Abstract:
The invention is directed to an apparatus and method that includes a bracket that attaches the bottom end of a vehicle interior door handle to a door panel in a rigid manner, the bracket including a first wall and second and third walls that extend, generally perpendicular to the door panel, from the first wall toward the door panel, and first and second flanges extending from the second and third walls respectively that are attached to the door panel. The second and third walls flank control components within the armrest such that the bracket is compact and provides a rigid connection.

Description:
BACKGROUND OF THE INVENTION 
   It is common in modern vehicles to include a number of control items upon a vehicle door armrest in order to increase driver or passenger convenience. Such items include door lock switches, power window control switches, side mirror adjustment controls, etc. Also, for the convenience of the driver or passenger, a large pull handle is provided, which the driver or passenger pulls from inside of the vehicle to close their respective door. Often, the arm rest and pull handle are incorporated into a single assembly (LNG), with the bottom end of the pull handle merging into the armrest. As a result, the armrest and pull handle are easier to manufacture and to attach to the vehicle&#39;s door panel. Also, when combining the two, a more compact design is provided which does not overly clutter the interior surface of the vehicle door. 
   A preferred door pull handle is rigidly attached to the vehicle door panel. Thus, when the vehicle driver or passenger pulls on the handle, there is minimal play or give, and an impression of a well constructed, high quality vehicle is provided. When the door handle is not rigidly attached to the door panel, the door panel and/or pull handle typically flexes (gives) slightly before the door moves in response to the force applied by the vehicle occupant. This flexing or play provides an impression that the materials or construction of the vehicle may not be of superior quality. 
   The best way to provide a rigid connection from the door pull handle to the door panel is to place a fastener through the handle at each end, in a direction perpendicular to the door panel. However, within a handle and armrest combination, the bottom end of the pull handle is often aligned with controls that are embedded within the armrest. Because a fastener cannot pass through these components, the attaching position is usually offset from the bottom of the pull handle to a different position on the armrest, using a bracket, where there are no restrictions. Unfortunately, the distance added by known offset brackets results in a loss of rigidity, allowing the door handle and bracket, between attachment points, to flex to a greater degree. The impression of a superior product given when the handle is pulled is lost in this instance. 
   To avoid such a situation, the vehicle styling must be changed to re-locate the components in the armrest. This is not desirable. What is desired is a way to maintain a rigid connection between the door pull handle and door panel in a door pull handle and armrest system including control components. 
   BRIEF SUMMARY OF THE INVENTION 
   An improved method and apparatus for attaching the door pull handle to the door panel is provided and includes using a bracket including walls that flank the control components (switches, etc.) that are embedded within the vehicle armrest. The bracket includes a first wall that is spaced apart from and is generally parallel to the door panel. Second and third walls extend from opposite ends of the first wall toward the door panel and are also generally perpendicular to the door panel. A first flange extends from an end of the second wall opposite from the end adjacent to the first wall. Similarly, a second flange extends from the end of the third wall opposite to the end adjacent to the first wall. The first and second flanges are connected to the door panel using fasteners. The first wall is attached to the pull handle using a fastener. 
   The improved bracket, and method for attaching the bracket, of the present invention provide superior rigidity in the joint between the pull handle and door panel because first, a fastener passes through the door pull handle near its bottom. Secondly, because the size of the bracket, namely represented by the length of the second and third walls, is minimized, (i.e. the second and third walls minimize the distance between the door panel and the first wall of the bracket) any flexing of the bracket itself is negated and overall play in the pull handle is minimized. 
   These and other features, aspects, and advantages of the present invention will be fully described by the following description, appended claims, and accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
       FIG. 1  is a side view of an interior door panel of a vehicle with an integrated pull handle and armrest attached thereto; 
       FIG. 2  is a cross-sectional view of the pull handle, armrest, door panel and control components; 
       FIG. 3  is an alternative cross-sectional view of the door handle, bracket, door panel and control components as seen in  FIG. 2 ; and 
       FIG. 4  is yet another alternate cross-sectional view, showing only the door handle, and door panel. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to the drawings, specifically  FIGS. 1-3 , a preferred attachment system  10  for providing a rigid connection between a vehicle interior door pull handle  12 , that is integrated into a vehicle armrest  14  at its bottom, and door panel  16  is illustrated. As described in more detail below, the system includes a bracket  18  that is attached to the bottom end  20  of the door pull handle  12 , wherein the bracket  18  avoids contact with any control components  22  within the armrest  14 . 
   Herein, the term door panel refers to a structural support member within the vehicle door in combination with a decorative cover that is placed on the interior surface of the structural support member. However, door panel could also be a single structural member with no decorative cover or a single member that has both structural and decorative qualities. 
   Referring to  FIGS. 2 and 3 , the bracket  18  is made from a single piece of material, formed to have first  24 , second  26  and third  28  walls and first  30  and second  32  flanges. The first wall  24  is flat, rectangular, and is located between the second and third walls  26  and  28 . The first wall  24  has a first end  34  and a second end  36  and defines an aperture  38  approximately half way between the first and second ends  36  and  38  for receiving a fastener  40 . When the bracket  18  is installed, preferably the first wall  24  is generally parallel to the door panel  16 , however, depending upon the shape of the arm rest, the first wall  24  may be slightly angled as shown in  FIG. 2 . 
   The second and third walls  26  and  28  are generally parallel to one another and generally perpendicular to the first wall  24 , again depending on the arm rest shape. The second and third walls  26  and  28  are also rectangular and have a height that is equal to the first wall  24 . Each one of the second and third walls  26  and  28  have a proximal end  42  and a distal end  44 , wherein the proximal end  42  of each joins with the first wall  24 . 
   A first flange  30  extends from the distal end  44  of the second wall  26  in a direction that is the opposite of the direction the first wall  24  extends from the proximal end  42 . The first flange  30  is generally flat and rectangular and defines an aperture  48  therein for receiving a fastener  50 . Similarly, a second flange  32  extends from the distal end  44  of the third wall  28  in a direction opposite of the direction the first wall  24  extends from the proximal end  42 . The flange  32  is generally flat and rectangular and defines an aperture  52  therein for receiving a fastener  54 . 
   The bracket  18  is preferably made from steel. 
   Referring to  FIGS. 1 and 2 , the door pull handle  12  is illustrated and includes a top end  56  and a bottom end  58 . The top end  56  merges into a transverse decorative assembly portion  60  of the door panel  16  that includes, for example, a light assembly  61  therein. The pull handle  12  is spaced, at its mid-section, from the door panel  16  when the pull handle  12  is attached thereto. The pull handle  12  is angled at approximately  45  degrees from vertical when the handle  12  is attached to the door panel  16 . The pull handle  12  is preferably made from a hard plastic frame surrounded by a soft plastic cover. Foam is preferably placed between the frame and cover to provide comfort when the handle  12  is gripped. At its bottom end  58 , the door pull handle  12  is integrated into the vehicle armrest  14 . 
   The armrest  14  is a generally rectangular solid that is generally horizontal when attached to the door panel  16 . The armrest  14  also includes a narrow tapered forward extension  62  that bends downwardly. The armrest  14  solid portion includes a forward end  64  and rear end  66  which are wider than the extension  62  and support the vehicle operator&#39;s arm when desired. Within the forward end  64  of the armrest  14 , a series of control components  22  are supported. The components  22  may include switches, touch surfaces, lights, rheostats, etc. Preferably, the control components  22  include a control portion  68  that is embedded within the armrest  14  and a touch portion(s)  70  that protrudes from the armrest  14  and which is contacted by the vehicle operator. The control portion  68  of the components is preferably held within a generally rectangular housing. The control components  22  are used to control vehicle door locks, power windows, mirrors, etc. 
   The rear end  66  of the arm rest  14  is generally flat and is cushioned for comfortable support of the operators arm. The arm rest defines a pull pocket  67  that can be used for closing the door. The door panel  16  is generally rectangular and has a shape similar to the vehicle door. The door panel  16  preferably includes a portion made from rigid plastic. 
   Referring to  FIGS. 1-4 , the vehicle is assembled by attaching the door panel  16  to the vehicle door. The armrest  14  and door pull handle  12  are attached as an assembly to the door panel  16 . The armrest  14  is held to the door panel  16  by a series of clips and screws. The screwed connections provide the strength required to support the weight of the vehicle operators arm when resting thereon. The clips simply hold more decorative portions in place against the door panel  16 . A screw connection is provided at least at the rear end  66  and front end  64  of the armrest. 
   The bracket  18  is preferably molded into the armrest  14 . 
   The door pull handle  12  is screwed to the door panel  16  at its top end  56  and bottom end  58 . At its top end  56 , a screw is directed through the door handle  12  in a direction perpendicular to the door panel  16 . At the bottom end  58 , the bracket  18  is connected to the door panel  16  by two screws  50  and  54 . A first screw  50  is inserted through the aperture  48  in the first flange  30  and into the door panel  16  in a direction perpendicular to the door panel  16 . A second screw  54  is inserted through the aperture  52  in the second flange  32  and into the door panel  16  in a direction perpendicular to the door panel  16 . An additional screw  40  is then placed through the bottom end  58  of the door handle  12  and the aperture  38  in the first wall  24  of the bracket  18  in a direction generally perpendicular to the first wall  24 . 
   Alternatively, the connections made using screws may be made using clips, bolts, or other types of fasteners. The bracket may be used alternatively to avoid other obstructions such as reinforcement structures within the armrest, ashtrays, or audio speakers. The fasteners that are attached to the door panel may alternatively be attached to other structural members of the door. 
   A primary advantage of the present apparatus and method is the ability to provide a rigid connection between the interior door pull handle and the door panel without having to move the location of control components on or within the armrest. Additionally, the present apparatus negates the need to provide additional attachment points that are in unusual places on the armrest that are either unsightly and/or difficult to place fasteners into. The bracket of the present invention also provides protection for the control components from damage caused by impacting the side of the armrest. 
   Although the invention has been shown and described with reference to certain preferred and alternate embodiments, the invention is not limited to these specific embodiments. Minor variations and insubstantial differences in the various combinations of materials and methods of application may occur to those of ordinary skill in the art while remaining within the scope of the invention as claimed and equivalents.