18 . However, it can be appreciated that handle  18  may be secured to free end  54  of second arm  24  by any conventional method. 
         [0028]    Handle  18  further includes a pin  80  that engages notch  56  of free end  54  of second arm. As handle  18  is inserted over free end  54  of second arm, pin  80  of handle  18  operatively contacts notch  56  of free end  54 . Notch  56  of free end  54  includes a ramp surface  82 , which exerts an upward force on pin  80  when handle  18  is inserted over free end  54  of second arm  24 . Once handle  18  is generally inserted over free end  54  of second arm  24 , pin  80  of handle  18  engages a cavity  84  in notch  56 , resulting in handle  18  being secured to second end of bell crank  20 . 
         [0029]    Typically, a passenger (not shown) exerts a force on handle  18  to exit the interior of the vehicle. The exerted force may pull the handle  18  upward and outward, away from inner surface  12  of substrate  10 . As the force is exerted on handle  18 , bell crank  20  rotates around pivot pin  40  to an actuated position, illustrated by phantom lines in  FIG. 4 . During rotation, first arm  22  of bell crank  20  rotates along the circumference of aperture  72  in a planar direction. As a result, first arm  22  of bell crank  20  actuates the cable assembly to open a vehicle door (not shown). Similarly, second arm  24  of bell crank  20  rotates around pivot pin  40  at an angle upward and outward from first arm  22 . As second arm  24  of bell crank  20  rotates around pivot pin  40 , neck portion  52  of second arm  24  of bell crank  20  passes through aperture  74  of substrate  10 . 
         [0030]    Biasing member  64  exerts a biasing force against bell crank  20 , resulting in a smooth transition from the rest position to the actuation position, and vice versa. Accordingly, when handle  18  is released by the passenger, biasing member  64  causes bell crank  20  to return to the rest position. Stopper  66  of back plate  62  cushions the contact between first arm  22  and back plate  62 . 
         [0031]    The overall shape of bell crank  20  transitions from a generally flat, rectangular first arm  22  to a generally tubular second arm. However, it can be appreciated that bell crank  20  is not limited by the above described shapes and angles and may include any particular shape and angle, so long as second arm  24  extends outward at approximately a forty-five-degree angle when bell crank  20  rotates about pivot pin. 
         [0032]    Referring now to  FIGS. 8A and 9A , a bell crank is shown generally at  100  according to an embodiment. In an embodiment, the material comprising the bell crank  100  includes die-cast zinc. 
         [0033]    The function of the bell crank  100  is substantially similar to the bell crank  20  of  FIGS. 2 and 5  and is therefore not described in greater detail. Structurally, the bell crank  100  is substantially similar to the bell crank  20 . In an embodiment, the bell crank  100  includes a base portion  102 , a first arm  104  extending from the base portion  102 , a pivot pin  106  extending from the base portion  102 , a neck portion  108  extending from the base portion  102  and a second arm  110  extending from the neck portion  108 . 
         [0034]    A lower surface of the first arm  104  is shown generally at  112  and an upper surface of the first arm  104  is shown generally at  114 . A lower surface of the pivot pin  106  is shown generally at  116  and an upper surface of the pivot pin  106  is shown generally at  118 . A lower surface of the second arm  110  is shown generally at  120  and an upper surface of the second arm  110  is shown generally at  122 . 
         [0035]    The base portion  102  also includes a lower surface shown generally as  124  and an upper surface shown generally at  126 . Further, the neck portion  108  includes a lower surface  128  and an upper surface  130 . 
         [0036]    In an embodiment, as seen in  FIG. 8A , the lower surface  112  of the first arm  104  extends from the lower surface  124  of the base portion  102 . The lower surface  128  of the neck portion  108  extends from the lower surface  124  of the base portion  102 . In an embodiment, the lower surface  116  of the pivot pin  106  extends from the lower surface  124  of the base portion  102 . In an embodiment, a collar surface portion  132  of the pivot pin  106  is shown extending between the lower surface  116  of the pivot pin  106  and the lower surface  124  of the base portion  102 . 
         [0037]    In an embodiment, as seen in  FIG. 9A , the upper surface  114  of the first arm  104  extends from the upper surface  126  of the base portion  102 . The upper surface  130  of the neck portion  108  also extends from the upper surface  126  of the base portion  102 . Further, the upper surface  118  of the pivot pin  106  extends from the lower surface  124  of the base portion  102 . 
         [0038]    Referring now to  FIGS. 8B and 9B , a bell crank is shown generally at  200  according to an embodiment. In an embodiment, the material comprising the bell crank  200  includes a composite-reinforced, injection-molded, high-strength, low-weight material. In an embodiment, the material of the bell crank  200  may include, for example, reinforced nylon (e.g., polyarylamide), nylon (e.g., polyamide), polypropylene, or the like. 
         [0039]    The function of the bell crank  200  is substantially similar to the bell crank  20  of  FIGS. 2 and 5  and is therefore not described in greater detail. Structurally, the bell crank  200  is substantially similar to the bell crank  100  with the exception that the bell crank  200  includes several pluralities of ribs, which are shown generally at  225   a ,  225   b ,  250   a ,  250   b  and  275   a.    
         [0040]    Referring to  FIG. 8B , the first plurality of ribs is shown generally at  225   a , the second plurality of ribs is shown generally at  250   a  and the third plurality of ribs is shown generally at  275   a . In an embodiment, the first plurality of ribs  225   a  are shown extending from the lower surface  224  of the base portion  202  and the collar surface portion  232 . In an embodiment, the second plurality of ribs  250   a  are shown extending from one or more of the lower surface  220  of the second arm  210  and the lower surface  228  of the neck portion  208 . In an embodiment, the third plurality of ribs  275   a  is shown extending from the lower surface  216  of the pivot pin  206 . 
         [0041]    Referring to  FIG. 9B , a fourth plurality of ribs is shown at  225   b  and a fifth plurality of ribs is shown at  250   b . In an embodiment, the fourth plurality of ribs  225   b  is shown extending from the upper surface  218  of the pivot pin  206 . In an embodiment, the fifth plurality of ribs  250   b  are shown extending from one or more of the upper surface  222  of the second arm  210  and the upper surface  230  of the neck portion  208 . 
         [0042]    Because the bell crank  200  is made from a polymeric material rather than a die-cast material, such as, for example, zinc, the bell crank  200  may be generally defined to include a uniform thickness for one or more of the base portion  202 , first arm  204 , pivot pin  206 , neck portion  208  and second arm  210 . Accordingly, in an embodiment, one of more of the plurality of ribs  225   a ,  225   b ,  250   a ,  250   b ,  275   a  may define a reduced overall volume/thickness of the bell crank  200  in view of the bell crank  100 . Further, the bell crank  200  may be formed to include larger radii rather than relatively sharp corners to promote material flow during the injection molding process. 
         [0043]    Regarding thickness uniformity, the following structural differences may result when comparing the structure of the bell crank  200  to the bell crank  100 . For example, the first plurality of ribs  225   a  of the bell crank  200  may reduce the overall volume/thickness of the bell crank  100  proximate one or more of the lower surface  124  of the base portion  102  and the collar surface portion  132  of the pivot pin  106 . Further, in an embodiment, the second plurality of ribs  250   a  of the bell crank  200  may reduce the overall volume/thickness of the bell crank  100  proximate one or more of the lower surface  220  of the second arm  210  and the lower surface  228  of the neck portion  208 . Even further, in an embodiment, the third and fourth plurality of ribs  225   b ,  275   a  of the bell crank  200  may reduce the overall volume/thickness of the bell crank  100  proximate one or more of the lower surface  216  and upper surface  218  of the pivot pin  206 . Yet even further, in an embodiment, the fifth plurality of ribs  250   b  of the bell crank  200  may reduce the overall volume/thickness of the bell crank  100  proximate one or more of the upper surface  222  of the second arm  210  and the upper surface  230  of the neck portion  208 . 
         [0044]    The embodiments disclosed herein have been discussed for the purpose of familiarizing the reader with novel aspects of the invention. Although preferred embodiments of the invention have been shown and described, many changes, modifications and substitutions may be made by one having ordinary skill in the art without necessarily departing from the spirit and scope of the invention as described in the following claims.