Patent Publication Number: US-10309133-B2

Title: Retractable outside door handle assembly for vehicle

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to and the benefit of Korean Patent Application No. 10-2016-0107731 filed in the Korean Intellectual Property Office on Aug. 24, 2016, the entire contents of which are incorporated herein by reference. 
     BACKGROUND 
     (a) Technical Field 
     The present disclosure relates to a retractable door handle assembly for a vehicle, and more particularly, to a retractable door handle assembly for a vehicle in which a door handle, in one state, can be retracted into an outer panel of the door, and in another state, can be projected outward from the outer panel of the door. 
     (b) Description of the Related Art 
     In general, a vehicle can have an interior of a predetermined size, in which a driver and perhaps additionally one or more accompanying passengers can ride. Accessible in the interior of the vehicle may be a mechanism for opening and closing a door of the vehicle. There may also be a similar mechanism accessible on the outside of the vehicle. 
     For example, there may be one door handle mounted on an inner surface of the door towards the interior of the vehicle and there may be another door handle mounted on an outer surface of the door toward the outside of the vehicle. 
     Each door handle is connected to a door latch that fixes the door to a vehicle body, and as a result, the door can be opened when the door latch is released by operating either door handle. 
     The outer door handle is normally pivotably mounted on an outer panel of the door (which may be referred to hereafter as the “outer door panel”) and is installed in the outer door panel and projected laterally outward from the vehicle (i.e., projected along a lateral axis or a “width direction” of the vehicle) so that the passenger can easily grip the door handle. 
     When the door handle is installed to project laterally outward from the vehicle, operating convenience for the passenger is improved, but the external appearance of the vehicle can deteriorate due to the projection of the door handle (i.e. the door handle is not flush with the door). In addition, driving noise can be exacerbated while the vehicle is driven and driving performance can also deteriorate due to additional resistance caused by the protrusion of the door handle. 
     In recent years, in order to solve this problem, a retractable door handle has been developed, in which a motor causes the door handle to be either projected laterally outward from the outer door panel or retracted into an recess formed in the outer door panel. 
     A fail-safe function may be desired that can improve stability of the retractable door handle or allow for a key to be used to operate the door handle in a scenario where the motor fails or is otherwise unable to project or retract the door handle. 
     The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art. 
     SUMMARY 
     The present disclosure provides a retractable door handle assembly for a vehicle, where, in one state, the retractable handle is retracted into an outer door panel as necessary to improve an external appearance of the vehicle, and, in another state, the retractable handle is projected laterally outward from the outer door panel to allow a passenger to more easily operate the retractable handle. 
     An example embodiment of the present disclosure provides a retractable door handle assembly for a vehicle, including: a retractable door handle installed in a door of the vehicle, the retractable door handle being configured to project laterally outward from or retract into an outer door panel; and a linkage connected to the door handle to support the door handle so that the door handle pops out from the outer panel and pops into the outer panel, where the linkage includes a main link having one end connected to the door handle, and an auxiliary link having one end connected to the main link to support pivoting of the main link. 
     The main link may include a first main link having one end connected to the door handle and further include a second main link having one end connected to the door handle. The auxiliary link may include a first auxiliary link having one end connected to the first main link to support a pivot movement of the first main link and further include a second auxiliary link having one end connected to the second main link to support a pivot movement of the second main link. The first main link and the first auxiliary link may form a first pair disposed toward a front end of the vehicle. The second main link and the second auxiliary link may form a second pair disposed toward a rear end of the vehicle. 
     The retractable door handle assembly may further include a base plate, a first elongated guide hole formed in the base plate towards a front end of the vehicle and a second elongated guide hole formed in the base plate toward a rear end of the vehicle. A first link pin is joined to the first main link and a second link pin is joined to the second main link, and the first and second link pins are inserted into and move along the first and second elongated guide holes, respectively. The first elongated guide hole may be shorter than the second elongated guide hole. 
     The base plate may include an outer surface facing the outside of the vehicle in the width direction of the vehicle, an upper surface extending towards a vehicle interior from an upper edge of the outer surface, and a lower surface extending towards the vehicle interior from a lower edge of the outer surface, and the first and second elongated guide holes may be formed on the upper surface and the lower surface, respectively. 
     The door handle may include a graspable handle body that can be grasped/gripped by a passenger, and may also include an insertion hole formed in the handle body, into which the passenger can insert a hand. 
     An inner cover plate may be joined to the base plate facing the vehicle interior, and a boss may be formed on the inner cover plate so that a pin can be inserted into the boss and the auxiliary link can be mounted such that the auxiliary link is pivotable around the pin. 
     The retractable door handle assembly may further include a cover mechanism connected with the linkage and guiding the handle when the passenger inserts the hand into the insertion hole by covering one surface of the insertion hole. 
     The cover mechanism may include an auxiliary cover guiding a passenger&#39;s hand when the passenger inserts a hand into the insertion hole by covering one surface of the insertion hole and a cover link having one end joined to the main link with the pin and the other end joined to the base plate in order to link the auxiliary cover with the door handle. 
     The retractable door handle assembly may further include a driving device providing operation force to the linkage, and the driving device may include a driving motor generating rotational force, and a cam allowing the first and second links to move along the first and second elongated guide holes by transferring the rotational force of the driving motor to the first and second link pins of the main link. 
     There may be a single cam or a pair of cams connected to be integrally rotatable by a rotational shaft. The rotational shaft may be connected to the driving motor so as to receive rotational force from the driving motor. 
     The cams may have an “S” shape and include two cam grooves having a “U” shape to engage and move the first and second link pins, respectively and two cam push surfaces having an arc shape to push and move the first and second link pins. 
     A torsion spring which elastically supports the auxiliary link may be installed in a region where the auxiliary link is joined with the pin. 
     A stopper protrusion may be formed on the base plate and a stopper projection may be formed at one end of the cam to block rotational movement of the cam by contacting the stopper protrusion. 
     The retractable door handle assembly may further include a door latch cable connected with a door latch that unlocks the door latch when pulled; and a door latch link rotatably installed and connected with the door latch cable. The door latch link may have an operation groove into which the second link pin is selectively inserted allowing the door latch link to rotate. 
     The retractable door handle assembly may further include: a key cylinder for inserting a key of the vehicle and rotatably operating the key; a first door latch release rod having one end connected to the key cylinder and another end connected to the pin; and a second door latch release rod having one end connected to the pin and another end connected to the door latch cam. 
     A guide groove which guides and moves the first door latch release rod may be formed on the inner cover plate. 
     The retractable door handle assembly may further include a control lever rotatably installed and capable of moving the first and second link pins. 
     A lower cover plate having a guide hole may be formed at one edge may be joined to a lower side of the base plate. The control lever may be rotatably installed on the lower cover plate, and a fixing screw may be joined to one end of the control lever. The fixing screw may be inserted into the guide hole so as to be guided and moved along the guide hole. 
     First and second cam surfaces contacting the first and second link pins may be formed in the control lever. 
     According to an example embodiment, in a retractable door handle assembly for a vehicle, when a door need not be opened, an door handle is retracted into an outer door panel to improve the external appearance of the vehicle and reduce driving noise and driving resistance caused by projection of the door handle laterally from the outer door panel, resulting in improved marketability of the vehicle. 
     The improved retractable door handle disclosed herein has a simple structure, and therefore provides reduced vehicle weight and cost, in addition to improving the ride quality and overall appearance of the vehicle. 
     When the door handle cannot be projected laterally (i.e popped out) due to a failure of the driving motor, a door latch can be released by use of a vehicle key, and as a result, the disclosure further provides a fail-safe, again improving marketability of the vehicle. 
     Because the height of projection of a skin surface of the door handle can be manually controlled through a skin surface control device of the door handle, assembly productivity can be improved by absorbing manufacturing tolerance and assembly tolerance. 
     The door handle is projected or retracted through a linkage, and as a result, the door handle can be stably projected and retracted. 
     Also provided in the disclosure is a cover for guiding a passenger&#39;s hand when a passenger operates the door handle by inserting his/her hand into an insertion hole formed in the door handle in order to operate the outward-projected door handle, resulting in improved operating convenience. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a retractable door handle assembly mounted on a outer door panel according to an example embodiment. 
         FIG. 2  is a perspective view of a retractable door handle assembly according to an example embodiment. 
         FIG. 3  is an exploded perspective view of a retractable door handle assembly according to an example embodiment. 
         FIG. 4  is a diagram illustrating projection of a retractable door handle assembly according to an example embodiment. 
         FIG. 5  is a diagram illustrating retraction of a retractable door handle assembly according to an example embodiment. 
         FIG. 6  is a diagram illustrating prevention of inverse rotation of a cam in the state where a door handle of the retractable door handle assembly according to an example embodiment projects laterally. 
         FIG. 7  is a bottom perspective view of a retractable door handle assembly according to an example embodiment. 
         FIGS. 8 and 9  are diagrams illustrating the process of unlocking a door latch by operating a retractable door handle assembly according to an exemplary embodiment. 
         FIGS. 10 and 11  are diagrams illustrating a fail-safe function of a retractable door handle assembly according to an example embodiment. 
         FIGS. 12, 13, 14, and 15  are diagrams illustrating a process of manually controlling whether the skin surface of a retractable door handle assembly according to an example embodiment is co-planar with the outer door panel. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Hereinafter, an example embodiment of the present disclosure is described in detail with reference to the accompanying drawings. 
       FIG. 1  illustrates a portion of a vehicle door, and in particular, a portion of an outer door panel  20  of a vehicle door. Outer door panel  20  includes a recess  22  for accommodating a retractable door handle  10 , which is mounted on outer door panel  20 . 
     Recess  22  has a profile corresponding to the shape of door handle  10 , and as a result, door handle  10  may be retracted into recess  22  or projected outward from recess  22  in the width direction of the vehicle. 
     Referring to  FIGS. 2 and 3 , an example embodiment of the retractable door handle assembly for the vehicle may include a retractable door handle  10 ; a linkage  30  which is connected to door handle  10  to kinematically project (hereinafter, referred to as “pop out”) the door handle  10  from outer door panel  20  in the width direction of the vehicle or retract (hereinafter, referred to as “pop in”) door handle  10  into recess  22  of outer door panel  20 ; a driving device  40  that drives linkage  30 ; a base plate  50  on which door handle  10 , linkage  30 , and driving device  50  are mounted and supported; a cover  60  connected with linkage  30  and covering one surface of an insertion hole formed in door handle  10  to guide a passenger&#39;s hand when a passenger reaches into the insertion hole, a control lever  70  for manually controlling a projection height of a skin surface of door handle  10 , and a door latch link  80  for unlocking a door latch. 
     In a further example embodiment, retractable door handle  10  also may include a handle body  12  that a passenger can grip and an insertion hole  14  formed in handle body  12  so that the passenger can grip handle body  12  by inserting their hand into insertion hole  14 . 
     Base plate  50  includes an outer surface  52  facing the outside of the vehicle in the width direction of the vehicle, an upper surface  54  extending towards a vehicle interior from an upper edge of outer surface  52 , and a lower surface  56  extending towards the vehicle interior from a lower edge of the outer surface  52 , such that the upper surface, the outer surface and the lower surface together have substantially a C-shape (“ ”). 
     A first and second elongated guide hole  57  and  58 , respectively, may be formed in both the upper surface  54  and the lower surface  56  of base plate  50 . Each elongated guide hole may each formed along an axis that is parallel to a longitudinal axis of the vehicle. For instance, as shown in the Figures, the first and second elongated guide holes are formed along substantially the same axis, and that axis is parallel to a longitudinal axis of the vehicle. As also shown, the first elongated guide hole  57  in each of the upper surface  54  and the lower surface  56  may be formed toward a front end of the vehicle, and the second elongated guide hole  58  in each of the upper surface  54  and the lower surface  56  may be formed toward a rear end of the vehicle. 
     First elongated guide hole  57  may have a relatively shorter length than second elongated guide hole  58 . 
     An inner cover plate  51  may be coupled to the side of base plate  50  facing the vehicle interior and a lower cover plate  53  may be coupled to the bottom of the base plate  50 . 
     Two bosses  512  (e.g., studs or other protuberances) may be formed on inner cover plate  51 , and respective pins may be inserted into the bosses  512 . Linkage  30  may then be mounted on bosses  512  such that linkage  30  can pivot around the pins. Linkage  30  may include a first link pin  31  inserted into the first elongated guide hole  57  and may further include a second link pin  33  inserted into the second elongated guide hole  58 . 
     Linkage  30  may also include two main links  32 , including a first and second main link. The first main link may have one end joined to the door handle  10  and may have another end coupled to the first link pin  31 . The second main link may have one end joined to the door handle  10  and may have another end coupled to the second link pin  33 . 
     Further, the linkage  30  may include two auxiliary links  34 , including a first and second auxiliary link. The first auxiliary link may have one end joined to a predetermined portion of the first main link in the longitudinal direction of the first main link and may have another end into which a first pin can be inserted. With that same first pin inserted into the boss  512  of the inner cover plate  51 , the first auxiliary link can pivot around the first pin. Likewise, the second auxiliary link may have one end joined to a predetermined portion of the second main link in the longitudinal direction of the second main link and may have another end into which a second pin can be inserted. With that same second pin inserted into the other boss  512  of the inner cover plate  51 , the second auxiliary link can pivot around the second pin. 
     Cover mechanism  60  may include an auxiliary cover  62  that guides a passenger&#39;s hand when the passenger inserts it into the insertion hole by covering one surface of insertion hole  14  formed in door handle  10 . Two cover links  64  having one end joined to main link  32  with the pin and the other end joined to base plate  50  link auxiliary cover  62  with door handle  10 . 
     The driving device  40  may include a driving motor  42  generating rotational force and a pair of cams  44  which transfer the rotational force of the driving motor to the first and second link pins  31  and  33  of main link  32  to allow the first and second link pins  31  and  33  to move along the first and second elongated guide holes  57  and  58 . In a separate embodiment, pair of cams  44  may be replaced by a single cam. 
     The pair of cams  44  may have substantially an “S” shape and each cam  44  may include two cam grooves  442  having substantially a “U” shape and two cam push surfaces  444  having substantially an arc shape. Pair of cams  44  may be connected by a rotational shaft  46  so as to rotate together when rotational shaft  46  is rotated by the driving motor  42 . 
     Operation of an example embodiment of the retractable door handle assembly is described below with reference to  FIG. 4 . 
       FIG. 4A  illustrates the state in which the door handle  10  is accommodated in recess  22  of outer door panel  20 , i.e., a pop-in state in which the door handle  10  is not projected outward from outer door panel  20  in the width direction of the vehicle. 
     When a driver approaches the vehicle while holding, for example, a smart key, a control device causes power to be supplied to driving motor  42 , thereby actuating driving motor  42  and causing cam  44  to rotate. When cam  44  rotates clockwise, first and second link pins  31  and  33  are pushed away from each other by cam push surface  444  of cam  44 , and the first and second link pins  31  and  33  are guided and moved along the first and second elongated guide holes  57  and  58 . As a result, the main link  32  is projected by pivoting towards a laterally-outward direction from the vehicle while being supported by auxiliary link  34 , thereby projecting door handle  10  from outer door panel  20  (i.e. door handle  10  transitions to a pop-out state, as shown in  FIG. 4B ). 
     As used herein, “clockwise” refers to a clockwise direction from the vantage point of a passenger facing the outer door panel from the outside of the vehicle. Similarly, “counterclockwise” refers to a counterclockwise direction from the vantage point of a passenger facing the outer door panel from the outside of the vehicle. 
     A pair of front and rear main links  32  and auxiliary links  34 , described in detail below, allow smooth and stable performance of pop-out and pop-in operation of door handle  10 . 
     Cover link  64  also pops out auxiliary cover  62  towards the outside of the vehicle in the width direction of the vehicle by pivoting of main link  32  towards the outside in the width direction of the vehicle. 
     Because the cover link  64  is shorter than main link  32 , the pop-out length of auxiliary cover  62  is less than the pop-out length of door handle  10 , and as a result, an insertion hole  14  into which the passenger may insert a hand is created between the door handle  10  and the auxiliary cover  62  due to a difference in pop-out length. 
     When a passenger pulls door handle  10  towards the outside of the vehicle in the width direction of the vehicle by inserting a hand into insertion hole  14  of the door handle while the door handle  10  is in the pop-out state, a rear part of door handle  10  in the longitudinal direction of the vehicle is projected further outward in the width direction of the vehicle than a front part of door handle  10 , as shown in  FIG. 4C . In this case, first link pin  31  positioned towards a front end of the vehicle will no longer move as it has reached the end of the first elongated guide hole  57 , while second link pin  33  positioned towards a rear end of the vehicle continues to move along the second elongated guide hole  58 , thus allowing the rear of door handle  10  to move farther towards the outside of the vehicle than the front of door handle  10 . As a result, as shown in  FIG. 4C , only one portion of the door handle  10  pops out—namely, the portion of the door handle  10  that is towards a rear end of the vehicle 
     Meanwhile, when the vehicle door is closed again, the front and rear auxiliary links  34  rotate clockwise and counterclockwise, respectively, due to the elastic restoration force of a torsion spring  36  wound on a pin shaft of auxiliary links  34 . Auxiliary links  34  move two first and second link pins  31  and  33  towards each other and cam  44  inversely rotates counterclockwise. 
     When first and second link pins  31  and  33  approach cam groove  442  during the simultaneous operating process, first and second link pins  31  and  33  forcibly move towards each other while being inserted into cam groove  442  due to rotation of cam  44 , as illustrated in  FIG. 5 . As a result, door handle  10  transitions to the pop-in state and is completely retracted into recess  22  of outer door panel  20 , as in  FIG. 4A . 
     A stopper protrusion  55  is provided on base plate  50  to prevent excessive inverse movement of cam  44  during a counterclockwise inverse movement. A stopper projection  446  is formed at one end of cam  44 . When stopper projection  446  contacts stopper protrusion  55  of base plate  50 , cam  44  may no longer inversely rotate. (See  FIG. 4A ) 
     Further, as illustrated in  FIG. 6 , even though cam  44  rotates counterclockwise once the door handle  10  pops out, because stopper projection  446  prevents cam  44  from further rotating while contacting the first link pin  31  or the main link  32 , undesired excessive inverse movement of cam  44  is prevented. As a result, the cam  44  may not move to a pop-in position to engage and fix the first and second links  31  and  33  into the cam groove  442 . 
     Accordingly, if a passenger&#39;s hand is inserted into insertion hole  14  when the door handle  10  is popped out, because cam  44  prevents the door handle  10  from popping in, a safety accident may be prevented. 
     Referring to  FIG. 7 , a conventional key cylinder  90  that is operated by inserting the key of the vehicle may be installed at one side of inner cover plate  51 . 
     A substantially disk-shaped door latch link  80  may be rotatably installed on lower cover plate  53 . 
     A connection groove  82  is formed at one side of door latch link  80  and one end of a door latch cable  84  connected with the door latch is inserted into the connection groove. 
     An operation groove  86  may be formed at the other side of door latch link  80  and a suspension protrusion  88  may protrude at a portion of door latch link  80  adjacent to operation groove  86 . 
       FIG. 7  illustrates a state in which door handle  10  pops in and the first and second link pins  31  and  33  are disposed to be close to each other and  FIG. 8  illustrates a state in which door handle  10  is popped out by driving motor  42 . When door handle  10  pops out, second link pin  33  inserted into the second elongated guide hole  58  is inserted into an inlet of operation groove  86 . In this configuration, when a passenger pulls door handle  10 , second link pin  33  further moves along second elongated guide hole  58 , door latch link  80  rotates clockwise due to movement of second link pin  33 , and door latch cable  84  is pulled. As a result, the door latch is switched to an unlocked state and the passenger may open the vehicle door. 
     Referring back to  FIGS. 7 and 10 , one end of a first door latch release rod  92  is connected to key cylinder  90  and the other end is connected to a pin  93 ; and one end of a second door latch release rod  94  is connected to pin  93  while the other end is suspended on a suspension protrusion  88 . First door latch release rod  92  may move along a guide groove  514  formed on inner cover plate  51 . 
     As a result, even when the driving motor is inoperable, the fail-safe function may be implemented so as to open the door. 
     As illustrated in  FIG. 11 , when the driver inserts the vehicle key into key cylinder  90  and rotates it, first door latch release rod  92  moves along guide groove  514  and the second door latch release rod  94  rotates the door latch link  80  while rotating with the movement of the first door latch release rod  92 . Door latch cable  84  is then pulled by rotating door latch link  80  and the door latch is unlocked to open the door. 
     Referring back to  FIGS. 3 and 7 , a guide hole  532  is formed at one edge of lower cover plate  53 , control lever  70  is rotatably installed on lower cover plate  53 , a fixing screw  74  is joined to one end of the control lever  70 , and fixing screw  74  is inserted into guide hole  532  allowing fixing screw  74  to move along guide hole  532 . 
     Furthermore, a pair of first and second cam surfaces  72  and  73  are formed at the other end of the control lever  70 , and control lever  70  is installed on the lower cover plate  53  so that first cam surface  72  contacts first link pin  31 , while second cam surface  73  contacts second link pin  73  when the door handle  10  pops in. 
     Control lever  70  may act to bring door handle  10  into outer door panel  20  such that the skin surface of door handle  10  and the skin surface of the outer door panel are co-planar, i.e. so that no step exists between the skin surfaces. 
     As illustrated in  FIG. 12 , when control lever  70  rotates, for example, clockwise, first and second links  31  and  33  contacting first and second surfaces  72  and  73  of the control lever  70 , respectively, positioned on the bottoms of first and second cam surfaces  72  and  73  are brought to positions where they are closest to each other along the shapes of the first and second cam surfaces  72  and  73 . As a result, as illustrated in  FIG. 13 , door handle  10  moves towards the vehicle interior (as shown by the arrow) through action of main link  32  and movement of the first and second links  31  and  33 . In fact, the skin surface of door handle  10  can move further into the vehicle interior than the skin surface of the outer door panel  20 . 
     Accordingly, when door handle  10  is projected outward from the outer door panel after the retractable door handle assembly is assembled to the outer door panel, door handle  10  may move into the vehicle interior by rotating the control lever  70  clockwise, and as a result, the skin surface of door handle  10  may be easily controlled so as to be co-planar with the skin surface of outer door panel  20 . This provides a more pleasant aesthetic appearance for vehicle and assists in diminishing vehicle noise. 
     After door handle  10  has been retracted into a position where the skin surface of door handle  10  is co-planar with the skin surface of outer door panel  20 , control lever  70  may be prevented from moving by tightening fixing screw  74 . 
     When door handle  10  moves further towards the vehicle interior than the outer door panel  20  after the retractable door handle assembly is assembled to outer door panel  20 , door handle  10  can be moved back towards the outside of the vehicle by rotating the control lever  70  counterclockwise as illustrated in  FIGS. 14 and 15 , in order to make the skin surface of door handle  10  co-planar with the skin surface of outer door panel  20 . 
     While this invention has been described in connection with practical example embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. 
     DESCRIPTION OF SYMBOLS 
       10 : Retractable door handle 
       20 : Door outer panel 
       22 : Accommodation hole 
       30 : Linkage 
       40 : Driving device 
       50 : Base plate 
       60 : Cover mechanism 
       70 : Control lever 
       80 : Door latch link