Abstract:
A motor vehicle door handle assembly, including a face plate positioned flush with the door outer surface. When operator pressure is applied to the face plate, the face plate pops out under spring pressure to a position where it may be gripped by the operator and pulled outwardly to unlatch the door and allow opening of the door. When the face plate is thereafter released, the face plate is returned to its flush position in the door by a damper mechanism which overcomes the face plate spring during the return movement of the door handle to return the face plate to its flush position.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to door handle assemblies and more particularly to door handle assemblies especially suitable for use with motor vehicles. 
     2. Description of the Art 
     A myriad of designs have been proposed and/or utilized for use as door handle assemblies for motor vehicles. Whereas these designs have been generally satisfactory, they have suffered from one or more disadvantages. Specifically, either the door handle has disturbed the otherwise smooth outer surface of the door, resulting in poor aesthetics, wind noise and wind resistence, or the door handle, if flush with the outer door surface, has been awkward to operate. 
     SUMMARY OF THE INVENTION 
     This invention is directed to an improved motor vehicle door handle assembly. 
     More specifically, this invention is directed to a motor vehicle door handle assembly that is totally flush with the outer door surface and is easy to operate. 
     The invention handle assembly is for use with a motor vehicle door having a panel defining an opening. 
     According to the invention, the assembly includes a face plate sized to fit in and fill the opening; a mounting structure mounting the face plate in the door panel for movement between a flush position in which an outer surface of the face plate presents substantially flush with the door panel and substantially fills the opening, and a grip position in which the face plate is displaced outwardly from the door panel and defines a finger access space between the face plate and the opening; and means operative in response to inward pressure applied to the face plate with the face plate in the flush position to move the face plate outwardly from the flush position to the grip position. This arrangement provides a flush door handle design that is easily operated. 
     According to a further feature of the invention, the mounting structure further mounts the face plate for inward movement relative to the door panel to a release position, and the operative means is operative in response to inward movement of the face plate to the release position to move the face plate outwardly through the flush position to the grip position. This arrangement allows the door handle assembly to be moved to an operative position by simply pressing on the face plate. 
     According to a further feature of the invention, the mounting structure comprises a handle base member adapted to be mounted for movement on the door between a latch position and an unlatch position; the face plate is mounted on the handle base member for movement between its flush, grip, and release positions; and the face plate is arranged to move the handle base member from the latch position to the unlatch position in response to further outward displacement of the face plate from the door panel with the face plate in the grip position. This arrangement allows the handle assembly to be readily moved to an unlatch position following movement of the face plate to a grip position. 
     According to a further feature of the invention, the handle base member is adapted to be pivotally mounted on the door proximate the opening for movement between its latch and unlatch positions, and the face plate is pivotally mounted on the handle base member for movement between its flush, grip, and release positions. This pivotal mounting simplifies and facilitates the operation of the handle assembly. 
     According to a further feature of the invention, the handle assembly further includes a casing adapted to be fitted into an aperture in the panel and including a rim portion defining the opening in the door panel, and the handle base member is pivotally mounted on the casing. This arrangement allows the use of a casing to facilitate installation and operation of the handle assembly. 
     According to a further feature of the invention, the operative means comprises a secondary spring means interconnecting the handle base member and the face plate and urging the face plate outwardly from the handle base member to the grip position, and detent means maintaining the face plate in its flush position and operative in response to inward pressure on the face plate to release the face plate from movement to the grip position under the urging of the spring means. This arrangement facilitates and simplifies the movement of the face plate to the grip position. 
     According to a further feature of the invention, the door handle assembly further includes restoring means operative in response to return movement of the handle base member from the unlatch position to the latch position to move the face plate on the handle base member from the grip position to the flush position. This arrangements ensures that the face plate will be returned to its flush position in the door following each unlatch/latch cycle. 
     According to a further feature of the invention, the restoring means includes a damper assembly operative during the return movement of the handle base member to apply a resistive force to the face plate greater than and opposing the urging force of the secondary spring means. This arrangement allows the restoring means to move the face plate from the grip position to the flush position during the return movement of the handle base member. 
     According to a further feature of the invention, the damper assembly includes a damper having a damper pinion and a rack connected to the face plate and meshingly engaging with the damper pinion. This arrangement provides a simple and effective means of operatively interconnecting the face plate and the damper assembly. 
     According to a further feature of the invention, the damper assembly is operative during the return movement of the handle base member to move the face plate from the grip position inwardly through the flush position to a further stop position, and the rack is arranged to disengage from the damper pinion following movement of the face plate to the stop position and return movement of the handle base member to the latch position. This arrangement allows the secondary spring means to move the face plate from the stop position to the flush position following return movement of the handle assembly to thereby restore the face plate to its flush position within the door panel opening. 
     According to a further feature of the invention, the damper is mounted on the casing, the face plate is pivotally mounted on the handle base member, and the rack is pivotally connected at one end thereof to the face plate and defines rack teeth proximate another end thereof for meshing co-action with the damper pinion. This arrangement facilitates the packaging and smooth operation of the assembly. 
     According to a further feature of the invention, the detent means is operative to normally maintain the face plate in its flush position against the urging of the secondary spring means; allows movement of the face plate to the release position against the urging of the secondary spring means in response to inward pressure applied to the face plate with the face plate in the flush position; allows the face plate to move outwardly from the release position to the grip position under the urging of the secondary spring means upon release of the inward pressure on the face plate; allows movement of the handle base member from the latch position to the unlatch position against the urging of the primary spring means in response to outward movement of the face plate with the face plate in the grip position; allows movement of the face plate from the grip position to the stop position in response to the resistive force of the damper assembly upon return movement of the handle base member from the unlatch position to the latch position; and allows movement of the face plate from the stop position to the flush position under the urging of the secondary spring means upon disengagement of the rack from the damper pinion. This specific detent construction defines and coordinates the co-acting movement of the handle base member and the face plate during an unlatch/latch cycle. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 is a fragmentary view of a motor vehicle employing a door handle assembly according to the invention; 
     FIG. 2 is a front view of the door handle assembly; 
     FIG. 3 is a top view of the door handle assembly; 
     FIG. 4 is an end view of the door handle assembly; 
     FIG. 5 is a front perspective view of the door handle assembly; 
     FIG. 6 is a rear perspective view of the door handle assembly; 
     FIG. 7 is a further perspective view of the door handle assembly with a face plate of the assembly omitted for purposes of clarity; 
     FIG. 8 is an exploded view of the door handle assembly; 
     FIG. 9 is a perspective view of a face plate assembly utilized in the door handle assembly; 
     FIGS. 10,  11  and  12  are schematic cross-sectional views illustrating the operation of the door handle assembly; and 
     FIGS. 13,  14  and  15  are fragmentary detail views of the door handle assembly. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The invention door handle assembly  10  is seen in FIG. 1 in association with a fragmentarily shown motor vehicle  12 , including a windshield  14 , a front quarter panel  16 , a hood  18 , an A pillar  20 , a sill  22 , a B pillar  24  and a door  26  positioned in the door opening defined by the A pillar  20 , front quarter panel  16 , sill  22 , and B pillar  24 . 
     Door handle assembly  10 , broadly considered, includes a housing or casing  28 , a handle base member  30 , and a face plate assembly  32 , each of which may be formed in known manner of a suitable plastic or metallic material. 
     Casing  28  has an oval configuration and includes a central bowl portion  28   a , a rim portion  28   b  surrounding the bowl portion, a damper housing structure  28   c  within the bowl portion, a pair of spaced posts or stanchions  28   d , and a pair of slots  28   e  positioned inboard of the respective posts  28   d . Rim  28   b  defines a central opening  28   g  in surrounding relation to the bowl portion. 
     Handle base member  30  includes a pair of spaced side plates  30   a  and  30   b , an arm  30   c  formed as an upward and rearward extension of side plate  30   a , an arm  30   d  formed as an upward and rearward extension of side plate  30   b , a skirt  30   e  interconnecting side plates  30   a  and  30   b , and a detent structure  30   f  formed on the outboard face of side plate  30   a.    
     Detent structure  30   f  includes a closed loop rib  30   g  and an island  30   h  positioned within the rib and coacting with the rib to define a closed loop detent groove  30   i.    
     Face plate assembly  32  includes a face plate  34 , a detent link  36 , a follower pin  37  mounted on the free end of link  36 , and a rack  38 . 
     Face plate  34  includes a generally planar main body portion  34   a  of generally oval configuration conforming generally to the size and configuration of the opening  28   g  defined by the rim  28   b  of the casing, and a plurality of spaced lugs  34   c ,  34   d ,  34   e  and  34   f  extending rearwardly from main body portion  34   a.    
     Detent link  36  is pivotally mounted at a forward end  36   a  thereof on the outboard face of lug  34   c  with follower pin  37  extending through an arcuate guide slot  34   e  in lug  34   c  for receipt in detent groove  30   i.    
     Rack  38  is pivotally mounted at a forward end  38   a  thereof between lugs  34   e  and  34   f  and includes a plurality of gear teeth  38   b  proximate the rear end  38   c  thereof. 
     A damper assembly  40  (FIG. 14) is positioned in damper housing  28   c  of casing  28  and includes a cylindrical damper casing  42 , a vane  44  mounted for rotary movement within casing  42 , a damper pinion  46  mounted on the central shaft  48  of the vane  44  and positioned exteriorly of housing  28   c , and a viscous fluid  50  filling the casing  42  in surrounding relation to vane  44  and providing shearing resistance to rotary movement of vane  44  within casing  42 . 
     In the assembled relation of door handle assembly  10 , handle base member  30  is positioned generally within the bowl portion  28   a  of casing  28  with arms  30   c  and  30   d  extending upwardly and rearwardly through slots  28   e  and pivotally mounted at their upper end on a pivot shaft  50  extending between posts  28   d  of the casing; face plate  32  is pivotally mounted on handle base member  30  by a pivot shaft  52  mounted on ear portions  30   j  formed as forward extensions of the side plates  30   a  and  30   b  and extending through suitable aligned apertures in lugs  34   c ,  34   d  and  34   e ; rack  38  extends rearwardly in overlying proximity to damper pinion  46  with the rear end  38   c  of the rack extending through a suitable aperture  28   h  in the bowl portion  28   a  of the casing and gear teeth  38   c  positioned immediately rearwardly of pinion damper  46 ; a primary coil return spring  54  positioned on shaft  50  bears at one end  54   a  against the bowl portion  28   a  of casing  28  and at its other end  54   b  against the upper end  30   k  of arm  30   d  so as to yieldably resists upward pivotal movement of handle base member  30  about the axis of pivot shaft  50 ; and a secondary detent coil spring  56  positioned on shaft  52  bears at one end  56   a  against the skirt portion  30   e  of handle base member  30  and at another end  56   b  against face plate  32  so as to urge the face plate for pivotal movement upwardly away from the handle base member. 
     Handle assembly  10  is mounted in door  26  by positioning the assembly in an aperture  26   b  (FIG. 13) in the outer skin or panel  26   a  of the door and suitably securing the flange portion  28   b  of the casing to an outer face of the skin  26   a  with the handle assembly positioned inwardly of the door skin  26   a  and the outer face of the flange portion flush with outer skin  26   a . An actuator link  60  is connected to the upper free end of arm  30   k  of the handle base member so that pivotal movement of the handle base member  30  about the axis of the shaft  50  has the effect, in known manner, of moving the latch mechanism  62  on the door  26  between latch and unlatch positions. 
     Face plate  34   a  is mounted on handle base member  30  for pivotal movement about the axis of shaft  52  between a flush position (seen in solid lines in FIG. 10) in which the face plate is positioned within and substantially fills the opening  28   g  defined by the casing flange  28 ; a grip position (seen in dash lines in FIG. 10) in which the face plate is pivoted outwardly and upwardly with respect to the handle base member to define a finger access space S between the face plate and the flange portion  28   b  of the casing; and a release position (seen in chain lines in FIG. 10) in which the face plate is moved inwardly with respect to the flange portion of the casing. The movement of the face plate between its flush, grip, and release positions is accompanied and defined (FIG. 15) by movement of the follower pin  37  in the closed loop groove  30   i  of detent  30   f.    
     Specifically, with the face plate in its flush position, the follower pin  37  is in the position indicated by reference numeral  37 F in FIG. 15 wherein the pin is received in a niche  301  defined at the rearward end of the island  30   h . With the face plate in the grip position, as shown by the reference character  37 G, the follower pin is received in a niche  34   m  defined at the forward end of the rib  30   g . With the face plate in the release position, the follower pin  37 , as shown by the reference character  37 R, is positioned in a niche  30   n  defined by rib  30   g  upwardly and rearwardly of niche  301 . 
     OPERATION 
     With the door in the closed and latched position and the face plate in the flush position, the handle assembly presents a smooth, clean, flush surface. Specifically, the outer surface of the flush plate is flush with the outer surface of the flange of the casing which in turn is flush with the outer surface of the outer skin or panel  26  of the door whereby to present an aesthetically pleasing appearance, minimize the wind resistence generated by the handle assembly during movement of the vehicle, and minimize whistling noises generated by the handle assembly. 
     When it is desired to open the door, the operator exerts a force P on the lower portion of the face plate to pivot the face plate inwardly or rearwardly about the axis of pivot shaft  52 . This inward pivotal movement acts via follower link  36  to move follower finger  37  upwardly and rearwardly into position  37 R in niche  30   n . Upon release of the face plate by the operator, secondary detent spring  56  acts to pivot the face plate upwardly and forwardly about the axis of shaft  52 . As the face plate pivots forwardly, follower link  36  moves follower pin  37  forwardly in the upper run  30   p  of the detent loop. As the face plate moves forwardly, it passes through the flush position of the face plate and moves to the grip position of the face plate as defined by arrival of the follower pin  37  at the position  37 G within the niche  30   m . Simultaneous with the arrival of the follower pin in niche  30   m , a stop structure  34   g  on face plate lug  34   e  engages a co-acting stop structure  30   k  on handle base member side plate  30   b  to further define the grip position of the stop plate and further couple the face plate to the handle base member. 
     A space S has now been defined between the lower edge of the face plate and the adjacent rim portion of the casing to allow access by the operator&#39;s fingers. During the movement of the face plate on the handle base member between the flush, release, and grip positions, the gear teeth  38   c  on the rack  38  are not in engagement with damper pinion  46 . The operator now inserts his fingers under the face plate into the space S and pulls upwardly and outwardly on the face plate. This has the effect, via the seating of the follower pin in niche  30   m  and the co-action of the stop structures  30   k  and  34   g , of pivoting the handle base member  30  upwardly and outwardly about the axis of pivot shaft  50  to move the handle base member from a latch to an unlatch position whereby to unlatch the door latch  62  via the link  60 . 
     As the face plate and handle base member are pivoted upwardly to unlatch the door, the teeth  38   c  of rack  38  engage damper pinion  46  and return spring  54  is wound to yieldly resist the opening movement of the face plate. Following movement of the face plate to the unlatch position, the operator releases the face plate whereupon the primary spring  54  returns the handle base member to the latch position. As the handle base member moves toward the latch position, the rack teeth  38   c  engage the damper pinion  46  whereby to generate resistance to the movement of the rack  38  and thereby the face plate  34 . The force of primary spring  54  is greater than the combined force of secondary spring  56  and the damper resistance, whereas the damper resistance is greater than the force of the secondary spring. Since the rack  38  is pivotally attached to the face plate above the axis of pivot shaft  52 , when the face plate is released to allow the handle base member to return under the urging of the primary spring to the latch position, the damper resistance overcomes the force of the secondary spring which has the effect of pushing the top of the face plate over the pivot axis  52 . Thus, as the handle base member returns to the latch position, the face plate pivots inwardly relative to the handle base member from the grip position and through the flush position. 
     This pivoting movement of the face plate on the handle base member is accompanied by movement of the follower pin  37  through the lower run  30   q  of the detent groove to the stop position seen at  37 S wherein the pin is resting in a nest surface  30   r  positioned immediately rearwardly of niche  30   l . Arrival of the follower pin at the position  37 S determines and delimits the inward pivotal movement of the face plate on the handle base member and corresponds to a position of the face plate relative to the handle base member that is depressed inwardly with respect to the flange portion  28   b  of the casing, and corresponds generally to the release position of the face plate. As the handle base member arrives at its latch position, the rack teeth  38   c  disengage from damper pinion  46  whereupon secondary spring  56  unwinds to move the face plate back to the flush position with the follower pin  37  returning to the position  37 F nesting in the niche  30   l . The handle assembly has now been returned to the latch position and the face plate has been returned to a flush position relative to the flange portion of the casing and relative to the outer door panel  26 . 
     The invention will be seen to provide a motor vehicle door handle assembly that is easy to operate and that presents a smooth, flush surface with respect to the outer door panel whereby to minimize wind resistance and wind noise and maximize handle aesthetics.